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Acknowledgement
Deloitte Touche Tohmatsu India Pvt. Ltd is thankful to Bureau of Energy Efficiency (BEE), Ministry of Power, Government of India for entrusting us the assignment of study of Technology gap assessment at Paper Mills located at Muzaffarnagar, Uttar Pradesh. .
Deloitte Touche Tohmatsu India Pvt. Ltd is also thankful to the all the Muzaffarnagar paper mill owners and their employees for showing interest to conduct of Energy Audit study in their plant as a part of program of BEE SME Program and supporting us for the same.
We also acknowledge support given by Shri Pankaj Agarwal for his continued help, co-ordination and cooperation throughout the study.
Deloitte Touche Tohmatsu India Pvt. Ltd. Gurgaon
MANUAL ON ENERGY CONSERVATION MEASURES IN PAPER CLUSTER, MUZAFFARNAGAR
CONTENTS
1 About BEE’s SME program .............................................................................................. 1 1.1 Project objectives ........................................................................................................1 1.2 Expected project outcome...........................................................................................3 1.3 Project duration ...........................................................................................................3 1.4 Identified clusters under the program .........................................................................3
2 Cluster scenario .................................................................................................................. 6 2.1 Overview of SME cluster............................................................................................6 2.1.1 Paper Industry ................................................................................................. 6
2.1.2 Cluster background ......................................................................................... 8 2.1.3 Product manufactured ..................................................................................... 9 2.1.4 Classification of units ................................................................................... 10 2.1.5 Production capacity detail ............................................................................. 10 2.1.6 Raw materials used ....................................................................................... 11
2.2 Energy Situation in the Cluster .................................................................................11 2.2.1 Types of Fuels Used and Prices .................................................................... 16 2.2.2 Energy Consumption in Typical Paper Unit ................................................. 16 2.2.3 Value of Specific Energy Consumption of Typical Paper unit in
Muzaffarnagar Paper cluster ......................................................................... 18 2.3 Manufacturing process/technology overview..........................................................19
2.3.1 Process technology........................................................................................ 19 2.3.2 Process flow diagram .................................................................................... 25
2.4 Issues related to energy usage and conservation and barrier in technology up gradation ...................................................................................................................26 2.4.1 Technological Barrier – Lack of awareness on energy efficiency ................ 26 2.4.2 Financial Barrier – Non availability of funds to implement energy
conservation measures .................................................................................. 26 2.4.3 Limited technical manpower ......................................................................... 27
2.5 Cluster Association Details .......................................................................................28 3 Energy Audit and Technology Assessment ................................................................ 29
3.1 Methodology Adopted for Energy Use and Technology Assessment......................29 3.2 Boundary Parameters ................................................................................................29 3.3 General Methodology ...............................................................................................30 3.3.1 Preliminary Audit.......................................................................................... 30
3.3.2 Detailed Audit ............................................................................................... 31 3.3.3 Post Audit Off–site Work ............................................................................. 32
3.4 Observations Made During the Energy Use and Technology Study ........................32 3.4.1 Manufacturing process and technology/equipments installed ...................... 32 3.4.2 Housekeeping Practices ................................................................................ 34 3.4.3 Availability of Data and Information ............................................................ 35
3.5 Technology Gap Analysis .........................................................................................35 3.6 Energy Conservation Measures Identified ................................................................39
MANUAL ON ENERGY CONSERVATION MEASURES IN PAPER CLUSTER, MUZAFFARNAGAR
3.6.1 ECM 1 – Boiler Efficiency Improvement..................................................... 39 3.6.2 ECM 2 – Boiler Feed Water Pump Efficiency Improvement ....................... 42 3.6.3 ECM 3 – Boiler Feed Water Pump Pressure Drop Reduction ...................... 43 3.6.4 ECM 4 – Boiler Fans Efficiency Improvement............................................ 46 3.6.5 ECM 5 – Flash Steam Recovery ................................................................... 48 3.6.6 ECM 6 – Digester Blow Heat Recovery ....................................................... 51 3.6.7 ECM 7 – Steam Consumption Reduction by Efficient Condensate
Evacuation from Dryers ................................................................................ 54 3.6.8 ECM 8 – Energy Efficiency Improvement in Process Pumps...................... 56 3.6.9 ECM 9 – Installation of Screw Press ............................................................ 58 3.6.10 ECM 10 – Installation of High Consistency Pulper ...................................... 60 3.6.11 ECM 11 – Installation of Pocket Ventilation System ................................... 61 3.6.12 ECM 12 – Installation of Pressurized Head Box .......................................... 63
3.7 Barriers in Implementation .......................................................................................64 3.8 AVailability of technlogy suppliers/local service PROVIDERS for identified
energy CONSERVATION proposals .......................................................................65 3.9 Identification of technologies for DPR Preparation ..................................................65
4 Environmental Benefits .................................................................................................. 67 5 Small Group Activities/Total Energy Management .................................................. 68 5.1 Introduction ...............................................................................................................68 5.1.1 Economic Factors of Energy Conservation .................................................. 68
5.1.2 Environmental impacts of Energy Conservation .......................................... 69 5.2 Small Group Activities (SGA) ..................................................................................69
5.2.1 Importance of SGA ....................................................................................... 70 5.2.2 How SGA leads to Energy Conservation? .................................................... 70 5.2.3 Steps of Small Group Activities for Energy Conservation ........................... 74 5.2.4 Tools that are Used Often for Small Group Activities for Energy
Conservation ................................................................................................. 79 6 Conclusion ......................................................................................................................... 82
6.1 All Energy Saving Measures Identified ....................................................................82 6.2 Techno-economics of Energy Saving Measures Identified ......................................83 6.3 Summary of level of awareness on energy efficiency and energy conservation
Potential in the cluster ...............................................................................................85
MANUAL ON ENERGY CONSERVATION MEASURES IN PAPER CLUSTER, MUZAFFARNAGAR
ANNEXS
Annexure 1:
Annexure 2:
Annexure 3:
Annexure 4:
Annexure 5:
List of Paper Mills in Muzaffarnagar Paper Cluster
Detailed Technology Assessment Report
Details of Technology / Service Providers in Muzaffarnagar Paper Cluster
Techno Commercial Bids from Service/Technology Provider
Financial schemes available for improving energy efficiency in cluster
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