Introduction:
It is a Writing & Printing and Tissue grade paper mills mainly based on agro residues and wild grasses & waste paper. As on date, the mill has grown to a 75 TPD mill in a decade, marching ahead to new heights.
1. SHIVA PAPER MILLS (SPM), Jain Nagar, 15 km stone from Rampur on Rampur Bareilly road since its inception, had strictly adhered to basic goals on which the entire edifice stands and set a noble example as a model mill in this western region of U.P.
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2. It is model mill, by itself, primarily to preserve the Eco balance of nature.
3. Environmentally friendly, in the sense, producing paper from agricultural wastes, a departure from forest based Pulp & paper mills, thus preserving large virgin forest and indirectly contributing to preserving wild life.
4. Upgrading the socio-economic status of the region around the mill by providing employment to the kins of the agriculturists in a big way.
5. Raising their standard living indirectly by paying adequate price for the agricultural wastes like bagasse, paddy, wheat straws, wild grass etc. for making paper.
6. Adopting environmentally friendly pulping process by which the ambient air quality is maintained pollution free off sulphurous smokes, an uncommon phenomena in Kraft wood based mills.
7. Last but not the least, it is the exhaustive treatment set up available to make the waste effluent generated from the plant, free of pollution hazard, at the same time assuring the small and medium farmers of growth potential in agricultural sector. It is worth mentioning that adequate sizes of land held by poor farmers, are brought under irrigation of cash crops without an iota of doubt on the utility value of treated in the entire stretch of 15 km open drain. This alone speaks of our commitment to the development of this region, and contributes to the self-reliance of the poor and downtrodden.
The Mill Set Up:
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The integrated Mill is established in 75 acre land, keeping huge land as open area. Raw material handling, pulping, Washing, Screening, Bleaching, Stock Preparation, 3 Nos. Paper Machines, Finishing Houses, are the major functional areas.
Utilities:
a. 4 nos. Husk fired Boilers, Dust collectors, 2 nos. 33 mtr. height Chimney, Economizer.
b. 6 nos. D.G. sets, 1250 KVA each with ducting and separate exhaust provided at the desired level of atmosphere.
c. Bore well – 3 nos., under-ground Water reservoir, Fire-fighting systems.
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d. Full fledged Effluent treatment Plant with anerobic Lagoons and the L.R.P. Process for the COLOUR REMOVAL. Large no of different varieties of trees and plants all along the plants and inside and outside the boundary of the factory.
Environmental Management:
SPM an Agro waste based mill, having adopted an environmentally free pulping, has given maximum stress to maintain ecosystem and environment, free from pollution.
1. Since its inception, SPM had gradually developed pollution abatement systems and equipment’s in all quarters wherever possible, as per experts guidelines, with a view to meet the stringent consent conditions of U.P State Pollution Control Board and Minas, as stipulated by Central Pollution Control boards. Major action plans embarked upon by SPM included:
2. Planting of more than 10,000 Eucaluptus, silver oaks and other varieties in & around the mill.
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3. Installation of full-fledged effluent treatment systems covering an substantial area at a gross capital cost.
4. Upgrading the effluent treatment plant step by step from the level of TPD paper production to, the present adequate in built capacity to treat effluents for 75 TPD paper production, giving adequate cushioning for higher production level.
5. Introduction of Krofta air-floatation clarifiers in M.F. and M.G. machine so as to recover back valuable fibers from excess waste water and recycle into in the bleach plant area, thus, cut down fresh water consumption.
6. Recycling of vacuum seal pit waters from both the machines within the vacuum pumps in place of fresh water partly and balance in bleach plant area.
7. Recycling of bleach plant effluents having higher BOD load mostly in bleaching process itself.
8. Segregation of excess waste waters such as non-biodegradable black liquor from pulp mill, high BOD lower solids (SS) bleach plant effluents (C-stage in total, part of E-stage and H-stage back waters) and low BOD and high S. solids excess machine back waters in separate streams – for treatment in stage in effluent treatment plant.
9. Full-fledged treatment plant to treat effluents, complete in all respects is in operation.
These included:
a. 4 huge polythene lined earthen lagoon of total holding capacity of 45,000 cu. m black liquor.
Retention time for Anerobic treatment of black liquor is 60-70 days.
b. The primary sedimentation tank of 28.5 m dia x 4.9 SWD effective capacity of 2,325 m3, surface loading rate of 11.37 m3/m2/day and higher detention time.
Aeration tank of 5469 cu. m., with 10 x 25 HP, total 250 HP agitators
c. The secondary clarifier of 25 m dia and volume 1370 m .
d. Deewan Krofta Super cell – 4000 lignin precipitation unit with all accessories for lignin precipitation from anerobically treated black liquor to remove COD, colour and BOD and subsequent treatment by aerobic cum activated sludge process in conjunction with bleach plant effluent from primary clarifier.
e. Indigenously built Deewan sludge dewatering machinery systems for thickening primary clarifier sludge from 2% consistency to 30% dryness. The dewatered cake at 28-30% dryness disposed off to units in trucks every alternate day to nearby board making and tray making plants.
f. The amount of paper will effluent and waste and their revse is given in following table.
Reutilization of the Waste:
Ligno Sulphonate:
The product of the project under proposal is LIGNO SULPHONATE. We have developed LIGNO SULPHONATE varieties from black liquor, a waste obtained from Soda bagasse cooking, a process in manufacturing paper.
The three varieties which have been developed:
1. Sodium Ligno Sulphonate.
2. Magnesium Ligno Sulphonate.
3. Ferro Chrome Ligno Sulphate.
Application of the product:
Sodium Ligno Sulphonate:
(a) Uses as disperser in Dye Industry.
(b) It increased viscosity of low density oil and used as emulsifier.
(c) It is used to increase the sensitivity for explosive, since the hydroscopic ligno sulphonate can hold tiny water particles resulting in increased conductivity.
(d) It is a coal dust/particles binder & hence used for briquetting industries to give smokeless combustion.
(e) It is grinding aid in Cement mill.
Magnesium Ligno Sulphonate:
(a) It is “Retarder” & used in Cement to delay the setting time of concrete in case of mass construction, to avoid cracking. Mainly used/consumed by;
1. Orissa Cement Company, Rajgangpur.
2. Associated Cement Company, Katni.
3. Belpahar Refractories, Belpahar.
4. Kumar Dhobi fire clay, Bihar.
5. Kesoram Spun & Pipe, West Bengal.
(b) It is grinding aid in cement mill.
(c) It is used for ‘core’ making in the FOUNDRY – SHOP.
Ferro Chrome Ligno Sulphonate (FCLS):
(a) Used as solid stabilizer while drilling, by oil industries.
The major users of the product are:
(i) Oil & Natural Gas Commission, Dehradun.
(ii) India Explosive Ltd. Gomia.