Beruflich Dokumente
Kultur Dokumente
By Sarang Wadyalkar
(1) pulp mills, which manufacture pulp from wood and other materials (such as wastepaper);
(2) paper mills, which manufacture paper from wood pulp and other fiber pulp; and
(3) paperboard mills, which manufacture paperboard products from wood pulp and other fiber
pulp.
Electricity is used throughout the typical pulp and paper mill to power motors and machine
drives, conveyors, and pumps, as well as building operations such as lighting and ventilation
systems. The largest use of fuels is in boilers to generate steam for use in pulping, evaporation,
papermaking, and other operations. Black liquor is the dominant fuel for boilers in the pulp and
paper industry, followed by hog fuel and natural gas, and to a lesser extent, coal (EEA 2005).
Natural gas and oil are typically used in lime kilns
5% 5% Compressed Air
Pumps
22%
Material Handling
32%
Miscellaneous
Fans
20% Material Processing
7%
9% Refrigeration
WOOD PREPARATION
PULPING
BLEACHING
STEAM PLANT
CHEMICAL RECOVERY
STEAM ENERGY
RECOVERY
ELECTRICITY
PULP DRYING
STEAM
PAPERMAKING
FORECASTING
Grades of paper
Price of electricity
Lot size
CHALLENGES IN IMPLIMENTATION:
Energy is a critical and often unpredictable production factor; many know that but very few
people act to manage it. In paper industry where a machine is run by a team consisting
manager, executive, supervisors, operators & their helpers. Each one’s role is defined but
when it comes to energy consumption they look at others or simply ignore because they
don’t own the responsibility or probably they think they don’t. But the real crunch goes to
the owner of the production firm who has to pay the energy consumption bills.
There are some challenges while implementing energy management in paper industry
1. Many mills still use old equipments which are not energy efficient and a replacement
of capital equipments is huge cost
2. The current set up needs to be re-engineered to accommodate new energy saving
technology
3. The workforce needs to be convinced and trained to accept and run new practices
4. Raw material should be of high yield so that energy utilized/ton of paper is lower
5. Resistance to “Change” has to be dealt with at every stage in organization
6. Sense responsibility ownership by each employee towards his role
7. Self driven zeal to contribute towards energy management
8. Reach to the grass root level so that each one in the paper mill knows the purpose
CHALLENGES FOR THE OWNER:
A. Estimating the future energy needs of the firm keeping in mind the expansion
and type of technology available at present and in future.
B. Allotment of dedicated budget and other resources as no business activity
could be brought into practice unless it is budgeted or funded for.
C. Establishing a dedicated human resource team working towards energy savings
and management
D. Identifying the leader and right people to drive the Energy Management
Dept/Cell. The owner has to find a team leader who understands the energy
saving needs and is able to drive people to match up with the organization’s
goal.
E. Making sure that the energy management cell’s purpose is clear to everybody
working in the organization; right from the top to bottom in the hierarchy.
F. Coordinating with energy suppliers for the Demand & Supply according to
production schedule and seasonality.
G. Commitment to the cause leading by example, so that everyone in the
organization follows and gets to see the owner’s commitment.
H. Setting target and taking frequent review.
I. Reward the best performers.
ROADMAP & STRATEGY:
At the component and equipment level,
Process control and optimization can be pursued to ensure that production operations are
running at maximum efficiency so as to make full use of available energy supplies.
Note down avg. energy needs and patterns for each variety in ideal conditions.
Use those as metrics for future references.
The efficiency of space lighting and ventilation can be improved while total facility energy
inputs can be minimized through process integration, where feasible.
Plant location should be such that all future needs of energy are fulfilled and where energy
costs are lower.
Factory layout should be made according to the flow of raw materials for each process.
Energy manager will occupy an important position and be the focal point of all the activities
pertaining to energy management in the organization. The energy manager will provide
leadership in the development of policy on Energy Management Action Plan and play a key role
in the formulation of corporate energy policy. He’ll also prepare the information to be
submitted to the Designated Agency with regard to the energy consumed and action taken on
the recommendation of the Accredited Energy Auditor.
Lastly,
At the level of the organization, energy management systems should be implemented to ensure
a strong corporate framework exists for energy monitoring, target setting, employee
involvement, and continuous improvement.
So the correct picture should be,
Opportunities for cost reduction are greatest when both electricity consumption and prices vary
over time, which is common in process industries. Typically, the overall cost reduction can be 2 to 5 per
cent of the total energy cost.
■ Early detection of poor performance based on real time monitoring of performance against set targets
■ Total savings 2-5% of the energy bill depending on the initial level
■ Consumption and cost of utilities per hour/day/month/year, by individual and aggregated users
■ Budget performance
The mill level systems collect real-time data from the process, calculate and report electricity, steam,
water and natural gas balances and predict energy consumption. Energy balance data and consumption
forecasts are consolidated in control centers.
Apart from the owner’s commitment and the set up of the energy management cell the
execution of the whole idea is the key. A paper manufacturing firm may go for specialist in this area to
achieve energy savings effectively. Vendors like ABB has energy saving solutions specifically designed to
match the needs of the paper industry.