JK PAPER LTD Unit : Central Pulp Mills PO : Central Pulp Mills Fort Songadh Dist. Surat (Guj)- 394660 Phone: (02624)

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JK PAPER LTDUnit Central Pulp MillsPO
Central Pulp MillsFort SongadhDist. Surat
(Guj)- 394660Phone (02624) 221228
221278/79/80Fax (02624) 221138Emailcpm_at_cpmjk
.jkmail.com
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• JK PAPER LTD, Unit Central Pulp Mills
• A large integrated Pulp and Paper Mill in Western
  India with installed capac22ity 47000 TPA
• Product- Writing and Printing Papers utilizing
  bamboo and hardwood as raw materials.
• Unit originally installed in 1966, taken over by
  JK Organisation in 1992 and rehabilitated in
  1993-94.
• Unit is ISO 14001 and ISO 9001 certified,
  manufacturing W P papers e.g. SS Maplitho,
  Copier, Ledger, Parchment, Base Paper, MICR
  Cheque Paper etc.

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JK PAPER LTD- CPMENERGY CONSERVATION
POLICYWe are committed to reduce the energy
consumption and cost by

• Optimization of plant and equipment efficiency
• Elimination and prevention of all types of losses
  such as water, power, steam, coal, compressed air
• Maximizing condensate recovery and use process
  heat recovery, waste minimization
• Increasing the cogeneration of steam and power
• Improved utilisation of natural resources leading
  to environmental benefits
• Energy conservation through total employee
  involvement

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• Utilities
• Boilers - Coal Fired of capacities 18, 27 tph
  (Both standby) 50 tph at 42 Kg/cm2 4100 C
• TG sets - 2 X 3 MW (Both standby) 12 MW running
  in cogeneration as double extraction cum
  condensing operation.
• Water supply - Raw water is pumped from Ukai Dam
  Canal 3 kms away. After treatment mill
  water is supplied for process and to DM plant.
  Excess white water from Paper Machines is
  clarified for fibre recovery and recycled..
  Treated effluent water is also recycled for chips
  washing, floor washing sprinkling for dust
  control.
• Compressed Air - For plant controls. Centralised
  operation being planned.
• Soda Recovery Waste Heat Boiler - 335 TSD, firing
  generates steam at 42 Kg/cm2, 4100 C burning
  black liquor from pulping and recovery of cooking
  chemicals for recycling.

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• Energy Cell Structure
• EC Cell headed by CE (Works) and reviewed by CGM
  (Tech)
• Coordinators - GM (Utilities), GM (Electrical),
  GM (Manufacturing) Sr Manager
  (Soda Recovery)
• Meeting held fortnightly for brain storming and
  identifying new ideas.
• Viable EC schemes analysed with estimates for
  expenditure v/s savings with payback and
  accordingly priority drawn, for finance
  allocation.
• EC team includes Mr Akash Saxena, AM (Utilities)
  and Mr S S Dixit, Mech Engg (Maint). They are
  qualified Degree engineers and holding EC Manager
  Certificate of FICCI and BEE, respectively.

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• Strategy followed
• Daily checks on Power, Steam, Water consumptions
  and Condensate return from Plant sections
  Analysis of variations done same day with
  corrective steps.
• Replacement of old and inefficient equipments
  consuming more energy like pumps, motors etc. as
  per required duty.
• Enhancing plant equipment availability.
• Upgrading technology and automation controls
  (DCS) for consistent quality and optimized
  resource and Energy Conservation specific
  consumptions.
• Adopting TPM steps to maintain data and
  improvements thereto.
• Internal and external energy audits done
  quarterly and yearly to sustain achievements
  under EC.

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Power KWH/T Paper Target v/s Actual (2001
to 2004 and Target-2004-05) Year July to June
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Steam -T/T Paper Target v/s Actual (2001
to 2004 and Target-2004-05) Year July to June
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Coal -T/T Paper Target v/s Actual (2001 to
2004 and Target-2004-05)Year July to June
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EC projects implemented during year 2003-04

• Scheme-1- Mill Water Savings - 80 m3/hr

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Scheme-2- Delivery head reduction of PM-I
Machine Chest Pump Investment
Rs. 0.10 Lacs Saving /Yr
- Rs. 0.58 Lacs Payback
2 months

• Scheme-3- Replacement PM-II Flat Box Seal Pit
  Pump with line
• Investment Rs.
  0. 6 Lacs
• Saving /Yr -
  Rs. 1.50 Lacs,
• Payback 5
  months

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Scheme-4- New Pump PM-II of low head
Circulation chest
Investment Rs. 1. 5 Lacs
Saving /Yr - Rs. 2.2 Lacs,
Payback 8 months
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Scheme-5- New Mill Water Pump of low head
Investment - Rs. 2. 5 Lacs
Saving /Yr - Rs. 12.5
Lacs, Payback - 3 months
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• Scheme-6- Level Control in Colony Water
  overhead tank
• Investment - Rs. 0.85 Lacs
• Saving /Yr - Rs. 1.62 Lacs,
  Payback 7 months

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Scheme-7- Replacement of Canal water pump with
low head, low discharge,
high efficiency pump Investment
Rs. 1.7 Lacs Saving /Yr
- Rs. 2.78 Lacs, Payback
7.5 months
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Scheme-8- Flash vapour utilisation for make
up DM water heating
Investment Rs. 0.35 Lacs
Saving /Yr - Rs. 3.7 Lacs,
Payback 2 months
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Specific Energy KWH Thermal, Reduction for period 2001-2004
Year Product Production (MT) KWH/Tonne reduction over 2001-2002 MkCal/Tonne Reduction over 2001-2002
2001-2002 W P Prodn -51010 1205.00 -- 6.323 --
2002-2003 W P Prodn 51743 1152.96 4.39 5.715 9.61
2003-2004 W P Prodn 50423 1168.00 3.07 6.507 -2.82

1. Specific figures exclude Power Thermal energy
   for Coal Boilers, Turbine and Colony
2. Thermal figure higher for 2003-04 due to lower
   production.

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Energy cost reduction achieved as percentage of
total manufacturing cost (2001 to 2004)
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Presentation concluded

• EC is Continuous Effort Process and Improvements
  have to go on on..
• Questions Welcome ?
• S GOSWAMI S K KAUL