CII National Energy Award for Excellence in Energy Management

JK PAPER Ltd, Unit: JKPM,RAYAGADA

J K PAPER …….Creating Lasting Impressions

1. Company Profile- PROCESS FLOW DIAGRAM

 Pulp Mill 230,000*

TPA bleached pulp

 Soda recovery
1400 TPD solids

 Paper Machine
315,000* TPA

 Power block 58.4

MW

*Installed Capacity

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 1. Company Profile- Technology Absorption over the year

2013 2014 2017 2018 2019

New Petcoke Centralize Methanol 3.4 MW
Old Plants Expansion Plant d refining Plant TG set

Shut Plants
New Expansion Project 2001 2002 2004 2007 2008
New PD New ET Coating Wills Lime Kiln
Plant Plant Plant Cutter-3 Plant

1995 1995 1995 1997 1998

1995
Wills 12 MW LF Wills RDH
PM-5
Cutter-1 TG set Boiler Cutter-2 Process

1988
1988
5.4 MW
PM-4
TG set

1974
1970 1972
Coating
PM-2 PM-3
plant

1962
PM-1

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2. Sp. Energy Consumption-Production Data

JKPM produced **PD sheet in

2021-22, to support the
machines runnability at CPM &
also to meet the Raw Material
import Scarcity problem due to
recent War broke-out at Europe.

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2. Sp. Energy Consumption-Overall Energy Consumption

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 2. Sp. Energy Consumption-Trend
SEC-TOE

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 3. Information on Competitors & Benchmark
Overall Improvement (%) ,PAT-1 to PAT-7
64
61
60

48
45 42
35
Improvement (%)

30 26

15 10
4
0
JKPM C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9
-6
-15 -12
C-Competitor

Improvement %
Overall
PAT-1 PAT-2 PAT-7 PAT-1 to PAT- in Last PAT
Company Improvement
Baseline Baseline Baseline 2 Cycle
(%)
JKPM 0.736 0.462 0.2653 37.2 42.6 64
C-1 0.655 0.252 0.2552 61.5 -1.3 61
C-2 0.457 0.569 0.5109 -24.5 10.2 -12
C-3 1.058 0.57 0.5523 46.1 3.1 48
C-4 0.555 0.443 0.3205 20.2 27.7 42
C-5 0.609 0.557 0.3971 8.5 28.7 35
C-6 0.572 0.768 0.5174 -34.3 32.6 10
C-7 0.636 0.321 0.6132 49.5 -91.0 4
C-8 0.684 0.64 0.5038 6.4 21.3 26
C-9 0.591 0.777 0.6248 -31.5 19.6 -6
* Data source- PAT gadget *CII

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 3. Major Encon Projects planned in FY 2022-23
Annual
Annual Thermal Thermal Total
Power Investme
Electrical Saving Saving Annual
Sl.No. Proposed EnCon Project description savings nt Rs.
Savings (MT of (Million Savings (Rs.
(kW) Million
(Million kWh) Steam/ kCal) Million)
Year)
Approach Flow
Modification in PM1.
Sequence operation control
1 Total 32 number of 32 0.27 NA 0.000 1.441 0.8
through process interlock
motor will be taken in
auto control

PM 3 & Recovery low

Motor up-gradation of different
efficiency motor to be
2 rating ( total 709 KW, 17 nos.) 103 0.87 NA 0.000 4.637 1.4
replace with IE4
will be replace with IE 4 grade
energy motor

The model generated through

python’s Sklearn module – PLS
Regression. In this module, a
Leap 200- Liquor partial least square regression is
3 Recirculation set up to estimate the values of NA NA 14.175 11.709 27329.4 0.4
Temperature Model. Cooking Circulation Temperature,
which lead to steam saving by
constant temperature control.
The saving will be 0.05 Ton.

The mentioned Major Projects are under nascent stage , the values are tentative and indicative only.

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 4. Energy Saving Projects implemented in last three years
40 Nos. of En-cons Total Encon
En-Con Trend Nos. of En-
35 Year with Zero Funds Projects
Con Projects
30 28 Investment (Nos.)
25
25 22
20
21 20 2017-18 16 5 21
15
9 9
2018-19 19 9 28
10 7
5 5
5 2019-20 20 5 25
0
2017-18 2018-19 2019-20 2020-21 2021-22
2020-21 13 7 20
Nos. of En-cons with Zero Funds Investment Total Encon Projects (Nos.) 2021-22 13 9 22

Thermal savings Savings

No of Energy Investments ( Rs. Electrical savings
Year (Million Kcal / (INR
saving projects Million) (Million kWh)
MTOE) Million)

2019-20 25 12 46.89 18168.87 43

2020-21 20 65 9.78 8976.45 23.1

2021-22 22 80 26.55 76563.88 193

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 4. Energy Saving Projects implemented –FY 2021-22

Type of Project Title Savings & Benefits

Major En-Con Steam Saving in Approx. 26 TPD of steam saving

Project-1 Digester corresponding to INR 90 lacs/ year.

Approx. 11 TPD of steam saving

Reduction in steam loss
Major EnCon corresponding to 38 lacs/ year
by eliminating steam
Project-2 savings .(considering the capacity of
venting in PM-1 to 5
55 tph of the vent valve )

Chemical and steam Approx. 2.0 Cr / year savings

Innovative
optimization through corresponding to net energy, and coal
Project
APC by ITOT System saving

Minimize the usage of Approx. 14.48 Lacs / year savings

GHG – R22 / R134 by corresponding to net energy and
Environment
optimizing the utilization savings of CFC approx.- XXXXX
Project
of AHU in place of Kg/Year
standalone AC unit.

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 4. Major En Con Project– 1
Title : Steam Saving in Digester
Background: MP steam Distribution
1%
3%
• Pulp-mill contributes 60% to total MP
Steam Consumption.
• Digester process consumes 80% of 35%
pulp mill MP steam. 61%

Need for Innovation:

Fibre line LFB-6 Evap Paper Machine
• Steam Saving.
• Process stability.

Action Taken:
• Multilevel cascade feedforward
control.
• Design change of steam control
valve.

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 4. Major En Con Project– 1
Title : Steam Saving in Digester
41.01 % reduction in stdev of digester temp 41.6 % reduction in stdev of digester pressure

1.05
0.24
1.78 0.14
1.26 0.16

Specific steam Consumption

0.73 0.72 Savings & Benefits:
0.72
0.71 0.7
0.7 Approx. **26 TPD of steam saving
0.68
0.69 corresponding to INR **90 lacs/ year.
0.68
0.67
Operation stability leading to reduction in
0.66
Stdev kappa number.
Before Mod1 Mod2

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 4. Major En Con Project– 2
Title : Reduction in steam loss by eliminating steam venting in PM-1 to 5
Background:
• Paper machines 1,3,4& 5 are major contributor of
unaccounted steam due to steam venting in PRDS
station.
• Steam was venting any time when there was a paper
break or grade change due sudden change in
pressure setpoints.
• Scope of improvement was there to minimize these
losses

Need for Innovation:

• Resource conservation.
• Making future ready.

Action Taken:
• Logic was prepared to ramp up and down at slow
rate whenever there was a Pressure setpoint change
due to paper break.
• Interactive Operator HMI was created for altering the
ramp rate.

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 4. Major En Con Project– 2
Title : Reduction in steam loss by eliminating steam venting in PM-1 to 5
Before trend After trend

Savings & Benefits:

Avg. number of steam vent / month
14 Approx. **11 TPD of steam saving corresponding
15
to **38 lacs/ year savings . (
10 considering the capacity of 55 tph of the vent valve )
Before
5 After LP steam Pressure variation was reduced in other
0 machines due cascading impact of abrupt venting of
0
Avg no. of vents/ month
steam.

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 4. Innovative Project
Title : Chemical and steam optimization through APC by ITOT System
Background:
• The dosage of chemicals in the Bleaching
process is manually driven .
• Set proportions of required chemicals are
decided by operators based on their experience,
leading to variability in finished product.

Need for Innovation:

• Resource conservation.
• Making future ready.

Action Taken:
• Predictive models for each key metric of the
process to recommend optimum chemical
dosage & air flow to get optimum brightness
and steam generation respectively.
• Interactive dashboard for quick decision
making.

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 4. Innovative Project
Title : Chemical and steam optimization through APC by ITOT System
• Bleaching Chem. - Predictive models
were build using python sklearn module-
PLS regression which will predict
chemical dosage as per the target
brightness and pH level.

• LFB steam- Multi variable clustering

through K-means was done to identify the
golden batch i.e. highest specific steam
generation. Pls model was build using
python Sklearn module as per golden
batch to predict required SA flow , which
was identified as the key modulator.

• The PLS model built was tested to have

an R² accuracy of more then 90%

• The coefficient generated from PLS

regression was extracted using a python
command and used build logic in DCS.

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 4. Innovative Project
Title : Chemical and steam optimization through APC by ITOT System

Specific ClO2 consumption (Kg / Ton) Specific NaOH consumption (Kg /Ton)

15.5 12
15.08 11.51
11.5
15
14.2 11 10.56
14.5
10.5
14
10
13.5 Before After
Before After

Steam / tons of dry solid (Kg / Ton)

Savings & Benefits:
2.85
2.82
Approx. **2.0 Cr / year savings corresponding to
2.8 net energy, and coal saving.
2.75
Operation stability .
2.75

2.7
Before After

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6. Utilization of Renewable Energy sources

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 6. Utilization of Renewable Energy sources

Renewable Energy Certificates / RPO

FY 2021-22

REC Issued-149867 MWH

REC Claimed-180586 MWH

REC Traded-281896 MWH

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 7. Waste Utilization and Management
Use of Bamboo & Wood Dust (Equivalent Coal-Lacs of MT) Bamboo Dust (waste) Quantity
0.27
0.30 (Ton)
0.26
22000 0.26 23500

Equivalent Coal (Lacs MT /Annam)

0.24
0.23 0.23 23230
Bamboo & Wood Dust ( MT)

0.25
0.21 23000
17000

0.20 22500

23230
23180 22451

22451
22165
22073
20687

12000
20392

22000 22165
0.15
7000
21500
2019-20 2020-21 2021-22
2000 0.10
2015-16 2016-17 2017-18 2018-19 2019-20 2020-21 2021-22

Use of Bamboo & Wood dust( MT/Annum) Equivalent Coal ( Lacs of MT) Waste as " % " of total Fuel
energy
1.30 1.27
Bamboo Dust 1.25 1.24
Type of Waste Fuel Total Thermal Waste as "
(waste) GCV
Year Waste as energy ( Million energy ( Million % " of total 1.20
Quantity (Kcal/Kg)
fuel Kcal /kg) Kcal /kg) Fuel energy 1.15
(Ton)
1.10

2019- 1.05
22165 4120 9132 885478.16 1.03 1.03
20 1.00
2020- Bamboo & 0.95
22451 4275 9598 758424.31 1.27
21 Wood Dust
0.90
2021-
23230 4300 9989 803231.90 1.24 2019-20 2020-21 2021-22
22

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 7. Waste Utilization and Management

High purity purged lime sludge.

Usage of High Purity lime sludge

Before After
High purity purged lime Built up the mechanism
sludge which was to utilize the high purity
generated from the lime sludge back in our
process was disposed of
at low lying areas or
system which serves the
Lime sludge Feeding
landfill. There was no purpose of 3R concept, Month
(MT)
proper mechanism to and thereby reduction of
feed the same in our cost and reduction of
system, resultant effect Q1-21-22 1200
load on landfill. A total of
was wastage of 4763 MT was re used
resources and thereby Q2-21-22 323
during the year. Some
increasing the cost. The
landfill was a big
part of the sludge is also Q3-21-22 2387
challenge due to space used by fish horticulture
constraint. people. Q4-21-22 853

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 8.GHG Inventorisation

Specific GHG emissions Intensity Ton of CO2 /

Ton of Paper - Scope 1 & 2

1.40
1.40 33 %
1.28
1.25

1.10 1.08
1.04 1.05

0.94

0.80
2015-16 2016-17 2017-18 2018-19 2019-20 2020-21 2021-22

• Targeting for 75 % renewable energy by 2025.

• Digital Transformation journey.

• Pilot project started in 2018 -19 , covering Pulp mill, Recovery and Power block.
• This year it is expanded to entire JKPL across value chain.

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 8.GHG Inventorisation
Water Saving Projects

year of Annual Water Investm

implement Saving ent cost
Title of water saving Payback
S.NO ation
project implemented Rs in (Month)
m3/ Rs.
Lakh /
annum Lacs
year

Reduce freshwater
consumption by
1 substituting hot water with 2021 170400 1.8 1 6
back water in EOP & D1
washer spray in bleaching.

To use reclaimed water in

2 2021 76680 8.2 1.25 1.8
SO2 plant.

To replace the existing low

capacity pump with higher
capacity pump to avoid
3 2021 17040 1.8 0.50 3.3
return cooling water pit
overflow in Chlorine
Dioxide plant.
O2 plant Compressor heat
exchanger outlet
4 freshwater collection and 2021 25560 2.7 0.2 0.9
its recycling to Cooling
Tower.
Reduction of Hot water
consumption in D-stage by
5 using Reclaimed water 2021 230040 2.5 10.0 48.0
through heat exchanger.

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 9.Green Supply Chain Management
• Green Supply chain policy is integrated with our Environment Management Policy

Procurement Logistics Manufacturing Products to

• IE4 motors • Inbound • Energy efficient replace plastic
• BEE star rated • Outbound technology • Straw paper
• Critical supplier visits • Internal • Continuous • Coated Cup stock paper
• Local Procurement improvement through • Carry bag paper
TPM • Food Product-Divine Ns
• Matchbox stick
• OGR-Oil and Grease Resistance
New Product Development , FY 21-22 Oil & Grease Match box Paper
Straw
resistance Stick
Coated Cup
DIVINE NS ECOSIP OGR HSMT
Stock
116T-Carry
Q1-21-22 243 16 59 18 65
Bag Paper
Q2-21-22 998 60 0 69 32
Q3-21-22 829 47 116 146 39
despatch in
Q4-21-22 1721 22 44 138 121 July-2022
Total 3791 145 219 371 257

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9.Green Supply Chain Management

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 10. Team work, Employee Involvement & Monitoring
Energy Conservation Policy
Optimization of plant and equipment efficiency
1

Elimination and prevention of all type of losses

in the use of water, power,
2 steam,coal,compressed air.

Maximize condensate recovery and use process

3 heat recovery , waste minimization

Increasing the co-generation of

4 system and power

Improved utilization of natural resources

5 leading to environmental benefits.

Energy conservation through total

6 employee involvement.

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10. Team work, Employee Involvement & Monitoring

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 11. Implementation of ISO 50001/Green Co/IGBC rating

ISO 50001 implementation under process

Approximately 0.30% Investment of ( 80 Million of Rs.) energy saving projects on

total turnover ( 27685 Million of Rs. FY-21-22)

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 12. Learning from CII Award or any other Award program

Maximize the usages

of Natural Resource
Light pipe project is 4 capital projects from
already under proposal the learning of Energy
stage to mitigate the
lighting issue at various 03 04 award program in
2018-19 & 2017-18
sheds of the Plant.

Use Energy Efficient Networking with other

Equipment LEARNINGS Energy managers has
PM-3 all old motors are
going to change with new
02 05 improved and it is
helping to reduce the
IE rated motor to achieve time gap
better efficiency.

Greenco document is
Implementation of of great help to
ISO 50001, the 01 06 implement best
implementation is under practices
progress

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 Recent Awards , Acknowledgement & Major Achievement
National Awards for Excellence in Manufacturing - Mill
Manager of the Year - EVP (W)

National Safety Award” for the

year 2018 from Ministry of
Labour & Employment,
Government of India under two
distinct categories- an Accident-
Free Year & maintenance of
Lowest Average Frequency Rate.

22nd National Energy Management
Award 2021 from CII- ‘’Excellent
Energy Efficient Units’’.
Overall Digitalization, Industry
4.0
State Level Electrical Safety
Best Green Practitioner Award
Awards , Best Electrical Safety
2022
Practices.

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J K PAPER …….Creating Lasting Impressions