Presentation on

FBC Boiler
By : P.K.Chanda, Sr. P.E.(Utilities) & B. K. Dash, Sr. P.E.(Utilities)
Nagaon Paper Mill , Assam
a unit of

Hindustan Paper Corporation Limited

At NPC , Guwahati on January 12, 2006

Paper for People from Bamboo to Books

OVERVIEW OF NAGAON PAPER MILL

PROJECT SANCTION COMMISSIONING INSTALLED CAPACITY PER ANNUM PROJECT COST PRODUCT CAPTIVE POWER PLANT MANPOWER (DIRECT) : 231 EXECUTIVE : 1977 : 1985 : 1 LAKH TONNE : Rs. 288 CRORES : WRITING & PRINTING PAPER : 30 MW

SUPERVISOR
WORKMEN

: 72
: 1051 TOTAL : 1354 : Over 10,000
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INDIRECT EMPLOYMENT

HPC- PRODUCT PORT FOLIO

W&P-REELS AND SHEETS (45 TO 130 GSM)
CREAM WOVE COLOUR WOVE WHITE OFFSET PRINTING DUPLICATING WHITE WOVE MAPLITHO COMPUTER STATIONERY COPIER

HPC PERFORMANCE
215000 210000 205000

Tonne

200000 195000 190000 185000 180000

Prouction Sales

2001-02 193011 196158

2002-03 200793 203241

2003-04 210015 204405

2004-05 197312 196820

2005-06 207068 211209

CURRENT STATUS OF UNITS

TECHNOLOGY USED IS 3 DECADES OLD
For continued efficient operation, modernization is need of the hour.

ENVIRONMENTAL CONCERNS
Statutory regulations are becoming stricter. HPC is bound by Corporate Responsibility for Environmental Protection (CREP) charter

LOW END PRODUCT

To sustain sales and profitability and for responding to changing market demand , value added paper a must.

INCREASING SCALE ECONOMIES

HPC mills have to expand to improve Scale economies to maintain competitive advantage. Inevitable increase in variable cost can be offset only through savings in specific fixed cost by augmenting the volume output.

MODERNISATION & TECHONOLOGICAL UPGRADATION PROGRAMME(MTUP) of HPC MILLS

KEY TECHNICAL FEATURES OF MTUP

MODERNISATION & UPGRADATION
CHIPPER HOUSE IMPROVEMENTS MULTI-FUEL FLUIDIZED BED COMBUSTION (FBC) BOILER UPGRADATION OF: PULP MILL STOCK PREPARATION PAPER MACHINE FINISHING HOUSE

NPM ENDEAVOURS TO BE A SOCIALLY RESPONSIVE AND RESPONSIBLE CORPORATE CITIZEN

Support to Local Community Development
Two villages adopted Tegheria and Uttar Deosal Facilities Provided: Construction of school building
Construction of toilets Drinking water facility tube well and direct water supply from mill Furniture & equipment for schools Construction and development of approach roads Plantation Dekachang (Community Centre) Handloom Shed with Loom (to women folk)
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NPM ENDEAVOURS TO BE A SOCIALLY RESPONSIVE AND RESPONSIBLE CORPORATE CITIZEN

Promotion of Income Generating Avenues: Encouraging Youth with an entrepreneurial bent of mind to become ancillary associates

Development of Rotary Island at Khanapara, Guwahati

CERTIFICATION
ISO 9001 : 2000 QMS CERTIFICATION FROM DNV, THE NETHERLANDS IN 2003 (Initial Certification in 1998). ISO 14001: 2004 EMS CERTIFICATION FROM DNV, THE NETHERLANDS IN 2005 (Initial Certification in 2002). 18001:1999 OCCUPATIONAL HEALTH & SAFETY ASSESSMENT SERIES CERTIFICATION FROM DNV, THE NETHERLANDS IN 2003, FIRST IN THE INDIAN PULP & PAPER INDUSTRY.
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AWARDS
Two leaves (Green Rating Project), 10th rank out of 28 Pulp & Paper Mills in 2002 IPMA Environment Award for the year 2003 2004 Greentech Safety Award for 2003 2004 (Silver) Greentech Safety Award for 2004 2005 (Gold) SHRAM SHRI Award to Shri R C Mishra in 2004
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AFBC BOILERAN EFFORT TOWARDS EXCELLENCE INTRODUCTION AFBC BOILER AT NPM ECONOMICS EFFECT ON ENVIRONMENT

INTRODUCTION
FBC - a new concept in boiler.
Suitable for new power plants, Boiler conversion (retrofit / replacement of part of the boiler with AFBC. Ability to burn the wide variety of coal wastes (mainly fines and low grade coal) Ability to reduce the SO x and NO x emission to meet the environmental obligation. Better efficiency and thereby lower operating cost. Lowering of coal consumption helps in getting CDM

INTRODUCTION

INTRODUCTION
ADVANTAGE OVER CONVENTIONAL BOILERS Bubbling bed can remove up to 90 percent SO2,by adding limestone . Circulating AFBC can achieve 95 percent SO2 removal, with a calcium-to-sulfur (Ca/S) molar ratio of 1.5 to 2.0. NOx emissions can be reduced upto 10 ppm with the addition of selective noncatalytic reduction (SNCR) processes. AFBC boilers are capable of burning low-quality coals (e.g., low-heating-value lignites, coal cleaning wastes, coal fines,petroleum coke, and other waste materials). Can accommodate a wider range of fuels than conventional pulverized-coal boilers or stoker fired boilers.

POWER SCENERIO AT NPM

Total number of TG set Total no. of boilers Power demand for the mill Total steam demand

: 2 X 15 MW capacity : 3 X 80 MT/hr CF boilers

1 no. Recovery boiler of 90 MT/hr capacity.

: 2 X 15 = 30 MW : 230 MT/hr

AFBC AT NPM
Reason for installation of AFBC boiler at NPM
The existing stoker fired boilers are 20 years old and maintenance prone. No stand by boilers. Dependence upon grid power during of outage of any of the boilers One CF boiler will become standby after installation of the AFBC boiler. Inability to adhere to the emission norms with existing stoker fired boilers . Utilization of coal fines from the input coal . Utilization of fly ash from existing boilers having CV of 2000 kcal/kg. Utilization of effluent sludge (20 MT/day) having CV 500 kcal/kg Provision for future expansion of the capacity of the mill. High cost of grid power (Rs. 5.77/KWH) compared to captive generation cost of Rs. 1.61 /KWH)

AFBC AT NPM
SPECIFICATION Outlet steam pressure- 60 kg/sq.cm
Outlet steam temp. 400 deg centigrade Fuel- 1.Coal Generation Capacity- 50 MT/hr fines from NEC & Meghalaya. 2. Fly ash from from existing boilers. 3. Effluent sludge from ETP. Additive crushed lime stone for SO x arrest.

ECONOMICS
Cost of one Boiler including civil : Rs. 19.49 crores : 11 MT : 2 MT

Coal saving per day due to better efficiency Coal equiv. Of effluent sludge of 20MT/day Total saving of coal per day ASEB rate per unit Own generation cost per unit

Coal equiv.of fly ash (35 % unburnt) of 35 MT/day= 11 MT : 24 MT /day : Rs. 5.77 : Rs. 1.61

Cost due to outage of boilers for 60 hrs. per month

ECONOMICS
Additional cost for using ASEB power/year
: Rs. 149.76 lakh Saving of coal per year : 24 MT X 330 days = 7920 MT

Saving on coal @ Rs. 2285.00 Per MT : Rs. 180.97 lakh

Total savings per annum : Rs. 149.76+Rs. 180.97 Rs. 331 lakh

EFFECT ON ENVIRONMENT
Minimization of solid disposal. Fly ash from existing boilers (35 MT/day) will be utilized. Fly ash from the AFBC boiler will be used by cement plants. Effluent sludge which is dumped outside will be utilized. Generation of bottom ash (bed ash) will be minimum. Coal fines (less than 6 mm) will be used in the AFBC boiler.

Requirement of less coal (7920 MT) and thereby minimizing the environmental pollution. Minimization of emission of SPM and Oxides of Sulphur and Nitrogen.

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