STAR PAPER MILLS LIMITED

Document Sample
STAR PAPER MILLS LIMITED Powered By Docstoc
					                          STAR PAPER MILLS LIMITED

1.      COMPANY PROFILE
Star Paper Mills Limited ,an ISO 9001-2000 company , is an integrated pulp &
Paper mill having four paper machines producing around 60000 TPA of quality
paper. The company has produced 60196MT of finished paper in year 2001-
02.The company is managed by the DUNCAN GOENKA group, headed by
Shri G.P.Goenka. It has made continuous investment for pollution control,
energy conservation, replacement of old & obsolete units for improvement in
product quality & increased output.
The mill uses Eucalyptus, Bamboo & Poplar as raw material. The steam
requirement of 9.4 T/T of finished paper is met with 2 nos. Coal fired & 1 no.
Chemical Recovery Boiler. To meet the power demand mills has 1 no., 5 MW
BHEL make turbine and 2 Nos., Diesel Generator sets of 4.1 MW each
commissioned in 1999. In the year 2001-02 The company has shifted more load
on DG sets to increase D.G.Set loading and reduced condensing load on 5
MW Turbine. This resulted in reduction of own generation power cost .
The following 2 nos. Tables shows how SPML reduced dependency on grid
power and also reduction in own generation power cost by transferring more
load on D.G.Sets.
 YEAR       OWN                PURCHASED        TOTAL POWER OWN             POWER
            GENERA-            POWER            CONSUMED           AS % OF TOTAL
            TION (KWH)         (KWH)            (KWH)              POWER
 1999-00 65300496              13491872         78792368           82.91
 2000-01 72741261              6685912          79427173           91.58
 2001-02 73068870              5767900          78836770           92.68
After commissioning of D.G.Sets SPMLhas shifted more load on D.G.Set
and reduced condensing load on 5 MW turbine . A table of last 2 years
for comparision is enclosed here with.

 Year      D.G.Power          T.G.Power          Total     own    % of D.G.Power
                                                 generated        of    total own
                                                 power            generated power
 2000-01   46804329           25936932           72741261         64.34
 2001-02   49686870           23382000           73068870         68.00
SPML has transferred more load on D.G. Set by shifting load of I No.
Transformer from turbine to D.G.Set resulting in condensing power
cost reduction. photograph is enclosed here with

In 2001-02 SPML has installed VFD for ID fan of Enmas Recovery Boiler and
replaced its hydraulic fluid coupling.

SPML has installed Digester condensate level controllers in all the Digesters in
2000-01 . A photograph is enclosed here with.
  SPML has modified Exhaust Port of Vacuum Pumps to reduce energy
  consumption. A photograph is enclosed here with.

  2.            ENERGY CONSUMPTION:

          A Pulp and Paper unit is a very energy intensive and consumption of
          power and fuel is sensitive to raw material used and quality of paper
          made. With implementation of various energy reduction proposals, it
          has been possible to reduce the specific Electrical and thermal energy
          consumption (see Table below)

  UNIT SPECIFIC ENERGY CONSUMPTION                  FOR    PAPER     &    BOARD
  PRODUCTION AND LIME KILN

YEAR         ELECTRICAL ENERGY (PAPER          ELECTRICAL ENERGY ( LIME KILN)
                     AND BOARD)
               KWH /        % CHANGE         KWH/ MT OF LIME        % CHANGE
              TONNE        (BASE 99-00)                            (BASE 99-00)
1999-00        1336                -               34.97                   -
2000-01        1310             - 1.95             34.48                 -1.40
2001-02        1298             -2.85              33.18                 -5.12

YEAR        THERMAL ENERGY (PAPER AND            THERMAL            Energy Cost
              BOARD) MKCAL/T of PAPER         ENERGY ( LIME          (% of total
                                                   KILN)           manufacturing
                                               MK-CAL/LIME             cost)
                                                PRODUCED
1999-00                  5.08                       1.24                 23.28
2000-01                  4.80                       1.20                 23.80
2001-02                  4.76                       1.16                 22.88

  3.      ENERGY CONSERVATION COMMITMENT, POLICY AND SET UP
  Energy management has been accorded top priority. An Energy Management
  Cell headed by the G.M.(P & D) and supported by Managers and Engineers from
  process, electrical and utility plant is in existence for regular and efficient
  monitoring and control of energy consumption. The reason for any deviation and
  the corrective action taken is recorded and analyses .
  The company has formed a Core Committee (SANKALP) for energy
  conservation and cost reduction proposals of senior engineers of various
  sections, headed by General Manager(E&I). The brain storming sessions are
  regular features of this committee.
  4.    ENERGY CONSERVATION ACHIEVEMENTS
  The implementation of various Energy Conservation Proposals in last 3
  financial years has yielded a cost savings of Rs.221.81lacs with an
  investment of Rs. 71.13 lacs. It has been possible to reduce the coal
  consumption per T of paper from 0.69 MT in 1999-00 to 0.59 MT in
 2001-02. Current power consumption is very encouraging and we are
 getting around 1255 Kwh/T of paper for 4 Months in current financial
 year. Write-up on the jobs completed during 2001-02 is furnished in
 the main application.

 5.      ENERGY CONSERVATION PLANS AND TARGETS
 To further improve the energy performance and to conserve the energy, the
 following projects are under implementation. The targets for year 2002-03 is to
 reduce the energy consumption by minimum 2 % below the previous year
 achievement. Some of the main energy conservation projects are listed below.

 1. Installation of Bio-Mass boiler and substituting conventional fossils fuel ( coal )
    by agro waste .
 2. Renovation of Paper Machines Hood fans
 3. Upgradation of Instrumentation in existing plant for proper monitoring &
    controls
 3. Installation of High efficiency Pumps in turbine & pulp mills.
 4. Installation of variable frequency drives for washers etc.
 5. Installation of efficient vacuum pump for Lime Kiln to conserve power..

 6.      ENVIRONMENT AND SAFETY

 A full fledged safety   department helped by various safety circles and
 departmental safety committees       is looking after the safety of the plant,
 personnel and equipments in the mills.

 The company has got full fledged effluent treatment plant using activated sludge
 process The treated effluent meets the standard prescribed by U.P.Pollution
 control Board.. All the boilers and lime kiln are equipped with ESPs to keep the
 environment pollution free. Use of Hydrogen Peroxide & enzymes as bleaching
 agent has reduced        the effluent coloration & feed flow to the ETP Plant.
 Under Social forestry programme 122 lacs. seedlings developed from quality
 seeds were distributed in the year 2001-02 to local farmers for planting on their
 farm land to keep environment green


 1. A. ENERGY CONSERVATION MEASURES IMPLEMENTED IN LAST 3
 YEARS (1999-2002)

YEAR           PROJECT             ACHIEVEMENT OF ENERGY                TOTAL        INVESTME
  OF         DESCRIPTION                  SAVING S                     MONETA             NT
COMMI                                  PER YEAR BASIS                     RY         INCURRED
  SSI-                                                                 SAVINGS          (RS.IN
ONING                                                                    (RS           LAKHS)
 1999-                                                                 .LAKHS)
   00
                       POWE              FUEL
                         R
                       LAKH   COA        F.     TOTAL
                        KWH   L MT       OIL     FUEL
                                         KL       IN
                                                  MK
                                                 CAL
1.   IMPROVED          -      60     -          216     1.48    0.70
     CONDENSATE
     RETURN FROM 62
     % TO 70 %.
2.   REDUCING THE      1.23   -      -          -       2.95    0.19
     SPEEDS OF
     EQUIPMENTS TO
     OPTIMUM.
3.   POWER SAVING      1.30   -      -          -       3.12    0.00
     BY CHANGING
     THE DISC
     PATTERN OF
     REFINERS.
4.   AUTO              2.11   -      -          -       5.07    0.35
     START/STOP
     SYSTEM FOR
     PUMPS &
     AGITATORS.
5.   BYPASS PULP       2.22   -      -          -       5.32    0.88
     CHESTS TO
     REDUCE PUMP S
     & AGITATORS
     RUNNING POWER.
6.   MODIFICATION IN   -      360    -          1296    8.90    2.08
     DIGESTER BLOW
     LINE SIZE.
7.   STEAM LINE        -      24.3   -          87      0.60    0.00
     MODIFICATION IN
     DIGESTER PRE-
     HEATER .
8.   REDUCING THE      -      526    -          1894    12.96   0.00
     COOKING
     PRESSURE OF
     DIGESTER.
9.   MODIFICATION IN   2.57   -      -          -       6.18    1.08
     BAROMETRIC
     LEGS OF EIMCO
     WASHERS.
YEAR         PROJECT        ACHIEVEMENT OF ENERGY             TOTAL    INVESTMEN
  OF       DESCRIPTION             SAVINGS                   MONETA          T
COMM                            PER YEAR BASIS                  RY      INCURRED
 ISSI-                                                       SAVINGS       (RS.IN
ONIN                                                           (RS        LAKHS)
   G                                                         .LAKHS)
1999-
  00
                            POWE            FUEL
                              R
                            LAKH    COAL        F.    TOTA
                             KWH     MT         OIL       L
                                                KL    FUEL
                                                         IN
                                                        MK
                                                        CAL
 10.     STOPPING           2.35    -       -         -     5.64       0.80
         PROCESS PUMPS
         BY PROVIDING BY
         PASS LINES.
 11.     INCREASED STEAM    --      728.4   -         2622   18.00     0.00
         ECONOMY FOR
         EVAPORATORS.
 12.     PROVIDE ROTARY     -       -       37.2      228    3.53      0.36
         FEEDER FOR LIME
         KILN STONE
         FEEDING SYSTEM
 13.     INCREASING THE     -       101.2   -         364    2.50      0.05
         SOOT BLOWER
         SPEED IN
         RECOVERY
         BOILER.
 14.     MAXIMISING THE     -       158.0   -         569    3.90      0.00
         SOLID
         CONCENTRATION
         IN ENMAS
         RECOVERY
         BOILER.
 15.     .MODIFICATION IN   -       -       57.0      350    5.40      0.10
         SALT CAKE MIXING
         TANK STRAINER
 16.     REDUCING THE       7.34    -       -         -      17.62     0.00
         ELECTRICAL
         FREQUENCY OF 5
         MW TURBINE.
 17.     REDUCING THE       13.25   -       -         -      31.80     0.00
       ELECTRICAL
       FREQUENCY OF
       D.G.POWER.
18.    IMPROVING THE       3.12     -       -      -      7.50        1.60
       POWER FACTOR
       OF 5.0MW
       TURBINE.
19.    REPLACING 2         1.04     -       -             2.50        0.31
       NOS.VACUUM
       PUMPS IN PM-1 BY
       A SINGLE LARGE
       PUMP.
20.    MODIFICATION IN     -        80.97   -      291    2.00        0.10
       S TEAM HEATING
       COILS OF
       CAUSTICISING
       TANKS.
       TOTAL (1999-2000)   36.53    2038.   94.2   7917   146.97      8.60
                                    8



 YEAR         PROJECT               ACHIEVEMENT OF            TOTA    INVESTME
  OF         DESCRIPTION            ENERGY SAVINGS              L          NT
COMMI                               PER YEAR BASIS             (RS    INCURRED
  SS-                                                         LAKH)     ON THE
IONING                                                                 PROJECT
2000-01                                                                  (RS.
                                                                       LAKHS)
                                  POWE          FUEL
                                    R
                                  LAKH    COAL     TOTAL         -
                                  KWH    TONNE     FUEL IN
                                           S       (Million
                                                    K Cal)
  1.      4L3 PUMP IN       0.083                             0.25    0.55
          CONICAL TANK IN
          PM-1 REPLACED BY
          KSB MAKE PUMP.
  2.      INTERLOCK VACUUM .46                                1.29    1.42
          PUMPS WITH FAN
          PUMPS FOR PM-
          1,3,4.
  3.      CENTRALISED       0.25                              1.52    1.97
          CONTROL DESK FOR
          PM-3 MAIN MOTORS.
4.    REPLACED FLOOD      0.45                      1.26    0.84
      LIGHTS BY
      MERCURY LIGHTS
5.    REPLACED TOWER      0.11                      0.30    0.80
      NO.7 PUMP BY HIGH
      EFFICIENCY PUMP.
6.    HIGH EFFICIENCY     0.10                      0.30    0.58
      PUMP FOR
      RECAUSTICISER
      TANK.
7.    RUN ONLY 1 HIGH     0.75                      2.96    5.26
      CAPACITY BOOSTER
      PUMP FOR SURFACE
      CONDENSER.
8.    HIGH EFFICIENCY     0.063                     0.16    0.58
      PUMP FOR MUD
      TANK .
9.    AUTO COMBUSTION     0.93    534.8    2012     15.93   8.83
      CONTROL FOR WIL
      BOILERS.
10.   HIGH EFFICIENCY     1.32    -        -        3.71    4.21
      PUMP FOR RPC-
      1,2,3,4.
11.   REDUCE              1.17    -        -        3.25    3.43
      DISTRIBUTION
      LOSSES IN
      D.G.POWER.
12.   REPLACEMENT OF      0.15    -        -        0.43    0.27
      PM-1 FAN PUMP.
13.   INSULATION IN       -       554.8    2087     9.92    3.43
      VARIOUS AERAS
14.   DIGESTER NO.3       -       18.2     68.4     0.44    1.15
      CONDENSATE
      CONTROLLER.
15.   TO OPERATE          0.06                      0.16    0.00
      UNDER LOAD
      MOTORS IN STAR
      MODE
16.   HIGH EFFICIENCY     0.13    -        -        0.38    0.51
      PUMP FOR PM-1
      WIRE PIT
17.   BIGGER SIZE BROKE   0.045   -        -        0.13    0.00
      PULPER
      TOTAL (2000 -01)    6.17    1107.8   4167.8   42.39   33.83
 YEAR           PROJECT             ACHIEVEMENT OF          TOTA INVESTMEN
  OF          DESCRIPTION          ENERGY SAVING PER          L  T INCURRED
COMMI                                 YEAR BASIS             (RS    ON THE
  SSI-                                                      LAKH   PROJECT
ONING                                                          ) (RS. LAKHS)
2001-02
                               POWE            FUEL
                                 R
 S.No.                         LAKH      COAL    TOTAL        -
                                KWH      (MT)     FUEL
                                                    IN
                                                 (Million
                                                  K Cal)

  1.      ID FAN VFD FOR       2.10      -       -          5.90    15.32
          ENMAS RECOVERY
          BOILER

  2.      MODIFICATION OF      1.40      -       -          3.92    0.70
          EXHAUST PORT OF
          KVM-600 PUMPS ( 4
          NOS.)

  3.      TO REDUCE THE       0.76       -       -          2.13    2.53
          MOTOR RATING OF 270
          H.P VACUUM PUMP
          (KVM-600) ON PM-2

  4.      ENERGY EFFICIENCY    0.25      -       -          0.70    2.65
          PUMP FOR BLOW
          TANK.

  5.      CONDENSATE           -         707     2746       19.80   7.50
          CONTROL SYSTEM
          FOR ALL DIGESTERS.

				
DOCUMENT INFO
Shared By:
Categories:
Tags:
Stats:
views:35
posted:2/9/2012
language:English
pages:8