1. 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

2. 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

3. Key Drivers for innovations in steam
Safety Uptime Efficiency

4. 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 !

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

6. Variability in paper plants !

7. 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 !

8. Sequence of technological deployment
Next Practice
Optimizing Efficiency
Stop Wastage

9. 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

10. 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

11. Steam Management Services
Steam System Management

12. High Efficiency Fuel Flexible Boilers
Copyright Forbes Marshall, 12

13. Housekeeping for a Five * Plant

14. Real time Boiler Efficiency & Safety Max

15. 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

16. BEESAS – Multi parameter tracking
BOILER EFFICIENCY ENVIRONMENT SAFETY AUTOMATED SYSTEM

17. 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

18. 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

19. 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

20. 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

21. Efficiency + Environment
Boiler Efficiency and Environment manager

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

23. Savings calculations

24. 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

25. 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?

26. 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

27. Effect of DryMAX:

28. DryMAX- How it deploys

29. Compact Steam trap Rotary Joints

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

31. Wireless Steam Traps

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

33. 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]

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

35. 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.

36. Thankyou