IPPTA Technical conference, Kashipur 10th December 2015 Innovations in Steam systems in Pulp and Paper Industry -Datta Kuvalekar Technical manager and Project Manager roles IPPTA Technical conference, Kashipur 10th December 2015

Forbes Marshall Pvt Ltd Steam Costs count ! % of cost hidden in steam 25% Boilers Papermachine Feedwater temperature 1% Excess Oxygen 2% Leakages 3% Condensate evacuation 10%  15%  3% 0% Flue Gas heat recovery 2 % Unburnt losses 1% Venting losses 5% Press moisture 4% Forbes Marshall Pvt Ltd

Key Drivers for innovations in steam Safety Uptime Efficiency

What drives advances in steamTechnology ? To enhance energy savings and bring plant closer to thermodynamic limits To bring down costs of Steam generation To Control steam heated processes more accurately with reduced cycle time To reduce Carbon footprint of plants through fossil fuel usage To enhance safety of steam plants Finally , objective of any Paper mill steam advances are focussed around Higher Production, Better Quality paper with Less steam !

Principles of Steam System Management Optimal Steam System Energy Efficiency Safety Ease of operation Conformance to Environmental norms Reliable life Cycle

Variability in paper plants !

Technology trends in steam Super Efficient Steam Generators with real time Efficiency monitoring Smart Technology in traditional products Creating a Data connected Steam world . Steam products that are intelligent and networked. ( Internet of Things) Process linked Diagnostics and controls Preventive Maintenance systems Affordable steam products like meters !

Sequence of technological deployment Next Practice Optimizing Efficiency Stop Wastage

Examples of innovations in steam Products and Services New Steam Management Services High Efficiency Fuel Flexible Steam Boilers Real Time Online Boiler Efficiency Monitoring & BEESAS Power from PRVs Paper Guard and Paper sense- Uptime improvement

More Innovations in steam… Drymax – Fuzzy Logic Engine for Smart Steam and condensate systems on Papermachines New Compact Rotary Joint Steam Traps Innovative Variable load Steam Traps Wireless Steam Traps that enable preventive maintenance Pinch Analysis for Pulp mill processes

Steam Management Services Steam System Management

High Efficiency Fuel Flexible Boilers Copyright Forbes Marshall, 2006-07 12

Housekeeping for a Five * Plant

Real time Boiler Efficiency & Safety Max

Effimax & Safetymax EffiMax Web Server Internet Remote User Real Time Data Display Trends Patterns Diagnostics Alarms Analysis Reports Settings Local Area Network (LAN) Mobile App

BEESAS – Multi parameter tracking BOILER EFFICIENCY ENVIRONMENT SAFETY AUTOMATED SYSTEM

Control and Automation Load based firing control FD and ID fan control with auto changeover Deaerator level and pressure control Fine combustion control 3 element/single element drum level control with auto changeover Auto blow down control Integrated boiler start-up Sequence and normal shut off BOILER EFFICIENCY ENVIRONMENT SAFETY AUTOMATED SYSTEM

Efficiency BOILER EFFICIENCY ENVIRONMENT SAFETY AUTOMATED SYSTEM BS845 Efficiency Calculation Lesser power consumption with VFD’s for FD, ID, feeder, stoker and feed-water motors Boiler Operator Performance Index Power consumption tracker Air pre-heater/Economizer performance tracker Bed temperature monitoring Remote monitoring BOILER EFFICIENCY ENVIRONMENT SAFETY AUTOMATED SYSTEM

Safety and Reliability Monitoring of all safety parameters Safety Interlocks Redundant transmitters and channels with auto changeover Hot swapping Watch dog for Instrument Reliability BOILER EFFICIENCY ENVIRONMENT SAFETY AUTOMATED SYSTEM

Environment BOILER EFFICIENCY ENVIRONMENT SAFETY AUTOMATED SYSTEM Lower SPM emission Reduced CO2 Emission Reduction in CO Mitigation of climate change Minimal carbon footprint BOILER EFFICIENCY ENVIRONMENT SAFETY AUTOMATED SYSTEM

Efficiency + Environment Boiler Efficiency and Environment manager

A typical invisible loss –PRVs ! Specially for small sized mills Engine Proprietary content © Forbes Marshall

Savings calculations

Paper “ Sense” Mobile Application: Mobile Application has following features : Overall Plant Health Summary. Critical Alerts of last 48 hours. Key Parameter’s live values. Summary of the Day. Trends. ‘Smart Schedule’ which helps you to optimize the planned downtime by suggesting number of equipment's due for maintenance in a given time frame Advance Health Alerts to predict failures

Drier SteamOptimisation system How can I save on steam consumption ? Why my SSC is high ? What are the pressure and differential set points for this grade of paper ? Are my dryers flooded with condensate ? If Yes, what are they? What should be my drive loads and dryer surface temperatures ? What is the affect of paper break on my production?

Customer Benefits with DryMAX: My machine runs consistently in optimum SSC limits. I saved my steam consumption I have diagnostics for high SSC I got my pressure and differential pressure set points for this paper grade These should be my drive loads and dryer surface temperatures Paper breaks affect this much of my production I know which of my dryers are condensate flooded

Effect of DryMAX:

DryMAX- How it deploys

Compact Steam trap Rotary Joints

Steam traps that Modulate An innovation for a product That has existed for over 100 years !

Wireless Steam Traps

Advanced Seals for Rotary joints Specially designed for Indian paper Machines and for low maintenance.

Application of Pinch Analysis Specially for Pulp mills with several Hot and Cold streams Acid Filtrate (75oC) PO filtrate (90oC) OWL (110oC) 40oC 80oC 88oC F (m3/h) Duty (MJ/h) 60 56 35 8715 2352 1470 Water (67oC) ClO2 (82oC) Water (65oC) EOP filtrate (88oC) O2 mixture (103oC) 30oC 10oC 78oC 75oC 100oC 3024 1260 3276 15 25 10 30 31 390.6 DHT filtrate (88oC) 1 [2352] 2 4 [672] H [1260] [1806] [390.6] 4.63 m3/h 5 26oC 3 [1470] C [4221]

Heat Pumps for waste heat Suitable for Heating hot water by Extracting heat at lower temperatures And transferring heat in reverse direction

Deliverables of Innovations Innovations in Steam systems must help our UP papermills as well as mills across India maximise their returns on investments Reduce cost of operations Reduce impact on environment Make papermills become sustainable and profitable.

Thankyou