Effective Utilization of Biomass to reduce Carbon Footprint

Case Study

Contents

Unit Profile Pulping Process Background Problem Statement Energy Efficiency Improvement Approach Root Cause Analysis Improvement Actions Benefits Sustainability Measures Way forward

ABG – Pulp & Fibre Units

VSF Plants

Nagda (MP)Harihar (Kar)Vilayat (Guj) PKharach (Guj)

IBR (Indonesia)

Harihar (Kar)

AV Cell , A V Nackawic, AV TB,

Canada

Baroda + 8 RO / BO

Jakarta

Bangkok

IstanbulCharlotte

Grasim (India) 4

TRC (Thailand) 1

BJFC (China) 1

IBR (Indonesia) 1

Pulp Plants

Grasim (India) 1

AV Cell, AV Nackc., AV TB (Canada)

3

Domsjo, Sweden 1

BLPP (Laos) 1

Marketing Offices

India Turkey

Thailand USA

Indonesia

BJFC (China)

BLPP (Lao)

TRC (Thailand)

VSF Plants

Pulp Plants

Marketing Offices

Domsjo, Sweden

Pulp Plant

Established : 1972 Raw Material : Eucalyptus

Process : Prehydrolysis Sulphate Capacity : 74,400 TPA

Product : Rayon Grade Pulp

Wood Operation Product

Wood to Pulp

Cellulose40%

HemiCellulose

30%

Lignin 25%Extractives

5%

C

O

O

K

I

N

G

AlphaCellulose

Waste PHLiquor

BlackLiquor

Cooked, Washed &Bleached

Anaerobic Digestion

Burnt inRecovery

Boiler

R G Pulp

Bio gas

Steam &

Power

Background

Biogas Plant Installed under BOOT scheme by M/s MGPL in 1996

Biogas plant handed over to Grasim in Dec 2013

Limitations of Biogas Plant as on Nov-2013 at the time of

takeover by Grasim

• Full capacity of the plant not utilised

• Maximum Methane Content in biogas – 60 %

• FO replacement in Lime Kiln – 34%

Problem Statement

Full potential to generate biogas, to replace FO and in turn reduce carbon

foot print not achieved

To improve Biogas plant efficiency

• Team Formation

• Training

• Data Collection

• Discussion with Experts

Approach

Root Cause Analysis

• No skilled supervisory staff

• Inadequate skill level of the operatorsMen

• Lime mixing with PH liquor was not proper

• Improper movement of Gas Holder due to damaged wheels thereby escape of gas from the holder

Machine

• Use of quick lime resulting in feed pH variation

• Use of crude SF oil as surfactant - foam generationMaterial

Method

• Non availability of standard operating procedures

• COD loading not uniform to all the three reactors

• Gas supply pressure to LK -2300 mmWC

• Dilution by UB backwater from pulp mill

• Adhoc addition of micronutrients

Root Cause Analysis

Men

Decided to maintain all the parameters withoutany changes and monitored the results for aweek.

Redeployment of suitable workforce withexclusive responsibility

Shift-wise monitoring of plant operatingparameters by staff.

Enhanced Competency of workers & officers byadequate training , assessment & re-training.

Actions Taken

Machine

Lime mixing tank capacity increased from 4 m3

to 10 m3

Connecting line size increased from 6ӯ to 8үto ensure proper gravity flow to clarifier.

Agitator Gear box replaced with higher capacityfor effective mixing.

Introduced baffles inside tank for better mixing Corroded channels of the gas holder replaced &

smooth movement of wheels ensured.

Actions Taken

Material

Replaced quick lime with hydrated lime tominimize feed pH variation.

Replaced crude SF oil with refined SF oil assurfactant for controlling foaming tendencyeffectively.

Actions Taken

Method

Developed Department procedure, plant start-up &stoppage procedure.

Standard method developed for uniform COD loading tothe reactors based on the VFA and alkalinity values ofthe reactor effluent.

Developed method to maintain higher gas pressure i.e.around 3000 mmWc.

Usage of unbleached backwater stopped and moreacclimatized reactor effluent recycle was increased fordilution

Usage of micronutrients viz. ammonium molybdate,nickel chloride and ferric chloride was controlled to dosein all shifts.

Actions Taken

Method

Developed standard methods and schedule for the reactorgutter cleaning & effluent overflow line cleaning to preventabrupt stoppage of the plant.

Developed procedure for regulating reactor effluent recycleto avoid substrate inhibition

Developed SOP to analyze all the vital parameters. Optimizedanalysis frequency in order to take immediate action in casethere is any upset in the reactor performance.

Online sensors provided to measure critical parameters likepH and temperature, for taking timely corrective action.

Actions Taken

Actions Taken

Dual fuel burner installed to get Compact Medium Length

Flame for efficient utilization of both fuels

Benefits - Tangible

Particulars Unit

Before (during MGPL

period)

After (during Grasim

period)

Remarks

FY13

FY14

(Apr13-

Nov 13)

FY14

(Dec13-

Mar14)

FY15

Volume of PH

Liquor treatedm3/d 400 540 560 600

23%

increase

Volume of Biogas

generatedNm3/d 13790 19190 20290 23360

32%

increase

Methane content % 55 60 63 6511%

increase

FO Replaced % 24 34 40 5157%

increase

Financial GainRs.

Lac p.a.207 161 356 779

208%

increase

59

.28

49

.52

42

.84

32

.03

35

.89

29

.32

29

.59

29

.34

30

.22

28

.18

28

.37

6.2

5

15

.94

23

.61

33

.30

29

.36

35

.75

35

.55

35

.84

34

.55

36

.98

36

.80

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

FY 12 FY 13 FY 14 FY 15 Budget FY 16 UTD FY 16 Apr'15 May'15 June'15 July'15 Aug'15 (Upto7th)

Bet

ter

Biogas replacement Furnace OIl

Lime Kiln - FO replacement in kg/t

Benefits – Intangible

Reduction in carbon emissions equivalent to ~ 1.5 Lac

tons CO2e per year.

Reduced COD load on ETP thereby increasing the ETP

efficiency.

Use of green energy replacing the fossil fuel helped to

improve industry’s image.

Use of renewable energy and conversion of waste into

wealth resulted in “Sustainable Development” of the

pulping operation

Reduced cost of production due to reduction in FO

consumption

Sustainability Measures

Compare operation of biogas plant with best run biogas plant to

standardize the operation further.

To overcome sudden jerks in performance regular addition of cow

dung and ETP biomass has been started.

Started plotting the control chart for all vital parameters such as

VFA, alkalinity & pH.

Weekly monitoring of biomass quality from port samples of all the

reactors.

SOP developed to take quick decision on PH liquor volume

increase or decrease to control COD loading.

Online methane analyzer installed for better control of reactor

parameters.

Housekeeping in the plant given utmost importance to improve the

productivity of the plant.

Way forward

To further increase methane content by using super

clones of microorganisms – work is in progress.

To enrich methane content in biogas by sequestering

CO2 – Project under formulation.

Biogas is being supplied to canteen to replace 75%

LPG. It is planned to replace 100% LPG in next three

months.

Thank You