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.