Production Process Process:

CPP is the first large pulp and paper mill in India, who had not only floated the idea of consuming bagasse for manufacturing Quality paper but also gave concrete base to its idea in the form of Bagasse Unit. The Bagasse Unit of CPP was commissioned in early 1995 with a capacity of 211 TPD for manufacturing quality paper. The salient features of bagasse unit are latest bagasse handling, pulping and paper making technologies. 1. 2. Bagasse handling, moist depithing, pile building reclaiming and washing Bagasse cooking continuous digester, cold blow to avoid Emissions and to retain fiber strength.

Beloit UK. Sunds

3. Brown Stock Washing. 4. Screening and cleaning

HDO Ahlstrom,Finland Sunds, Sweden

5. Bleaching system based on C/D, E/O D sequence to attain final pulp

brightness of +88 without affecting the strength of pulp.

Bagasse:
Bagasse is received from the Sugar Mills either in bale form or in loose form as per the requirement. Whole bagasse from the sugar mill is available only in the sugar cane crushing season which is stretched over a period of maximum six to seven months only, whereas the process of production of paper is continuous throughout the year. Therefore, it is essential to store bagasse in a proper way so as to make it available for paper making through out the year i.e. during off season without affecting the quality Hence, the total amount of bagasse required for the production throughout the year is carefully stored so that the production is not affected due to the shortage of bagasse.

Writing and Printing Paper Plant Process (WPP)

This integrated plant is based on Eucalyptus and Bamboo furnish to produce paper ranging between 45 to 210 gsm. The best selected species of Eucalyptus and other hard wood/bamboo which are locally available from nearby forest is used for pulping. Pulping process is conventional kraft process. For high brightness and good strength pulp output latest technology of bleaching sequences consisting of Hydrogen peroxide, chlorine dioxide & sulphur dioxide is used. Pulp is further processed in highly sophisticated continuous stock preparation plant. To cater to market requirement of reels and sheets facilities of winding, sheeting and packing is available. The packing of reels & sheets is conforming to seaworthy standards suitable for export.

Business Strengths

Business Strengths
Century Pulp and Paper is the manufacturer of Rayon Grade Pulp, Wood based Writing Printing Paper & Bagasse based Writing Printing Paper. CPP employs around 2500 well trained manpower including 700 staff and 1800 workmen. CPP Specialties in manufacturing : Wide variety of quality writing printing paper (agro based) with Bagasse as raw material. Best quality photocopiers paper which has been highly appreciated in the market, both international and domestic.

The mill established at Lalkua is unique because : It is the only mill in the world producing both rayon grade pulp, wood-based paper and bagasse based paper. The level of control instrumentation is relatively high. CPP is the first mill in the world to use ClO2 for bagasse pulp bleaching. The mill features a unique pile building system for preventing deterioration of stored bagasse fiber. Bagasse fiber fed to the digester has a high fiber pith ratio (more than 5:1). CPPs farm forestry scheme ensures that raw material is cultivated and replenished. CPP is the driver for good forestry management and manages socio-forestry nurseries for cultivation and distribution of plant saplings. The mill has a well equipped laboratory to monitor various water and air pollution control measures including AOX level.

Marching Ahead : CPP has embarked on a prestigious green field expansion programme to implement a modern technology paper manufacturing unit of 250 TPD based on Secondary Fiber including de-inking plant.

Brief Profile
Century Pulp & Paper (an ISO-9001:2000 & ISO-14001:2004 certified Division of Century Textiles and Industries Ltd.) , a Division of Century Textiles and Industries Ltd. is a member of B.K. Birla Group of Companies. The company chairman is Syt. Basant Kumarji Birla. Established in 1984, the Division is situated at Lalkua on the Bareilly-Nainital Highway. The Head Office of the Division is on the 11th

Floor of Industry House, 10, Camac Street, Kolkata. Product range of the CPP comprises a vast range of quality Writing & Printing Paper and superior quality dissolving Rayon Grade Pulp used for Viscose/Staple fiber/filament yarn. It has other uses in preparing urea, formaldehyde, melamine formaldehyde and phenol formaldehyde. CPP has a well equipped and planned department for Environmental Conservation and Pollution Control. CPP pays sincere attention to the overall development of its employees and that of the community. It also has a well organized HRD Department for supervising these activities. CPP maintains an excellent infrastructural set up with modern facilities in order to carry out organizational activities. Century Pulp & Paper is the recipient of the following awards: Eco-Mark by BIS for its Bagasse based products. Central Pollution Control Board and National Productivity Council have selected the company as a Model unit in the field of Waste Minimization among pulp and paper industries. CPPs Effluent Treatment Plant has been selected by Central Pollution Control Board for carrying out studies and data collection for preparation of Minimal National Standards (MINAS) for large pulp and paper industry group. CPPs waste reduction schemes have been included in the World Bank Data Base on Waste Minimisation. Awarded Indo German Greentech Award for Environment Excellence for the year 2000-01. CPP was awarded First Prize at All India Farmers fair for the year 2004-2005 for its significant efforts towards farm forestry. CPP was adjudged as the Efficient Unit in energy conservation by CII for the year 2004-2005 CPP was awarded First Prize for energy conservation by Indian Paper Makers Association as well as the National Award for Energy Conservation in Pulp & Paper Sector by the Honble Prime Minister of India for the year 2004-2005.

SLIDE FOR ELECTRICAL

Slide2:
CENTURY PULP AND PAPER LALKUA, NAINITAL ( A BK BIRLA GROUP OF COMPANY ) ISO 9001 2000 AND ISO -14001 CERTIFIED COM PANY AN INTEGERATED PULP & PAPER UNIT 31320 TPA RAYON GRADE UNIT 37250 TPA WOOD BASE WRITING PAPER 84600 TPA BAGASSE BASE PAPER ECO MARKED BAGASSE PAPER

Slide3:
CENTURY PULP AND PAPER POWER ARRANGEMENTS 6.8 MW TG SET 21 MW TG SET 7.5 MVA CONTRACT DEMAND FROM UPCL 6,10,000 UNITS /DAY

Slide4:
CENTURY PULP AND PAPER THERMAL ENERGY ARRANGEMENTS 23 TPH 46 Kg/cm2 FBC C F B 3 NO 25 TPH 46 Kg/cm2 SPREADER STOCKER CFB 1 NO 50 TPH 62 Kg/cm2 FBC C F B 2 NO 40 TPH 46Kg/cm2 CHEM REC BOILER( BHEL ) 1 NO 50 TPH 62Kg/cm2 CHEM REC BOILER( ABL ) 1 NO

Slide6:
ELECTRICAL ENERGY (KWH) : 2001 - 2004

Slide7:
ELECTRICITY CONSUMPTION AND COST 2001-02 2002-03 2003-04 PURCHASED UNITS (Lac kwh/yr) 239.83 192.27 159.73 COST ( Rs lacs/yr) 1399 1177.84 746.84 OWN GENERATION THROUGH DG SETS UNITS (Lac kwh/yr) 47 34.81 19.37 COST ( Rs lacs/yr ) 219.44 182.88 117.13 THROUGH STEAM TURBINES UNITS ( Lac kwh/yr) 1754.58 1865.88 2001.13 COST ( Rs lacs/yr) 1937.58 1974.96 1903.86

Slide8:
TOTAL CONSUMPTION OF ELECTRICITY 2001-02 2002-03 2003-04 UNITS (Lac kwh/yr ) 2041.41 2092.96 2180.23 COST (Rs lac/yr) 3556.02 3335.68 2767.83

Slide9:
THERMAL ENERGY CONSUMPTION FOR PROCESS 2001-02 2002-03 2003-04 COAL HEAT VALUE (Mkcal/yr) 728037 653007.6 651336.7 BLACK LIQUOR HEAT VALUE 659445 704815 711616.75 PITH HEAT VALUE 60501 78867 74641.5 TOTAL 1447983 1436690 1437595

Slide10:
APPROACH FOR ENERGY CONSERVATION AWARENESS EDUCATION & TRAINING CAPACITY UTILIZATION INCREASED OPTIMIZATION OF VOLTAGE OPTIMIZATION OF FREQUENCY OPTIMIZATION OF OPERATING PROCEDURES THRUST ON RECYCLE & WASTE MINIMIZATION FINE TUNING OF PLANTS & EQUIPMENTS INSTALLATION OF VFDS ADOPT ENERGY EFFICIENT LIGHTING USE OF EFFICIENT EQUIPMENT TECHNOLOGY UPGRADATION ASSESSMENT AND MONITORING

Slide11:
ASSESSMENT & MONITORING AUDIT CONDUCTED BY CII : APRIL2003 39 ENERGY SAVING SCHEMES IDENTIFIED AUDIT CONDUCTED BY INGERSOLL RAND : SEPT 2003 8 SCHEMES IDENTIFIED AUDIT CONDUCTED BY ECKO PUMPS FOR PAPER M/C III VACUUM SYSTEM : OCT2004 4 SCHEMES IDENTIFIED AUDIT CONDUCTED BY DSCL FOR ENERGY COST REDUCTION IN FEB 2004 : 4 SCHEMES IDENTIFIED MOTOR EFFICIENCY ASSESSMENT BY VBI SYSTEMS PLANT TECHNICAL AUDITS BY INDEPENDENT COUNSULTANTS : AUG 2004

Slide12:
EC CELL PRESIDENT LOSS IDN COM ISO 14001/ ISO 9001/QC * PRODUCTION * TPM SEC * 3 MEMBERS * MR. * POWER HOUSE * PILAARS * CROSS FUNCT * SYSTEM COORD. TEAMS * ELECT&INST * OVERLAPPING * QUALITY CIRC COMMITTEES * ENV & WATER * STO & PUR * PURTA ORGANISATIONAL SET UP FOR ENERGY CONSERVATION TPM

Slide13:
ENERGY CONSERVATION CELL FUNCTIONS COORDINATE STEAM & POWER REQUIREMENTS STUDY VARIANCE IDENTIFY ENERGY CONSERVATION OPPURTUNITIES REVIEW ENERGY AUDIT FINDINGS STRATEGY INCREASE AWARENESS ACHIEVE MAXIMUM PLANT EFFICIENCY INDUCT LATEST TECHNOLOGY ENSURE TIME BOUND IMPLEMENTATION

Slide14:
TPM ENHANCE PLANT EFFICIENCY A ZERO BASED APPROACH

Slide15:
0 LOSS FAILURE DEFECT DOUBT ACCIDENT BREAKDOWN

Slide16:
AUTONOMOUS MAINTENANCE ( JISHU HOZEN ) MY MACHINE I MAINTAIN

EDUCATION AND TRAINING :

EDUCATION AND TRAINING SKILL DEVELOPMENT : TRAINING PROGRAMME TPM AWARENESS 118 TECHNICAL 722 BEHAVIORAL 99 FIRE AND SAFETY 209 ON JOB TRAINING THROUGH ONE-POINT-LESSON SHEET

Slide18:
TPM RE- DEFINED

Slide19:
LOSS IDENTIFICATION COMMITTEE HIGHLIGHT PROCESS INEFFICIENCIES CHECK LOSSES OF ALKALI,FIBRE,WATER, CHEMICAL AND STEAM ARRANGE CORRECTIVE MEASURES

Slide20:
ISO 9001-2000 CONTINUAL IMPROVEMENT WASTE MINIMIZATION ISO14001 CONSERVATION OF RESOURSES ADOPTING CLEANER TECHNOLOGIES ALTERNATIVE FIBRE RESOURSES UTILIZATION OF WASTE LIME MUD UTILIZATION OF WASTE PITH QUALITY CIRCLE 19 CIRCLES OPERATIVE

ANNUAL SAVING IN POWER UTILISATION WITHOUT INVESTMENT :

ANNUAL SAVING IN POWER UTILISATION WITHOUT INVESTMENT

Slide22:
NO / LOW INVESTMENT SCHEME 2001-02 2002-03 2003-04 NO OF SCHEMES 2 8 9 SAVINGS / ANNUM KWH (LACS) 11.82 8.914 36.755 COAL EQ (TONS) - 16366 32550 Rs ( LACS) 24.65 312.45 658.64 INVESTMENT 2.11 - - TOTAL Rs 995.74

Slide23:
ENERGY CONSERVATION SCHEMES NO / LOW INVESTMENT ( 2001 02)

Slide24:
ENERGY CONSERVATION SCHEMES NO / LOW INVESTMENT ( 2002 03)

Slide25:
NO / LOW INVESTMENT ( 2002 03)

Slide26:
NO / LOW INVESTMENT ( 2002 03)

Slide27:
NO / LOW INVESTMENT ( 2003 04)

Slide28:
VARIABLE FREQUENCY DRIVES

Slide29:
ENERGY CONSERVATION SCHEMES VFD 2001-02 2002- 03 2003-04 TOTAL NOS INSTALLED 16 11 25 INVESTMENT 39.3 8.06 31.03 SAVINGS /ANNUM KWH (LACS) 21.2 3.66 11.36 Rs (LACS) 42.4 8.22 22.72 73 . 34 LACS UNIT COST Rs 2.00

Slide30:
Q(LPM) Q1 Q2 P2 P1 P mtr of wc VFD - FANS, BLOWERS & PUMPS AFFINITY LAWS Q1 = N1 Q2 N2 2 P1 = N1 P2 N2 3 HP1 = N1 HP2 N2

Slide31:
THROTTLING VS SPEED CONTROL

Slide32:

.2 .4 .6 .8 1.0 100 80 60 40 20 Fan/ Pump Input Power Q(LPM) Per unit flow discharge A B A- damper control = 0.4 +0.6Q B -VSD control = Q3 ASSUMPTIONS : Static Head on fan/ pump is negligible. Fan/pump input is 0.4 Per Unit under full valve/ damper closed condition. POWER REQUIREMENT VSD VS VALVE THROTTLING

Slide33:
ENERGY CONSERVATION SCHEMES ELECTRICAL VFD (2001-02)

Slide34:
ELECTRICAL VFD (2002-03)

Slide35:
ELECTRICAL VFD (2003-04)

Slide36:
ELECTRICAL VFD (2003-04)

Slide38:
SLD BAGASSE PAPER M/C

Slide39:
SLD BAGASSE PULP

Slide40:
SLD RGP MCS

Slide41:
SLD WPP CCS ETP TR 3

Slide42:
TG 2 21 MW TG 1 6.8MW 132/11 KV BPULP B M/C RGP WPP 10MVA 11/11KV

Slide43:
HARMONICS STUDY FINDINGS TG1 TG2 DG GR TR 1 GR TR 2 Vthd 1.93 3.80 2.98 0.72 1.78 Ithd 3.52 3.63 3.42 1.17 1.78 PERMITTED VALUES 5 %

Slide44:
OTHER ELECTRICAL SCHEMES FOLLOWED: PROVISION OF LOAD TRANSFER FROM GRID TO TG WITHOUT INTERRUPTION TO UTILIZE SOURCES PREVENT IDLE RUNNING OF EQUIPMENTS BY INTERLOCKING OF PUMPS & AGITATORS EFFECTIVE CONTROLS LIKE ONE PB FOR COMPLETE GROUP EQUIPMENTS OF PLANT SWITCH OFF EQUIPMENTS THROUGH TIMERS DELTA - STAR FOR

LIGHTLY LOADED MOTORS NEUTRAL COMPENSATORS FOR UNBALANCE LOADS LEDS FOR INDICATING LIGHTS LOW LOSS HRC FUSES USE OF ENERGY SAVERS FOR LIGHTING CIRCUITS USE OF PHOTO CELLS FOR STREET LIGHTS SPLITTING OF CIRCUITS FOR BETTER CONTROL

Slide45:
TOTAL SAVINGS / ANNUM ( FOR LAST THREE YEARS) KWH (LACS) 4.62 Rs (LACS) 9.24 INVESTMENT Rs (LACS) 9.65

Slide46:
ENERGY CONSERVATION SCHEMES ELECTRICAL OTHERS

Slide47:
ENERGY CONSERVATION SCHEMES ELECTRICAL OTHERS

Slide48:
TOTAL SAVINGS THERMAL / PROCESS 2001-02 2002-03 2003-04 INVESTMENT 77.55 78.90 853.79 SAVINGS KWH (LACS) 29.02 27.69 19.73 COAL EQ.(TONS) 6765.7 5500 3593 Rs (LACS) 235.48 160.58 574.46 KWH = Rs 2.00 COAL/TON = Rs1800 970.52

Slide49:
ENERGY CONSERVATION SCHEMES THERMAL / PROCESS 2001 - 02

Slide50:
THERMAL / PROCESS 2001 02 contd

Slide51:
THERMAL / PROCESS 2002 03 contd

Slide52:
THERMAL / PROCESS 2003 04

Slide53:
THERMAL / PROCESS 2003 04 contd

Slide54:
TOTAL ENERGY SAVINGS FOR LAST 3 YEARS 2001- 02 2002- 03 2003- 04 NO OF MEASURES 8 34 47 ( IMPLEMENTED ) INVESTMENT (LACS) 77.85 138.8 893.85 SAVINGS ACCHIEVED KWH (LACS) 38.94 66.27 78.614 THERMAL (FUEL ) 11063 87900 143608 ( MkCAL ) Rs LACS 205.61 541.17 1141.75 1888.53

Slide55:

RGP 44 PAPER 92 SPECIFIC POWER CONSUMPTION TREND

Slide56:
RGP 1.468 PAPER 1.346 SPECIFIC STEAM CONSUMPTION Mkcal / TON

Slide57:
INNOVATIVE SCHEMES SUBSTITUTION OF FURNACE OIL UTILIZATION OF SOLID WASTE OPTIMIZATION OF GENERATION

Slide58:
RECALCINE LIME SLUDGE LIME PRODUCER GAS PLANT ENERGY THROUGH RFO HIGH COST FUEL

Slide60:
RECALCINE LIME SLUDGE LIME PRODUCER GAS PLANT INVESTMENT Rs 338.0 LACS SAVINGS IN2003-04 Rs 196.0 LACS ENERGY THROUGH COAL - LOW COST FUEL

Slide61:
BAGASSE STORAGE

Slide62:
DE - WATERING PITH PRESS WASHING BAGASSE CONTINUOUS DIGESTER WET PITH 80 % MOISTURE

Slide63:
BAGASSE WASHING CONTINUOUS DIGESTER DE - WATERING PITH PRESS DE WATERING PITH PRESS 50 % MOISTURE PITH INVESTMENT : Rs 348.29 LACS ANNUAL SAVINGS : Rs 134 LACS

Slide65:
PRDS PRDS 62 110.5 27.28 80.75 2.5 4.7 68.94 33.17 37.41 15.8 46 B5 B6 A BL 130.6 B4 BH EL B1 70.65 3.5 10.5 3.5 10.5 PRDS 15.0 PLANT PLANT PLANT PLANT 21 MW 6.8MW OPTIMIZATION OF GENERATION POWER GENERATION 23.5 MW COND

Slide66:
PRDS PRDS 62 111.2 23 73.43 14.71 3.36 68.94 33.42 35.52 2.0 46 B5 B6 A BL 133.4 B4 BH EL 50.6 3.5 10.5 3.5 10.5 PRDS 20.27 PLANT PLANT PLANT PLANT 21 MW 6.8MW OPTIMIZATION OF GENERATION POWER GENERATION 22.0 MW B1 COND

Slide67:

OPTIMIZATION OF GENERATION SAVINGS FULL EXTRACTION AT 10.5 Kg/cm2 REDUCED PRDS FLOW HIGHER STEAM FOR COGEN IMPROVED EFFICIENCY REDUCED VENTING OF STEAM STOPPED ONE CFB DEARATOR STEAM REDUCED ONE BOILER FEED PUMP STOPPED LOAD ON COOLING TOWER REDUCED COAL @2700MT/MONTH Rs 583 LACS POWER @350 KWH Rs 56 LACS TOTAL Rs 639 LACS

Slide68:
ENVIRONMENTAL MANAGEMENT GREEN PRACTISES SYSTEMATICALLY ADOPTED AND INTEGRATED INTO OVERALL PRODUCTION PROCESS ENZYMATIC PRE BLEACHING BIO REFINING OF PULP COOKING AIDS IN DIGESTER FARM FORESTERY CONSERVATION OF RESOURSES SOLID WASTE MANAGEMENT REQUIREMENT FOR CORPORATE RESPONSIBILITY FOR ENVIRONMENT PROTECTION

Slide69:
WATER CONSUMPTION TREND KL/TON 24

Slide70:
RECYCLING OF BLEACHING BACK WATER RECYLING OF SHEETING M/C BACK WATER RECIRCULATION OF COOLING WATER RECLAMATION OF PAPER M/C & STOCK BACK WATER WATER CONSERVATION ACHIEVED THROUGH 23 SCHEMES IMPLEMENTED IN LAST THREE YEARS

Slide71:
CHLORINE CONSUMPTION KG/TON 24

Slide72:
FUTURE PLANS

Slide73:
FUTURE PLANS CONTD.

Slide74:
FUTURE PLANS CONTD. SCHEMES WITH AN INVESTMENT OF Rs 125.08 LACS AND SAVINGS OF Rs 113.59 LACS

Slide75:
SCHEMES IN HAND INSTALLATION OF WASTE FIRED BOILER 2000 LACS INSTALLATION OF BLACK LIQ CLARIFIER 120 LACS RETROFITTING OF LIME KILN 374 LACS AUTOMATION OF PULP MILLS BY DCS 300 LACS

Slide76:

AWARDS & RECOGNITIONS SELECTED AS A MODEL UNIT BY CPCB/NPC FOR WASTE MINIMIZATION AWARDED CERTIFICATE OF APPRECIATION FOR ADOPTING CLEANER PRODUCTION TECHNOLOGY UNDER UNEP ECO MARK FOR BAGASSE BASE PAPER BY BUREAU OF INDIAN STANDARDS GREENTECH INDO GERMAN AWARD FOR ENVIRONMENTAL EXCELLENCE : 2002 BEST ENERGY CONSERVATION AWARD BY INDIAN PAPER MANUFACTURERS ASSOCIATION : 2003 AND 2004 AWARDED ENERGY EFFICIENT UNIT FOR 2004 BY CII AWARDED FIRST PRIZE FOR ENERGY CONSERVATION FOR 2004 BY MINISTRY OF POWER Urania Followers: 2 Start Following

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