Technology

Technology Info

TNPL commenced its operations in Kagithapuram, Karur District, in 1984, with an annual installed capacity of 90,000 tpa. Over the years, the capacity of TNPL’s Unit I in Kagithapuram has risen from 90,000 tpa in 1984 to 400,000 tpa in 2011. Today, TNPL is an acknowledged leader in the technology of manufacture of paper from bagasse – the sugar cane residue. Over the period of its operation for over three decades, TNPL brought several new technologies in the company’s fold like ECF bleaching, Oxygen delignification, Integrated Chlorine dioxide production, Wash presses, Odour free recovery boiler, Incineration of non-condensable gases, production of bio-gas from bagasse wash effluent, Deinked Pulp etc. Today, by way of implementing the state-of-the art technologies, TNPL enjoys the status of the most environmentally benign mill in the country with least water consumption. To further better the operation, the company is examining the ways and means to reduce the mill water consumption. The mill is also examining the possibility of recycling and reusing the waste water in order to reduce dependence on the fresh water.

As the Paper Board segment is identified as a growing segment compared to Paper TNPL thought it is prudent to foray into this market segment. Accordingly, a project for manufacture of Paper Board was conceived, and thus TNPL Unit II emerged. TNPL commissioned a 200,000 MT per annum Multilayer Coated Paper Board machine (BM 4), along with a 30 MW captive co-generation power plant, in January 2016. The four layer Board machine has facility to manufacture varieties of coated boards like White line Chip board (WLC), Folding Box Board (FBB) and Solid Bleached Sulphate Board (SBS) in the substance range of 170 to 450 gsm, coated on both sides. The Board machine is controlled by the latest Distributed Control System (DCS) and Quality control systems (QCS). TNPL has installed a state-ofthe-art Automatic Storage and Retrieval System (ASRS) with a capacity to store 30,000 MT Reels and 6,000 MT Sheets. The Power plant of the TNPL Unit II is equipped with a high efficient boilers operating with atmospheric fluidised combustion technology. The power plant is equipped with an Air Cooled Condenser (ACC) to conserve water to the maximum extent. The Board machine also has facility to recover the white water and reuse to the extent possible. For optimizing the consumption, variable frequency drives have been introduced in various sections of the Board machine and power plant. In October 2017, TNPL installed a Roll Grinding machine equipped with high end control automation including online measurements and CNC based Grinder Control System, for carrying out grinding of various rolls in Board machine. 

The modern waste water treatment plant in TNPL Unit II enables utilization of the entire waste water generated from the mill to be used for irrigation in TNPL’s own lands to an extent of 575 acres. In the plantation area, drip irrigation method is deployed, to raise more than 6 lakh trees, with various varieties of fruit bearing, flowering, avenue trees including some pulp wood species. The TNPL Unit II is gearing up for the next expansion, wherein a state-ofthe-art hardwood ECF pulp mill will be installed in Phase 1 and a Paper Machine in Phase 2. The process of obtaining Environmental clearance for the project has already commenced and Phase 1 of the project is targeted for commissioning by May 2021.

Energy: Pulp and Paper Industry is Energy intensive and the Energy cost is around 25% of its Manufacturing cost. TNPL is taking constant efforts to reduce the carbon footprint. TNPL consumes biofuel and bio-gas to a larger extent. The Consumption of bio-fuel and bio-gas accounts for 35.41% of the total Energy consumed during 2017-18 against the value of 40.14% in 2016-17.

Agro / Internally generated waste Fuels Utilised

2017-18 MT

2016-17 MT

Agro fuel

461

472

Pith

99483

161017

Wood Dust/bark

6891

10610

BL Solids

331393

411671

Bio Methana- tion gas (‘000 M3)

6326

6852

TNPL is operating two bio-methanation plants to treat high organic wastewater from bagasse handling and storage system and to generate bio-gas under waste to energy concept. The Biogas generated is utilized in the lime kiln to replace furnace oil. For the year 2017-18, biogas generation was 63.26 Lakh M3 against 68.52 Lakh M3 in the previous year. The bio-gas generated is used in lime kiln as fuel to replace 3724 KL of furnace oil and in Power Boiler to replace 319 MT of Imported Coal. TNPL is self sufficient in power in both the units. The installed capacity of Power Plant in Unit-1 is 103.62 MW and Unit-2 is 35 MW. Power Generation and consumption details are as given below.

 

2017-18
Captive Power Plant
Generation Self Consumption

Export

Import

Unit-1 5262.94 5201.11 61.83 93.48
Unit-2 1130.37 1038.20 92.17 30.08
Wind Farm 515.40 44.66 470.74 10610
Total  6908.71 6283.97 624.74 123.56

As a part of Energy Conservation Act 2001, the Ministry of Power notified the list of designated consumers (DCs) of various power intensive industries across the country on 30th March 2012. It also specified the baseline energy consumption of the individual DCs and their targeted energy consumption norms to be met in the period from FY 2012-13 to FY 2014-15 as per “Perform Achieve and Trade” (PAT) scheme. For Ist PAT Cycle BEE notified Specific Energy Consumption  for TNPL was 0.572 TOE / TON and the Target was 0.550 TOE/TON.

TNPL Achieved 0.530 TOE / TON during the assessment year 2014-15. As the actual specific energy consumption was less than the target fixed TNPL was awarded 4969 of Escerts (Energy Saving Certificates).The Ministry has also notified the Second PAT cycle on 31st Mar 2016 and the values of Specific Energy Consumption were given without normalization. Accordingly the target value for TNPL is 0.7234 TOE / TON against the Base line value of 0.7680 TOE/ TON. This target is to be achieved by 31st March 2019 i.e at the end of three year PAT II cycle starting from 2016-17.

TNPL has obtained the Energy Efficient Unit award for the  year 2017 from Confederation of Indian Industry (CII). During the FY 2017-18,TNPL has saved 24.97 lakh units of Power (previous year 19.14 lakhs units), 2417.38 MT of Imported coal (previous year 4391.57 MT)  and  3760.11  KL   of   furnace oil (previous year 4237.29 KL ) by implementing various Energy saving projects.TNPL has installed the first wind Farm of 15 MW  capacity  during  1993-94 at Devarkulam perungudi, Tirunelveli District. Since then the company has increased the wind farm capacity to 35.5 MW in phase manner. The wind farm power is exported to the grid with a small consumption for corporate office by wheeling.

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