BALLARPUR INDUSTRIES LIMITED Unit A.P.

Rayons, Kamalapuram, Warangal,(AP)

BILT,Unit-A.P.Rayons was established in 1979 and is one of the India's leading manufacturer of Rayon grade pulp , having an installed capacity of 98550 Tones per annum based on 100 % hard wood as raw material. Plant is situated at the banks of River GODAVARI at village-Kamalapuram ,Warangal Dist ( AP) and 110 km away from Warangal / Kazipet railway station. APR produces mainly 2 qualities of Rayon grade PULP. Our respectable customers are Grasim and NRC. Company is having turn over of about Rs. 260 Crore. Silent Features of plant: Plant has flexibility to manufacture Rayon Grade or Paper grade pulp Entire plant starting from Raw material to Pulp Dispatch is on Distributed control system ( DCS) Single DD washer instead of conventional 4 drum washer Single Recovery Boiler of 618 TPD BL solids firing capacity. 2 separate streams of Effluent treatment to treat entire effluent of the Mill.

Factory layout

ENERGY MANAGEMENT POLICY

We at BILT, Unit-APR are committed to continuously improve our Energy performance in all our activities of product and services. To achieve this, we are committed to improve: 1. Capacity Utilization. 2. Up-gradation of process, instrumentation & utility/equipments for energy conservation. 3. Continuously review specific energy consumption norms and benchmark with the best in the industry. 4. Energy efficient power generation equipment for replacement of old ones and achieve 100% self power generation. 5. Optimize consumption of natural resources, in particular fuel, water, air & electricity and wherever feasible, reduce, re-use and recycle. 6. Carry out Internal and External audits to identify areas of improvement. 7. To ensure that the new projects are energy efficient payback period less than one year. 8. Create awareness among all employees for efficient use of energy resources.

ENERGY CONSUMPTION
SPECIFIC POWER CONSUMPTION DETAILS Annual Production of pulp Total Energy consumption per annum Total Thermal Energy Consumption Total Manufacturing Cost Total Power & Fuel Cost Energy Cost as % of manufacturing cost Sp Power Consumption Sp Thermal energy Consumption UNIT M Tons KWH (lakhs) Million Kcal Rs. Lakhs Rs. Lakhs % KWH/MT MKcal/MT 2003-2004 93725 1035 40137 19697 1905 9.7 1104 0.428 2004-2005 83183 975 48011 15185 2208 14.5 1172 0.577 2005-2006 74585 847 53074 13977 1892 13.5 1136 0.712 *

* Plant shut for about 70 days for modification jobs etc.

GRAPHICAL REPRESENTATION OF SPECIFIC ENERGY CONSUMPTION

Specific Power Consumption
1180 1160 Kwh/ Ton 1140 1120 1100 1080 1060 2003-04 2004-05 Year 2005-06 1104 1172 1136

K c a l/ t o n M

Specific Thermal Energy Consumption 0.712 0.8 0.577 0.428 0.6 0.4 0.2 0 2004-05 Year 2005-06

Kwh/ton

2003-04 M Kcal/ton

SALIENT FEATURES OF ENERGY CONSERVATION CELL Unit Head is the adviser and final approving authority We carryout our energy conservation activities by adopting TQM methodology The unit has Energy Conservation Cell, headed by Manager Energy and reporting to General Manager (operation) as Chairman and General Manager (Engg) as chief coordinator. We have core committee with functional heads to study and analyze the proposals, identified by the sub task force and individuals before freezing for execution of job. Manger Energy coordinates all energy conservation activities. We have 3-subtask force teams for Energy Conservation activities and coordinated by the Manager Energy. The sub task forces and Energy Manager meets once in two weeks for discussing status of on going energy saving jobs and as well as the new energy saving proposals of the members of the team/ concerned department. The energy conservation activities includes recording/reporting /analyzing of data and immediate corrective action on daily basis. This sub task force teams finds energy saving potential in their working areas, brings the proposal for elaborate discussions in the meeting. The proposals shall be further studied with relevant data before taking up further action. For any clarifications and final decisions on critical issues regarding to energy saving jobs, matter will be discussed with Apex committee (with functional heads). . .

ENERGY CONSERVATION CELL STRUCTURE Cell Adviser CGM

Chairman General Manager (Operations)

Chief Co-Coordinator General Manager (Engg)

DGM (Prod & R&D)

Manager Energy & PED Manager Energy

DGM (P/H)

Sub task force Power block

Sr Mgr-Mech (F/Line)

Sub task force Fiber line

Sr Mgr-Elect.

Sub task force ETP &others

Sr Mgr-Inst

Major Energy Conservation Projects Implemented during the Year 2005-06

ACHIEVEMENTS OF ENERGY CONSERVATION PROJECTS 2005-06

Saving details Power Coal LP steam Total 3148200 kwh/ annum 1398 T/ annum 5069 T / annum

In Rs lacs / annum

66.54

18.38

7.09

92.00

S. No

Energy Saving Job Description KWH /yr Rs lacs/Yr 35.84 Turobo Feed pump

Reduction of Grid power by shifting the Grid load onto TG with Turbo feed pump operation in place of Electric feed pump. Power saving = 280kw (Considering 250 days/annum Cost of unit Rs 3.30 / kwh) Saving = 280x24*250*3.3 = Rs 55.44 lacs Cost of Hp steam for higher condensing load one ton/hr Keeping in view the gain in reduction of HP to LP PRV opening = 1*24*250 x 0.235 x 1390 = Rs 19.60 lac Net saving = 55.44 19.60 = Rs 35.84 lacs Investment: Rs 6.0 lacs ( for over hauling of pump)

2217600 kwh

S. No

Energy Saving Job Description KWH /yr Rs lacs/Yr Newly installed dilution air compressor Removed (old ) dilution air compressor

Installation of efficient Dilution air compressor in place of old design at Clo2 Plant Reduction of power = 7.5 Kw

59400 kwh

1.96

Investment = Rs 0.70 lacs

S. No

Energy Saving Job Description KWH /yr Rs lacs/Yr 7.09 LP heater installed at recovery

Reduction of LP steam Installation of LP Heater and by using of flash steam from digester condensate & CBD of SRB for heating the 42 M3 DM water (from 42 deg to 51 deg C) Reduction LP steam consumption = 0.64 Saving = 0.64 x 24 x330 x(1/1.1x 140 = Rs 7.09 lacs Investment: Rs 1.25lac (Old LP heater over hauled and used)

LP steam reduction 5069 T/ yr

S. No

Energy Saving Job Description KWH /yr Rs lacs/Yr 28.74 1) 2) (37 kw compressor) (5 hp compressor)

Stopping of 2Nos. Air compressors (2 x 110 kw) 1) By reducing the header air pressure from 5.5 4.8 kg/cm2 2) By installing two small dedicated (5 kw + 37 kw) compressors for sheeting machine & caustisizing) Reduction of power consumption Reduction of power (69 +74) = 143 kw Additional power consumption = 3 + 30 = 33 kw Net saving in power = (143 33) = 110 kw saving = 110x24 x330x3.30 = 28.74 lacs Investment = Rs 0.75 lacs

871200 kwh

S. No

Energy Saving Job Description KWH /yr Rs lacs/Yr 16.18 Saw dust feeding

Using of chipper Sawdust 10 tons/ day (equivalent of 5 Tons coal / day) Saving: Reduction of coal / annum = 5 x 250 x 1390 = Rs 17.37 lacs Cost of saw dust transportation = 1.25 lacs Net saving = 17.37-1.25 = Rs 16.18 lacs (Considering 250 days in year & excluding rainy season

Coal reduction 1250 MT/ yr

S. No

Energy Saving Job Description KWH /yr Rs lacs/Yr 2.20 Reject Screen for CFB coal crushing Saw dust boiler air heater

Reduction of unburntCoal from 18 % to 12 % in CFB Boiler : 1) by putting rejects screen after revamping the damaged screen 2)Improving the efficiency of saw dust boiler by revamping of air heater by salvaging damaged FBC APH tubes.

Reusing of unburnt coal 0.75 T/ day

Saving of 0.75 @60% Eff gcv tons/day coal Rs 2.20 lacs /annum

Investment: 1.5 lacs

Energy Conservation Target for the year 2006-07

To achieve specific power consumption = form 1136 to 1100 kwh/ ton of pulp

To reduce the specific Thermal Energy consumption from 0.712 to 0.570 M kcal / ton of pulp

Energy Conservation plans for the year 2006-07

1) Installation of additional finisher body for optimization of Evaporation process of Weak black liquor solids in Evap. Plant Expected saving Rs 186 lacs / annum Investment cost - Rs 190 lacs (approx.) Insulation of 2 Nos of Digesters (600 M 2 area) Expected saving 0.4 tons coal /day (Rs 1.8 lacs/ annum) Investment cost is Rs 3.6 lacs Expected saving Rs 20 lacs/annum (excluding chemical cost) Investment Cost Nil ( operating cost -Chemical cost Rs 69 lacs / annum)

2)

3) Fuel additive mixing with coal

Our mission is aimed at providing Total Energy Conservation Solutions for our mill by selection of appropriate technologies and best practices, which will be economical to industries and also environmental friendly

Environmental and Safety policy Environment:

Effluent treatment plant:

We have a full-fledged effluent treatment plant to treat influent generated from process.. Also we recycle treated effluent for process use.

Safety APR has a Safety Department with safety officer, which maintains stringent safety

standards and ensure that safety measures are being followed strictly. Safety committee meets once in month to review /discuss the safety related issues. Safety Department organizes training programmes and various competitions at the occasion of 4th March national safety day for employees awareness on safety

Health APR has full pledged hospital in the colony with all the facilities First aid center is there in mill premises operating round the clock An Ambulance is also readily available to shift the patients in case of emergency. Our company provides medical aid to near by /surrounding villages