e.i.d.-parry (india) limited, pudukottai,...

06-09-2017

1

18th NATIONAL AWARD FOR

EXCELLENCE IN ENERGY MANAGEMENT - 2017

E.I.D.-Parry (India) Limited,Pudukottai,Tamilnadu

06-09-20172

Murugappa Group Overview

06-09-2017

3

• E.I.D is Over 225 years old, Started in 1788.

• Flagship company of Murugappa Group since

1981, pioneers in extending businesses and value

addition.

• E.I.D Parry is ranked 51 amongst the top 200

Companies in India – Economic Times 2009

survey

E.I.D.- PARRY (INDIA) LIMITED

EID PARRY

BUSINESS

SUGAR

DIVISION

BIO-PRODUCT

DIVISION

SUGAR COGENERATION DISTILLERY

TN,

KARNATAKA, AP

& PONDY

39800 TCD

TN, KARNATAKA,

AP & PONDY

153 MW

TN,

KARNATAKA, AP

225 KLPD

NUTRA

DIVISION

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Pudukottai Unit Milestone

Green field project commissioned in 2000

Integrated sugar complex with a crushing

capacity of 4500 TCD, 19.50 MW

Cogeneration Power Plant

We have ISO 14001, OHSAS 18001, ISO

9001 certified by DNV

Highest cane crushed 9.21 Lakhs MT in

2011-12 with a sugar recovery of 9.51%

First TPM practicing company in cane

sugar manufacturing industry

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ENERGY POLICY

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Understanding Sugar products

Sugarcane Juice Syrup

Bagasse Press mud Molasses

CogenerationPower plant

Organic Manure Alcohol / cattle feed

Primary

By Products

Value added

Products

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ParametersGlobal Bench

markEID –Achievement

Specific Thermal

Energy Consumption

26-34 %

As per ISSCT

proceedings 2013

36.94 %

Steam / ton of cane

(Main season)

Specific Electrical Energy

consumption

27-28 kWh/ton of

cane

As per NFCSF

27.61

kWh / ton of cane

(Main season)

Comparison with global benchmarks

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Innovative Ideas Project Description BENEFITS

ACHIVED

Introduction of additional

juice drainage area on

mill rollers

Elimination of re-absorption

of juice resulting in

reduction of pol % bagasse

& Moisture % bagasse

Rs. 0.95 Lacs / day

Rs. 190.00 Lacs /

annum

Effective Utilization of

Compressed air by

installing air pressure

booster.

Power Saving in Air

Compressor operation.

Rs. 0.05 Lacs / Day

Rs. 10.40 Lacs /

annum

Elimination of sub

process through Process

Modification

Elimination of Vacuum Filter

Operation in Sugar Process

Rs. 0.51 Lacs / Day

Rs. 2.55 Lacs for 5

days operation

Innovation in Projects Implemented

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Innovative Project – 01

Loss reduction

Objectives:

To reduce losses by eliminating juice re-absorption in

milling operation.

Action Plan:

Improve juice drainage area in mill rollers by introducing

additional juice drainage nozzles.

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554

Nozzles

Introduction of additional juice drainage area on mill rollers


Loss Reduction

Single row Nozzle Triple row Nozzle

Drainage

nozzles

Drainage

pipe 1662

Nozzles

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Moisture % Bagasse

49.71

48.45

47.5

4 8

4 8 . 5

4 9

4 9 . 5

5 0

Before After

Mois

ture

%

Bagasse

Pol % Bagsse

1.821.38

0

0.5

1

1.5

2

Before After

Pol%

bagasse

Results achieved :

•Moisture % bagasse reduced from 49.71

% to 48.45 %

•Saving Amount Rs. 70 Lacs for 3 Lacs

MT Crushing

• Pol % bagasse reduced by 0.44 % which

resulted in recovery of 351 MT of Sugar

savings for 3 Lac Crushing.

• Savings amount Rs. 120 Lacs


Loss Reduction

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Innovative Project - 02Power Saving - Air Compressors

Objectives:

Power conservation in utilities ( Air compressor)

Action Plan:

1. Replacing existing 4nos of lower capacity Reciprocating Air

Compressors (138 kw) with 2 no higher capacity Screw Air

Compressor (95 kw).

2. Providing VFD for screw compressors.

3. Operating air compressor at low air pressure and boosting pressure

with help of pressure booster where ever high pressure required.

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Inst. Air Compressor

(Reciprocating) _ With out VFD

Ash Handling Air

Compressor

(Reciprocating)

With out VFD

Plant Instrumentation

Air requirement

@ 6.0 Kg/Sq. CM

Plant

Instrumentation

Air requirement

@ 6.0 Kg/Sq. CM

Plant Ash handling

Air requirement

@ 4.50 Kg/Sq.CM

Inst. Air

Compressor

(Screw) With

VFD

Pressure

Regulating

Valve

Replacement of reciprocating compressor

by VFD operated screw compressor

Innovative Project - 02

Power Saving - Air Compressors

Reciprocating Compressor

Without VFDScrew Compressor With VFD

Power Consumption – 3312 units/days Power Consumption – 2302 units/days

Savings 1010

units/day

Screw Compressor With VFD

Power Consumption – 3312 units/daysPower Consumption – 3312 units/daysPower Consumption – 3312 units/days Power Consumption – 2302 units/daysPower Consumption – 3312 units/days

2 Nos Compressors

(1No. with standby)

95 KW – 2 Nos

4 Nos Compressors

93 KW – 2 Nos

45 KW – 2 Nos

Plant Ash handling

Air requirement

@ 4.50 Kg/Sq.CM

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Instrument Air Pressure Reduction

Plant

Instrumentation

Air requirement

@ 6.0 Kg/Sq. CM

Plant Ash handling

Air requirement

@ 4.50 Kg/Sq.CM

Inst. Air

Compressor

(Screw) With

VFDPressure

Regulating

Valve

Regular Operation

Pressure

BoosterCommon Plant

Instrumentation

Air requirement

@ 5.0 Kg/Sq. CM

Plant Ash handling

Air requirement

@ 4.50 Kg/Sq.CM

Inst. Air

Compressor

(Screw) With

VFD Pressure

Regulating

Valve

Centrifugal areaInstrumentation

Air requirement

@ 6.0 Kg/Sq. CM

With Pressure

Booster Operation


Power Saving - Air Compressors

Power Savings

300 units/day

@ 6.0 Kg/Sq. CM

@ 5.0 Kg/Sq. CM

Centrifugal area Instrumentation

Air requirement

@ 6.0 Kg/Sq. CM

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(Stopping of vacuum filter operation)

Objectives:

To conserve energy in vacuum filter area by diverting muddy juice to mill.

Action Plan:

1. Diverting muddy juice to mill section to mix with bagasse to extract juice.

2. Stopping of vacuum filter operation ( vacuum pump, filtrate pump, mud

mixer drive, bagacillo blower and filter drum).

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Process Failure Mode Effect Analysis (PFMEA)


(Stopping of vacuum filter operation)

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Power Saved = 6221 Kw

Cost Saving = Rs.254046/-

Trail Running days = 5 Days


(Stopping of vacuum filter operation)Scheme:

Data:

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SPECIFIC ENERGY CONSERVATION

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Power Consumption / Tones of Cane

27.2525

26.6327.6130.59

29.0427.06

20

25

30

35

40

45

50

13-14 14-15 15-16 16-17

Special

16-17

Main

17-18

Special

17-18

Main Plan

Financial Year

Un

its

/ To

n

Due to Low rate of Cane Crushing & Intermittent

stoppage - want of Cane raised out of CHL issues

Global Bench Mark – 28 KW / MT

SEC REDUCTION PERCENTAGE

Sugar - Power

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Due to Low rate of Cane Crushing & Intermittent stoppage

Steam % on cane crushed

Global Bench Mark – 34%

39.39

34.8634

36.2836.87

39.25

36.93

32.00

34.00

36.00

38.00

40.00

13-14 14-15 15-16 16-17 Sp 16-17

main

17-18 Sp 17-18

Main PlanFinancial Year

%SEC REDUCTION PERCENTAGE

Sugar - Steam

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Average cane crushed per tons per day

3417

27432844

23542074

3258

1500

2000

2500

3000

3500

4000

13-14 14-15 15-16 16-17

Sp

16-17

Main

17-18

Sp

Financial Year

%

Reduced rate of crushing based on Cane availability during 2015-16 & 2016-

17

SUGAR PLANT PERFORMANCE

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Power Generation & Export

MW / HR

13.7714.82

11.3110.26

12.66

9.179.78

7.20 7.648.74

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

2012-13 2013-14 2014-15 2015-16 2016-17

YEAR

MW

/ H

R

Power generation MW / HR Power export MW / HR

COGENERATION PLANT

PERFORMANCE

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9.048.44

9.759.63

8.348.25

6.00

7.00

8.00

9.00

10.00

11.00

12.00

13-14 14-15 15-16 16-17 17-18 Sp 17-18 PlanFinancial Year

%

As per STOA from TNEB, power export quantum restricted to < 30 %

which resulted in higher Aux Power

Cogen Auxiliary Power Consumption % On Generation

8.50 @

16-17 Main


Cogen Aux. Power

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Steam – Fuel (Bagasse) Ratio (Kg of steam/Kg of Bagasse)

2.46 2.46 2.42 2.41 2.49 2.55

1.50

1.75

2.00

2.25

2.50

2.75

3.00

13-14 14-15 15-16 16-17 17-18 Sp 17-18 PlanFinancial Year

Kg

of

Ste

am /

Kg

of

Bag

asse

As per STOA from TNEB, power export quantum restricted to <

30 % which resulted in Lower SFR

2.47 @

16-17 Main


Cogen – Steam Fuel Ratio

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Energy Saving Projects

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Case Study

NoProjects

Investement

(Rs in Lacs)

1 Thermal Saving 6.97

2 Power Saving 5.07

3Expense for Training and Development of

our own staff and suppliers.5.23

4 Total Investment 17.27

5 Turnover of unit 11162

6% Investment on Encon projects on

Turnover0.155%

Investment on Encon Projects in the Year

2016 - 2017

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THERMAL SAVINGS

DescriptionNumber

of projects

Annual

Savings (Rs Lacs)

Investment

(Rs Lacs)

Savings With Investment 3 9.79 6.97

Savings Without Investment 1 42.95 0

Total 4 52.74 6.97

POWER SAVINGS

DescriptionNumber

of projects

Annual

Savings (Rs Lacs)

Investment

(Rs Lacs)

Savings With Investment 8 6.16 5.09

Savings Without Investment 2 8.84 0

Total 10 15.00 5.09

Key Energy Saving Projects Implemented

in the Year 2016 - 2017

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Sl.

No

.

Title of ProjectAnnual Savings

(Rs Lacs)

Investment

(Rs Lacs)

1Reduction in Hot condensate wastage by

changing the Sampling method.0.85 1.00

2 Improved Thermal Insulation in boiler 6.40 2.97

3Elimination of vacuum filter operation

from sugar processing2.54 3.00

4 Alternative Bio mass fuel - Wood Bark 42.95 0.00

Total 52.74 6.97

Energy Conservation Measures taken

FY 2016-17 (Thermal)

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Sl.

No.Title of Project

Annual Savings

(Rs Lacs)

Investment

(Rs Lacs)

1

Replaced Worm& worm wheel gear box (30

KW) with helical gear box in Rake carrier

(Saving 4.0 Kwh/Hr)

0.80 0.50

2

Fixed Transparent roof sheet in sugar

Godown – Lighting load reduced during day

time

0.631.00

3

Pneumatic pressure booster is installed to

raise the air pressure for Centrifugal

machine Instrument air system.

1.20 0.67

4 VFD Installed for unsulphited syrup pump 1.04 0.68

5 LED Lightings in plant area 0.51 0.85

6Domestic water consumption reduction (50

TPD)0.54 1.13


FY 2016-17 (Power)

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Sl.

No.Title of Project

Annual Savings

(Rs Lacs)

Investment

(Rs Lacs)

7LED Issued to employees during Safety Day

Celebration 1.41 0.21

8 WTP flushing water re-usage 0.03 0.05

9

Lighting control during Off season

(Provided only focus lamps in walk way

area)

8.42 0

10Switch off standby UPS system for DCS to

reduce the power loss during Off-season0.42 0

Total 15.00 5.09


FY 2016-17 (Power)

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Sl. No Financial year Projects

Actual

Cost Saving

(Rs in Lacs)

1

2015-2016

Thermal Saving 58.31

2 Power Saving 20.69

3

2014-2015

Thermal Saving 102.15

4 Power Saving 11.79

Key Energy Management Improvements

2014 - 2016

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Encon Team Work & Projects

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Sr. Vice President

As Adviser

Sr. General Manager

Shop Floor Engineers and Process Technologists along with Team Members

Source of ideas and implementation team

Engg Process Co-gen * Elect * INST

Department Head

H.O.D

(Engg)

H.O.D

(Process)

H.O.D

(Cane)

Resource Leaders

Note : * Certified Energy Auditor

ENERGY CONSERVATION CELL

Sr. Vice President

As Adviser

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S.N

oFinancial years

Major No: of

ENCON

Projects

Annual

savings Rs in

Lacs

Capital

Investment

(Rs. In Lacs)

1 2016-2017 6 47.58 4.01

22015-2016

9 55.62 15.33

32014-2015

6 91.14 45.20

4 2013-2014 3 6.72 3.0

Total 24 201.06 67.54

Involvement of Employees in

implementing Encon Projects

Power & Energy saving related major & minor projects of 873 Nos. received from

176 employees and implemented 640 Nos.

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• Introduced Real Time Online monitoring system to control the plant critical operating parameters from the Desktop PCs of all Senior Executives

• Cane crushing details is being sent to all HOD’s through CMS based Hourly SMS

• PROMIS capturing all the production details an hourly basis and generated daily production report

• SAP Generated auto alerts - Plant comparison, Stores & Warehouse reports, Inventory, R&M

Budget Vs Actual

• Trend charts from QA- Incoming raw material & In process- Weekly compliance report

Encon Monitoring Methodology

06-09-2017

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Frequency Report Reviewed By

Hourly All Energy Consumptions like

Sp. Thermal & Power Consumption for Sugar & Cogen Plant

Shift Engineer

Shift wise All Energy Consumptions like


Department Head

Daily All Energy Consumptions like


Unit head

Monthly All Energy Consumptions like


Business Group Management Committee (Business head & EID’s Function head)

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Sample Power Monitoring report

FY 2017-18

•Steam % Cane – 34

•Power/MT cane – 25

•Steam fuel ratio – 2.5

•Aux Power % - 8.25

FY 2019-20





FY 2020-21





FY 2018-19





FY 2021-22





Road Map for future Encon Activities

Resources planned for accomplishing Targets

S.No. Equipment Cost Deliverables

1 1. 4th mill all three roller pitch has to be changed from 40 to 30

including scrapper, Trash plate with triple nozzle lotus roller

2. 3rd mill all three roller pitch has to be changed from 40 to 30

including scrapper, Trash plate with triple nozzle lotus roller

50

Lacs

Reduction in pol%

bagasse from 1.35

to 1.00

2 Bagasse moisture reduction unit to be provided in the outlet of

first & fifth mill.

40

Lacs

Reduction in

moisture% bagasse

from 48.50 to 47.0

3 1. Auto de-hooking system for cane unloader 2 nos

2. Provide planetary gear box with VFD system - Mills, Rake

carrier, Feeder table, Cane carrier, Lime tank, B Vacuum Xlr

3. Automation of cooling tower

4. Injection pump automation

5. VFD for cane preparatory devices

6. Rope coupling for 5 mills

360

lacs

Reduction in Power

per ton of cane from

29 to 20

4 1.VLJHReplacing with PHE both series. 2.By providing DCH

system in juice heater

100

Lacs

Reduction in Steam

% cane from 38.5 to

30


Resources Planned for accomplishing Targets

S.No. Equipment Cost Deliverables

5 Planetary Gear Boxes For Bagasse

Drum feeder –

5 No, (5.5.KW, 5 to 40 RPM)

15 Lacs Reduction in Power consumption by

15 %

6 Baggasse Drying System – CF fan, 2

No. Belt Conveyors, Cyclone Chamber,

Back Filter and Ducting

250 Lacs Increase in Steam Fuel ratio from

2.5 to 2.8 thereby reducing fuel cost

or cost of power production.

7 Energy Conservation System:

50 tph Boiler Feed Pump 12 lacs

Reduction in In-house Power

consumption.

8 100 CFM, 6kgf, Screw Compressor 7.5 Lacs Reduction in In-house Power

Consumption

9 Addional capacity in APH 25 Lacs To recover waste heat from the Flue

Gas (From 150 Deg C to 140 deg

C).


06-09-2017

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1Introducing VFD for 7 Equipments (150 KW) to save power of 35

Unit/Hr.

2 Introducing Solar street lights (20 Nos.) to save power of 40 Unit/Hr.

3

4

Improving of power factor from 0.9 to 0.95 lag by providing additional

capacitor banks.

Harmonic reduction in all power centers by providing Harmonic filters to

improve power quality.

5Introducing Planetary gear box for 5 nos of equipments to save power of

17.5 Units/Hr.

6

Introduction of Auto Hydraulic de-hooking system to eliminate operation

of one no of 25 KW motor for 2 nos cane unloaders to save power of 14

Units/Hr.

7Process modification and Introduction of Automation in various areas to

save power and steam consumption.

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Utilization of Waste Materials as fuel

1. Match Box Waste

2. Eucalyptus Wood Bark

3. Juliflora Thorns

4. Juliflora Chips

5. Pencil wood waste

6. Wood Industry waste

7. Pressmud

Following Waste Bio

mass as fuel in our boiler

for generating power

Till date 12320MT Bio

waste fired

06-09-2017

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1) Treated water from ETP is used for cane irrigation and Trees plantation

around the factory.

2. Co-Gen boiler Ash is utilized as manure in Cane fields.

• RO Reject water / Boiler Blow down water is used for boiler Ash

quenching in place of raw water.

Waste utilization

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Waste materials from forest is

used as fuel to maximize the

power generation at Co-Gen. We

generated 2.86 million units in

the last run.

Renewable Energy

Solar Powered Irrigation pumping system (10 HP) in cane forms are being installed widely in our command area of 25000 acers.

06-09-2017

45

CO2 Emission Reduction:

• 500 no Trees planted inside the plant towards the target of 1000 Nos for theyear

• Reduced the Fuel consumption for the same power production by reducingthe Specific steam consumption. ( From 5.49 to 5.34 )

• Co-Gen Captive power consumption is reduced from 9.75 % to 8.34%.

Green House Gas Emission Reduction

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Moving towards digital India

• By introducing I-Cane software we have created Paperless office for cane management. I-Cane - Plot MAP – With Measurement Details

Green House Gas Emission Reduction(Paperless office & Diesel Consumption Reduction)

40 % of time spent on traveling by cane staff reduced by this Application usage

06-09-2017

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Pest Affected Field – Captured by I-Cane Mobile(Paperless Office)


06-09-2017

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(Paperless Office)

I-Cane-Digital Task Scheduler


06-09-2017

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1) Zero Ground water drawl

2) Plantation of Trees – 1000 Trees / Year

3) Utilizing Renewable Energy (Solar Power for Effluent Treatment Plant, Cane Cultivation Etc)

4) Ensuring Emission test for vehicles entering in to Factory premises

Way forward towards Green House Gas

Reduction

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1. Drip irrigation / Micro irrigation for cane cultivation to preserve water & save

pumping Electrical Power

Best Practices Replicated on Energy front in

Green Supply Chain

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2. Encouraging Cane cultivation closer to factory to reduce the Cane transport for reducing diesel consumption.

3. By using daily tracker S/W we have identified that 60% of cane staff time is wasted in traveling between Cane field and Office. By Implementation I-Cane Software (Satellite mapping, machine based management system) effectively the necessity of travel to office is drastically reduced to 20% this resulted in significant reduction in Petrol/Diesel for Cane Staff vehicles

Best Practices Replicated on Energy front in

Green Supply Chain

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1) Sugar process water requirement is met with vapour condensate from cane juice.

So, ground water drawl for Sugar Process is Nil.

2) Excess condensate water is cooled in Fan-less cooling Tower and used for

Greenery development inside the factory.

Green Supply chain – Recycling and Reuse

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CII AWARD FOR

ENERGY MANAGEMENT – 2016 & 2014

06-09-2017

54

CII AWARD FOR

EXCELANT ENERGY MANAGEMENT - 2015

06-09-2017

55

Receiving Shield from

Hon’ble Minister of Power

Mr. PIYUSH GOYAL at New

Delhi

National Level

second Prize

(Silver Shield)

NATIONAL ENERGY CONSERVATION AWARD 2014

FROM BUREAU OF ENERGY EFFICIENCY,

GOVERNMENT OF INDIA

06-09-2017

56

Group level Best Cogen Award - 2017

06-09-2017

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TPM Awards

06-09-2017

58

Best Performing Company Winner in the

‘Sugar’ Sector for the Dun & Bradstreet Corporate

Awards 2016

06-09-2017

59

06-09-2017

60606 September 2017

e.i.d.-parry (india) limited, pudukottai,...

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