ANALYTICAL STUDY ON POWER AND WATER ENERGY

MANAGEMENT TOWARDS OPTIMIZED PERFORMANCE WITH

REFERENCE TO TNPL

INDUSTRY PROFILE ON TNPL

Globally over 400 million tonnes of paper and paper products are consumed. The world's three largest paper
producing countries are China, the United States, and Japan (these three countries account for approximately
half of the world's total paper production), while India accounts for a small but growing share of the global
market. The global paper and pulp mills industry has contracted slightly over the past five years, primarily
due to the shift to digital media and paperless communication across most developed economies. However,
demand in emerging markets has partially offset the decline by driving increased demand for paper used in
packaging materials.

India’s share in global paper demand is gradually growing as domestic demand is increasing at a steady pace
while demand in the western nations is contracting. The domestic demand in India grew from 9.3 million
tonnes in FY08 to 15.3 million tonnes in FY16. In spite of the sustained growth witnessed by the industry, the
per capita paper consumption in India stands at a little over 13 kg which is well below the global average of
57 kg and significantly below 200 kg in North America. As per IPMA’s (Indian Paper Mills Association)
estimates, this industry provides employment to over 5 lakh people across approximately 750 paper mills.

The Indian Paper & Paperboard industry is one of the

oldest organized manufacturing industries in India and
the first paper mill was started in 1812 in Serampore,
West Bengal. The industry accounts for approximately
4% of the world’s production of paper. IPMA (Indian
Paper Mills Association) estimates the industry turnover
at approximately Rs50,000 crore which year contribution
of Rs4,500 crore to the exchequer while providing
employment to over 5 lakh people across approximately
750 paper mills.
The paper industry is classified into four segments, Printing & Writing (P&W), Packaging Paper & Board,
Specialty Papers & Others, and
Newsprint. The chart depicts the
variation of the consumption across the
segments globally and in India. The
table below illustrates the sub-
segments and movement in share of
total demand over the years. The first
paper mill was stared in china and then
Baghdad. After 40 year a paper mill
was started at Hainault in France. Then
the art of paper making entered into England, Switzerland and Netherlands. In 1800 a book was published
describing the method of manufacturing paper from wood pulp and vegetable pulp. Paper industry plays an
important role in the industries development in India. Paper industry occupies a large percentage in India
market. It provides wide employment opportunities. Paper industry not only plays vital role in India economy
but also enhances our product values in world market.

COMPANY PROFILE OF TNPL

Tamil Nadu Newsprint and Papers Limited (TNPL) is in the business of manufacture and marketing of paper,
paper board, cement and generation of power. The installed capacity of Paper is 400000 tons per annum (TPA).
Power Generation Capacity is 174.12 MW consists of 138.62 of Turbo Generators (TG's) and 35.50 MW of
Wind Farm. Generation of Power is primarily for self-consumption and surplus is sold. The products are being
marketed throughout the country and also being exported to 30 countries around the world.

The company's Newsprint and Printing & Writing Paper plant is located at Kagithapuram in Karur District of
Tamil Nadu. Tamil Nadu Newsprint and Papers Ltd was established by the Government of Tamil Nadu in
April 1979 as a public limited company to produce Newsprint and Printing & Writing Paper (PWP) using
bagasse as the primary raw material. The plant located at Pugalur in Karur District was commissioned during
1984 with an initial capacity of 90000 tonnes per annum. During the year 1994-95 the company undertook
expansion programme and doubled their capacity to 180000 TPA. They entered into a long term agreement
with Tamil Nadu Forest Plantation Corporation Ltd for continuous supply of pulpwood. The company received
Special Export Award from CAPEXIL in recognition of outstanding export performance. They received
Received the 'Best Energy Conservation Award' for the year 2007 from the Government of Tamil Nadu. They
also received TERI Corporate Environmental Award 2008 for the efforts towards environmental management
and innovative initiatives among corporate.

TNPL has installed its own power generating facility to make it 100% self-sufficient through the installation
of 61.18 MW Power Generating Equipments installed at the paper mill site. The surplus power generated is
being exported to the State Grid. TNPL also generates green power through the 18 MW wind farm installed
at Devarkulam and Perungudi of Tirunelveli district. The entire power generated at the wind farm is being
exported to the State Grid. The wind farm capacity has been enhanced to 21.75 MW in March 2004 by
installing 3 wind turbine generators of 1250 kW capacity each. TNPL exports their products to countries like
Australia, Egypt, Greece, Indonesia, Jordan, Kenya, Malaysia, Myanmar, Nepal, Nigeria, Philippines,
Singapore, Sri Lanka, South- Africa, Taiwan, Turkey, U.A.E.., U.K. Yemen.

BOARD OF DIRECTORS
1. Thiru N Muruganandam, IAS (Chairman)
2. Thiru S.SivaShanmugaraj, IAS (Managing director)
3. Thiru S Krishnan, IAS (Director)
4. Dr. M Arumugam (Director)
5. Thiru V Nagappan (Director)

OBJECTIVES OF TNPL ON QUALITY

 The most important objective of TNPL is to satisfy customer requirements at competitive
prices.
 Maximizing the usage of eco-friendly agro-waste fuels for generation of fuels.
 To improve the quality of the paper to that of International standards.
 Become globally competitive in terms of cost, pricing and quality.
 To reduce the usage of trees for the production of paper pulp.
 Involvement of all the employees for cost reduction and efficient utilization in generation of
steam and electricity.

ACHIEVEMENTS OF TNPL
 The centre for science & economics, New Delhi has awarded TNPL “3 leaf green rating”
awarded in appreciation for its environmental management system.
 Confederation of Indian industry has recognized the bio-machination project implementation
by TNPL as an “innovative project”.
 Received the special export award from CAPEXIL in recognition of outstanding export
performance, for the seventh consecutive time.
 Achieved “zero-stock” of finished goods at the end of financial year for the sixteenth time.

STATEMENT OF PROBLEM
TNPL is a government organization which is into paper industry, which consumes a lot of power for the
production of paper. Around 30MW of power is required for the machines to run. The company uses multiple
methods to manage the demand of power like producing power from coal and wind. The surplus power is
being sold out to the government. From the cauvery river, around 3tonnes of water are taken per day for the
machines to run. Due to the production of power to satisfy the requirement is very high, the pollution rate also
rises. Hence this study is done to analyze the process and identify areas where energy in the form of power,
water can be conserved and minimize the pollution.
LITERATURE REVIEW

1. Energy Conservation and Management for Houses and Building in Oman-Case study, by
Miqdam T Chaichan, The paper explains the importance of appropriate design of a house for better
energy conservation and management. To achieve it consideration of a suitable lighting, efficient
ventilation, insulation is very important.

2. Energy Conservation Opportunities in Pulp & Paper Industry, by Ashok Kumar Pandey, The
pulp & paper industry energy auditing process is used to establish the overall energy consumption in
the industry, estimate the scope for saving, identify the easiest areas for attention, identify immediate
improvements and savings, set a reference point, identify areas for more detailed study and
measurements. Such an industrial energy audit will help to keep focus on variations which occur in
the energy costs, availability and reliability of supply of energy, decide on appropriate energy mix,
identify energy conservation technologies, retrofit for energy conservation equipment etc.

3. Specific Energy Consumption/Use (SEC) in Energy Management for Improving Energy

Efficiency in Industry, by Akvile Lawrence, the increasing importance of monitoring improved
industrial energy efficiency and the rising popularity of SEC as an energy key performance indicator
(e-KPI), an in-depth analysis and problematization on the pros and cons of using SEC would appear
to be needed. The aim of this article is to analyze SEC critically in relation to industrial energy
efficiency.

4. Energy management in industry: a systematic review of previous findings and an integrative

conceptual framework, by Mike Schulze, One of the most promising means of reducing energy
consumption and related energy costs is implementing an energy management in an organization.
Research in relation to energy management must be conducted in the area of energy audit practices,
evaluation of energy audit programs, energy system or process optimization by statistical modeling,
development and evaluation of energy end-use industrial policy programs and measures, as well as
performing energy efficiency benchmarking. A comprehensive review of published scientific articles
on energy management practices in industry is currently lacking, calling for such a review to be
conducted.

5. An assessment of improvement potentials at different levels in paper industry, by Jobien

Laurijssen, Energy efficiency improvement potentials could be found in stock preparation, de-inking
and dispersion, but energy use in these processes was found to be too dependent on quality
requirements and product specifications to quantify this potential.

6. Energy efficiency opportunities for pulp and paper industry in South Africa, by Hilton
Maverengo, Measures suggested to reduce electricity distribution losses include repairing of leaking
steam pipes and broken steam traps on site, proper management of steam venting by either using steam
pipes, deaerator tanks, or demineralized water tank as steam accumulators/sinks. Suggestions to curb
equipment energy losses include installation of VFD on electric motors, proper sizing of pumps and
its piping system.
7. Energy Cost Reduction in the Pulp and Paper Industry, by D.W. Francis, in this paper the author
explains that there is considerable potential for energy use reduction in pulp and paper mills. The
process steam and electricity demands can be met by burning the spent pulping liquor and the hog fuel
associated with the chip supply.

8. The Pulp and Paper Industry: Addressing the Need for Energy Efficiency, To improve energy
efficiency, the pulp and paper industry in the European Union has invested in combined heat and
power (CHP) generation and – in Europe – now produces almost half the electrical energy it consumes.
Due to efficiency improvements over the last 30 years, direct CO2 emissions have decreased while
pulp and paper production has increased. Potential breakthrough technologies are being tested to
demonstrate market viability and increase efficiency even further.

9. Technology compendium on energy saving opportunities in pulp and paper industry, by

sustainable energy foundation, Methane gas has high calorific value, can be used as fuel in the boiler
to produce steam and thus power from steam. This saves the fuel cost and reduces the pollution.

10. Energy flow analysis in pulp and paper industry, by Gui-Bing Hong, The paper focus on how to
capture some of the energy currently lost in the processes and then identifying the areas with energy-
saving potential that could also have large impacts across a variety of industries. The greatest energy-
saving potential lies with improving energy distribution and equipment efficiency, which would
together potentially comprise 86.8% of total energy conservation.

11. A changing industry: from paper to fiber business, by Simens, this explains paper can be made
from tomato plants, cosmetics made of eucalyptus or fiber-based insulating materials using new
opportunities and exploring new markets for a sustainable future. Byproducts from the timber and
pulp industry – electricity, biogas, turpentine – are gaining in economic significance, as are both new
applications for natural fiber in the chemical and textile industries and new technologies for producing
biofuels, carbon, and composite materials.

12. Energy Efficiency Improvement and Cost Saving Opportunities for the Pulp and Paper
Industry, by Klaas Jan Kramer, this paper explains the injection of CO2 into the wash water of
brownstock washers reportedly improves pulp drainage, which can enhance washing efficiency and
lead to improved throughput and reduced water usage.

13. Declining energy intensity in the pulp and paper industry in India, Sandeep Kumar Kujur, This
paper explains the various methodologies that can be used to eliminate the wastage of power in various
sectors.

14. Process heating for industrial facilities, by pulp and paper technologies, this explains that several
ways were discovered during these assessments to reduce energy consumption in several paper
industries. These included improving boiler combustion efficiency, using blow down steam energy
rather than live steam to preheat makeup feed water, and installation of a stack economizer.
 15. Energy efficiency opportunities in the U.S. pulp and paper industry, by Kramer, in tis paper the
author hopes that the energy guide can be used by energy managers in the U.S. pulp and paper industry
to identify areas for energy efficiency improvements, to evaluate potential energy improvement
options, to develop action plans and checklists for plant-level energy management, and to educate
company employees on the importance of and actions for improved energy efficiency.

OBJECTIVES OF STUDY
• The main objectives of this project work in TNPL is to equip myself with practical knowledge by
studying the existing system of the organizational structure and to understand the aspects of the various
activities of the organization.
• To analyze the organization thoroughly and identify the areas where energy can be conserved.
• To study the functions of various process in the production process.
To analyze the system and come up with suggestions in the areas of power generation, steam
production and water utilization.

NEED FOR STUDY

The paper industry in India is growing in a rapid speed with demand increment and oppor-tunity creation and
attraction to the international players. Paper products are used in education, healthcare, food, trade,
communication and packaging. The population of India has been growing at a significant pace which has led
to the increase in the paper consumption as each individual utilizes paper and other related products .Paper
Industry in India is moving up with a strong demand push and is in expansion mode to meet the projected
demand of 20 Million tons by 2020. To meet the requirements a large amount of power will be required.
Production of energy leads to pollution and produces green-house gases. This study is done to analyze and
identify various areas where energy can be conserved to protect the environment.