INTRODUCTION

• M/s. Rama Newsprint and Papers Ltd. is

engaged in the business of manufacturing
Newsprint and writing and printing paper,
with an installed capacity of 1,50,000 MT per
annum.

• This is a Enviro Friendly Green Field Recycled

Based Project situated at vill. Barbodhan,
Tal. Olpad, Dist. Surat, Gujarat State.
Paper Machine # 1
Paper Machine # 2
 DEINKING PLANT

Sl Plant Description Capacity

No

01 Washing Deinking Plant   230

(existing) MT/Day

02 Floatation Deinking Plant 170

(existing) MT/Day

03 Floatation Deinking Plant 600

(proposed) MT/Day
 BOILERS
Max.
Design Design
Sl. Description Continuous
Pressure Temperature Rating
No. Item/Section
(Kg/Cm2) ( C)
o
(TPH)
1 Multi-fuel 84 483 90
Boiler#3(AP-2)

2 Multi-fuel 84 483 107

Boiler#4(CE-4)

3 Oil fired 64 480 60

Boiler(OK-8)
 TURBINES
Inlet
Sl. Inlet Steam
Description Type Steam Capacity
No. Temperature
Pressure

1 SIEMENS TG Condensing 35 410 oC 8 MW

(TG#2) kg/cm2(g)

Extraction
2 AEG TG cum back 82 480 oC 15 MW
(TG#1) pressure kg/cm2(g)

Extraction
3 BHEL TG cum 81 470 oC 23 MW
(TG#3) condensing kg/cm2(g)
BHEL 23 MW TURBO
GENERATOR
 ORGANIZATION CHART
ENERGY CONSERVATION CELL
CHAIRMAN
Energy Conservation
Core Task Force

Core Task Force Members

-GM (Utility)
-GM (Proj. & Dev.)
-GM (Elect. & Inst.)
-Engineer (Energy Conservation)

Utility Paper M/c

Task Force Task Force

Electrical Deinking
Task Force Task Force

Instrument ETP
Task Force Task Force

Mechanical Lighting
Task Force Task Force
 NEED FOR
ENERGY CONSERVATION

• RNPL was established in 1996.

• As new technologies came, RNPL
accepted them & modified the old one.
so some process parameters changed.
• New technologies also came in Energy
Conservation Field.
• Awareness increased towards Energy
Conservation.
 ENERGY CONSERVATION
ACTIVITIES IN PAPER MACHINES
Sr. Saving Quantity Saving
Description
No (per Year) (Rs/Year)
Interlocking PV steam
1 Steam: 500 MT 2,29,500/-
with PM#1
Reducing running hrs
2 Power: 13,86,000 KWh 27,72,000/-
of Refiner in PM#1
By passing Broke
3 Power: 8,07,840 KWh 16,15,680/-
chest pump & agitator
Installation of Krofta Power: 64,350 KWh
4 30,19,500/-
in PM#2 Water: 3,96,000 m3
Save Water in Krofta
5 Water: 3,96,000 m3 28,90,800/-
by level adjustment
Steam and Power: 7,44,480 KWh
6 condensate system in Steam: 4904 MT 39,24,846/-
Paper Machines DM water: 4500 m3
Total 1,44,52,326/-
 ENERGY CONSERVATION
ACTIVITIES IN DEINKING PLANT
Saving Saving
Sr. Description
(Per Year) (Rs/Year)
WDP: It was found by monitoring
1 that virtually no difference in pulp 7,12,800 KWh 14,25,600/-
quality without Deflaker so stopped
By passed Thickener Feed chest
2 2,72,448 KWh 5,44,896/-
pump & agitator in FDP
Replacing air compressor of 30 KW 1,66,320 KWh
3 5,06,088/-
with 11 KW for Krofta clarifiers Water:23,760 m3
Using recycled water in Floatation
4 Water:47,520 m3 3,46,896/-
cell sealing & cooling gland packing
5 Stopped Dump chest agitator 1,32,000 KWh 2,64,000/-
Replacement of 400 W HPMV
6 lamps by 150 W HPSV lamps in 12000 KWh 24,000/-
FDP
Stopping Frovi Pulper, Pump &
7 16,07,760 KWh 32,15,520/-
Conveyor
63,27,000/
Total
 ENERGY CONSERVATION
ACTIVITIES IN UTILITY
Sr Saving Saving
Description
no (per Year) (Rs/Yr)
Installation of new 23 MW Extraction
1 1255 lacs
Condensing Turbine
Using recycled water for ash handling Water:
2 28,90,800/-
system 3,96,000 m3
Reducing compressed air consumption in
Utility by tuning auto time & loading Air:
3 2,97,000/-
time of ash handling system with boiler 9,90,000 m3
operation
By diverting bearing cooling water of
Water:
4 Boiler Feed Pump & jacket cooling water 4,81,800/-
66,000 m3
of ash handling system to cooling tower
5 Running 4th CT fan only in summer 1,21,000 KWh 2,42,000/-
 …Continue

Sr Saving Saving
Description
no (per Year) (Rs/Yr)

Started new BFP of same capacity

6 2,64,000 KWh 5,28,000/-
which consumes less power

Trimming of two no of Clear Water

7 1,58,400 KWh 3,16,800/-
Pumps in WTP

Replacement of existing pump set in

8 1,44,000 KWh 2,88,000/-
CST transfer pump

DM Water:
9 Condensate Recovery System 1,89,000/-
4725 m3
Total 1305 lacs
 ENERGY CONSERVATION
ACTIVITIES IN OTHER AREAS

Saving Saving
Sr. Description
(Per Year) (Rs/ Year)
Isolation of ideal transformers
1 40,900 KWh 81,800/-
to save no load loss
Replacement of cement roof
2 sheets by semi-transparent 21,900 KWh 43,800/-
sheet in go down
Reducing operating frequency
3 23,76,000 KWh 47,52,000/-
from 50.3 Hz to 49.5 Hz

Continuously monitoring for

4 - -
minimize leakages and wastage
 ENERGY CONSERVATION
PROJECTS UNDER PROGRESS
Net
Sr. Saving
Description Saving
No (Per Year)
(Rs/Year)
Modification in Stock
1 preparation system & by 3,92,000 KWh 7,84,000/-
passing 3 chests.
Interlocking of PV steam with
2 Steam: 900 MT 4,13,100/-
PM#2
Sealing water of vacuum Water:
3 condenser to be diverted to 5,54,000/-
Warm Water Tank 75,900 m3

Access water from Warm Water:

4 Water Tank to be transferred 4,52,000/-
to Water Treatment Plant 66,000 m3
 …Continue

Sr. Saving Net Saving

Description
No (Per Year) (Rs/Year)

Air chiller to be installed in

5 compressed air line going for 3,16,800 KWh 5,48,000/-
Calendar cooling.

Mega Booster to be put in ash

6 9,90,000 m3 2,15,000/-
handling system

Energy Audit performance

7 Profit Sharing Basis
contract
 SPECIFIC STEAM CONSUMPTION
IN NEWSPRINT PRODUCTION

8 7.16 6.88 6.66

6.47 6.45
7 6.11 6.08
5.81 5.68 5.64
6
MT per MT Prod.

5
4
3
2
1
0
Aug Sept Oct Nov Dec Jan Feb Mar April May
‘05 ‘05 ‘05 ‘05 ‘05 ‘06 ‘06 ‘06 '06 '06

Target for 2006-07 : 5.75 MT/MT

 SPECIFIC POWER CONSUMPTION
IN NEWSPRINT PRODUCTION

1200 1190
1162
1150 1127
1123
KWh per MT Prod

1100 1063
1040 1058
1050 1015
1002
999.2
1000

950

900
Aug Sept Oct Nov Dec Jan Feb Mar April May
‘05 ‘05 ‘05 ‘05 ‘05 ‘06 ‘06 ‘06 '06 '06

Target for 2006-07 : 991 KWh/MT

 SPECIFIC WATER CONSUMPTION
IN NEWSPRINT PRODUCTION

50
50 47 46 45
45 40
39 38
40 34.4 35.5
34
M3 per MT Prod.

35
30
25
20
15
10
5
0
Aug Sept Oct Nov Dec Jan Feb Mar April May
‘05 ‘05 ‘05 ‘05 ‘05 ‘06 ‘06 ‘06 '06 '06

Target for 2006-07 : 30 M3/MT

 SPECIFIC TOTAL ENERGY CONSUMPTION
IN NEWSPRINT PRODUCTION

7.00 6.88 6.66

6.05 5.92 6.03
5.77 5.74 5.62
6.00 5.28 5.22
5.00
Million Kcal/MT

4.00

3.00

2.00

1.00

0.00
Oct '05
Aug '05

Sep '05

Nov '05

Dec '05

March '06
Jan '06

Feb '06

April '06

May '06
 VISION
 
1000 MT PRODUCTION PER DAY
 
EXPANSION PLAN OF 1,50,000 MT/ANNUM
 
 
OVERALL PRODUCTION
 
P.M.# 1 -- 70,000 MT/ANNUM
P.M.# 2 -- 80,000 MT/ANNUM
P.M.# 3 -- 1,50,000 MT/ANNUM
(PROPOSED)
------------------------------
TOTAL. : 3,00,000 MT/ANNUM