18th National Award for - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/General/EID...(Spent wash) Pressmud Bagasse Bio-Compost ... Increase Bio –gas

E.I.D-Parry (India) Limited,Nellikuppam.

18th National Award for Excellence in Energy Management 2017

9/6/2017 1E.I.D Parry (India) Ltd, Nellikuppam.

Murugappa group

295

28 Business


EID Parry – Nellikuppam

First sugar plant in India

First cane sugar factory in the

world to practise TPM

Sugar Plant 7500 Tons cane

crushing per day

Refinery 170 Tons sugar per

day Distillery 75 Kilo

litres per day

Co-Generation 24.5 MW/Hr


Our Certifications

Accreditations

&

Certifications

ISO 9001-2008

FSSC 22000

Halal

Indian Pharmacopeia

US Pharmacopeia

British Pharmacopeia

ISO 14001


ENA / Rectified Spirit / Ethanol

Distillery

Sugar

Molasses

Waste water (Spent wash)

Pressmud Bagasse

Bio-Compost

Refinery

An integrated sugar

factory produces sugar,

power for export,

alcohol and organic

manure

POWER


UNDERSTANDING THE SUGAR FLOW PROCESS

Energy Conservation Activities – 2014 to 2017


Contd.,

S. NoYear of

Implementation Energy Saving project

Annual Savings

(Rs. In Lakh)

1 2014-15Sugar recirculation in batch centrifugals reduced by the introduction of air cutting in plough scrapper.

95.37

2 2014-15 VFD for Cooling Tower Fan-2 3.02

3 2014-15 DM Make up Water Transfer Pump 0.86

4 2015-16 Installation of VFD screw compressor 11.34

5 2015-16 Sugar recirculation avoided by altering the grader transfer points. 33.80

6 2015-16Usage of first vapour for heating treated juice reduced by 50 % by adding a new direct contact heater for second body vapour.

22.50

7 2015-16 Installation of VFD for condensate Extraction Pump-2 2.16

8 2015-16 Installation of VFD for Submergible belt conveyor (Both Boiler) 1.29

9 2015-16 Installation special alloy multi nozzle roller in 4th mill 279.27


S. NoYear of

Implementation Energy Saving project

Annual Savings

(Rs. In Lakh)

10 2015-16Injection Header modification by eliminating separate pump for evaporator

27.27

11 2015-16 Eliminating sugar grader operation during Raw sugar producction 2.27

12 2016-17Improvement in refinery input melt brix from 60 to 64 – Reduction of steam consumption by 0.1 Ton/Ton of Refined Sugar Output.

37.40

13 2016-17Second body vapor Bleeding for 8 hrs/day to refinery operation -Reduction of steam consumption by 0.15 Ton/Ton of RSO.

56.10

14 2016-17Evaporator syrup brix improvement by challenging the standard operating Procedure

208.89

15 2016-17Replacement of electric strip heater with hot water coil system in VAM – Eliminated 12 KW/hr power consumption

3.45

16 2016-17 Waste Heat Recovery from Sugar second body condensate 104.13

17 2016-17 Utilization of Bio-gas from Bio digester 104.90

18 2016-17Direct pumping of sugar first body condensate to Cogen deaerator instead of Feed water storage tank

105.27

Covered in case Study-3

Covered in Case Study-1




Reduction in Thermal Energy Consumption (Steam % Cane)


Reduction in Electrical Energy Consumption(KWH / MT of Cane)

30.5830.18

29.5829.30

28.7228.3

26.00 25.98

25.1524.74

24.51

20

22

24

26

28

30

32

34

06-07 07- 08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17

Financial Year

Po

we

r (K

WH

) /

MT

of

Ca

ne


ParametersNational

Bench mark

Global Bench

mark

EID –

Nellikuppam

Achievement

Specific Thermal

Energy Consumption 38-40 %

38 %

As per

ISSCT proceedings

2005 32.60 %

Specific Electrical Energy

consumption

28

kWh / ton of

cane

27-28 kWh/ton of

cane

As per NFCSF

24.51

kWh / ton of cane

Comparison with global benchmarks


• A Whopping reduction in Thermal Energy

• A Saving of 2.62 % of Thermal energy

• In terms of money …..

• A saving of Rs.265 Lacs

Steam % Cane prior to

Implementation 35.22 %

Steam % Cane post to

Implementation 32.60 %


• A Whopping reduction in Electrical Energy / MT of Cane

• A Saving of 1.47 Units of Electrical energy

• In terms of money …..

• A saving of Rs.87 Lacs

Power/MT of cane

prior to Implementation 25.98 KWH

Power/MT of Cane

post to Implementation 24.51 KWH


“To reduce the energy consumption in Sugar Manufacturing Process by challenging the

Standard Operating Procedure of juice clarification”

Case Study -1


Steam consumption high

Syrup concentration low

Evaporator tube scaling

Uneven Juice Distribution

Uneven Juice level in evaporator

Why?

Why?

Why?

Scaling of calcium sulphate salt

KAIZEN-1

KAIZEN-2

KAIZEN-3


Analysis of high steam consumption in evaporators

Why 1 : Syrup tank level high at pan floor

Why 2 : Evaporator syrup (concentration)

brix low

Why 3 : Evaporator tube scaling

Why 4 : High calcium scale

Why5 : Shock pH high

Why 6 : Change in Spec


Why 2 : Evaporator syrup (concentration)

brix low


Why 4 : Evaporator tube getting dry

Why 5 : Evaporator body level low

Why 6 : Juice cut over valve passing

Why 7 : Wrong Selection of Valves


Why 2 : Evaporator syrup concentration

(brix) low


Why 4 : Evaporator tube getting dry

Why 4 : Juice level low in evaporator

Why5 : No distribution coil

Why 6 : Weak Design

Kaizen-1 Kaizen-2 Kaizen-3

Uneven juice distribution

Uneven level in the evaporator

High scaling of Calcium sulphate salt


Why Why Analysis - Low Concentration Syrup

Before After


Kaizen-1 Mechanism

Butterfly

Valve

Before After

Vacuum

Evaporator

Vacuum

Evaporator

Globe

Valve

Vacuum

EvaporatorVacuum

Evaporator


Kaizen-2 Mechanism

Before After9/6/2017 18E.I.D Parry (India) Ltd, Nellikuppam.

Kaizen-3 Mechanism

BEFORE AFTER

Evaporator outlet

syrup concentration54 60

5152535455565758596061

Sy

rup

con

cen

trati

on

Evaporator outlet syrup concentration

11 % increase

GOOD


Steam % Cane

35.22

32.89 32.81 32.60

31.00

31.50

32.00

32.50

33.00

33.50

34.00

34.50

35.00

35.50

Percen

tag

e

Steam % Cane 35.22 32.89 32.81 32.60

Before Kaizen-1 Kaizen-2 Kaizen-3

GOOD

Reduction in steam consumption

per 100 ton of cane crushed

9/6/2017 20E.I.D-PARRY (INDIA) LIMITED, NELLIKUPPAM

6.62 % decrease

0.24 % decrease

0.64 % decrease

6 % increase GOOD

Benefit in crushing rate

1.6 % increase

7.9 % increase


Result

Amount saved on account ofreduction in evaporator steamconsumption by improving thesyrup concentration

Rs 208.89 lakhs annually


Waste Heat Recovery from Evaporator second body condensate

Case Study - 2

9/6/2017

23

E.I.D Parry (India) Ltd, Nellikuppam.

Requirement

To provide clean environment with temperature and air control to reduce

microbial load for manufacturing Import substituted sugar to meet Pharma dry

blending by M/s Abbott

Problem

130TR of chilling load required to eliminate high microbial load in Refined sugar

packing area which is a cause of causing food safety concern.

Options Available

1)Vapor Compresssion – Power intensive

2)Vapor Absorption with Steam – Cogen steam available but power will get hit

3)Vapor Absorption with hot water – Available waste heat to be utilised

Waste Heat Recovery from Sugar second body condensate

9/6/2017 24E.I.D Parry (India) Ltd, Nellikupam.

Kaizen 1

Condensate Water temperature reduction

Process Hot Water Cooling

Tower Stage-I

Benefits:

Process Condensate

Temperature reduction up to

45°C

Fanless Cooling Tower

Stage-II

Benefits:

Cold Condensate Temperature

reduction up to 37°C

End Users:

1. Sugar plant & ECCT make up

2.Distillery Cooling tower make up

• Minimal Operating cost

• High Durability and Long life

• Low Maintenance

• Better Part load Performance

• Noiseless operation

• Reduced dependency on unreliable grid

power

Operational Benefits

Lowest Energy Input

Highest COP

Unmatched Reliability

Simultaneous Cooling and

HeatingLow ROI

Sub zero cooling up to -40 °C

Remote monitoring

system

Hot water up to110 °C

Environmental Benefits

• Zero Ozone Depletion Potential

• Reduced Carbon Footprints

• Water Refrigerant

Absorption Chiller Technology


VAM FLOW CHART


Kaizen 3

Kaizen 2

Kaizen 4

DryingPacking

Raw sugar Melting Clarification Filtration

5% 1%

70% 3%

3%

18%

Stratification of the problem – Defect &

rework mapping

28E.I.D Parry (I)

Ltd,Nellikuppam

KAIZEN – 2 ( Sugar drying with Dehumidified air )

29E.I.D Parry (I) Ltd,Nellikuppam 29

KAIZEN – 2 ( Sugar drying with Dehumidified air )

BEFORE AFTER

Benefit – Eliminate Remelting steam cost ( 1T of sugar requires 1.8T of

steam )

70T/month rejection

Power demand 12 KWH

12 KWH Power demand

eliminated

KAIZEN – 3 Control Humidity and Maintain temperature

3131E.I.D Parry (I) Ltd,Nellikuppam

KAIZEN – 4 Moisture percentage reduction in Bagasses ( Steam fuel saving)

What : High moisture in bagasses

Where : Mill Operation

When : Addition of Imbibition water

Who : Low temperature water

Which : Imbibition water

How : Bagasse moisture - 48.5%

Why 1 : High moisture in bagasses

Why 2 : Water content presence in bagasses

Why 3 : moisture water not evaporated in bagasses.

Why 4 : Imbibition water temperature low

Why 5 : Existing in let water temperature low

Why 6 : Weak design

48.5

48.27

48

49

Before After

BAGASSES MOISTURE %

Pe

rce

nta

ge %

GOOD

E.I.D-PARRY (INDIA) LIMITED

Benefit from PQCDSM


0

1500

0

500

1000

1500

2000

Before After

PRODUCTIVITY INCREASED(ABBOTTS PHARMA SUGAR)

MT

/ Y

ear

GOOD

COST SAVING Rs.75 LAKHS/YEAR

80.6

23.53

0

20

40

60

80

STEAM POWER

ENERGY SAVING (Steam & Power)

Rs.

in L

akh

s

COSTSAVING

Rs.104.13 LAKHS/YEAR

Improved Bio-gas Boiler Steam generation

BIO-GAS BOILER

BIO-DIGESTER

DISTILLATIONFERMENTATIONMOLASSES

BIO-GAS BURNER


Case Study -3

BIO DIGISTER

9/6/2017 E.I.D Parry (India) Ltd, Nellikuppam. 34

Problem Analysis

Kaizens received to improve steam generation

Three important Kaizen ideas

1. Burner nozzle hole size to be increased

2. Introduction of Air preheater

3. Increase the line size of Bio-gas


COMPANY :EID NKM KEIZEN IDEA SHEET DOC No: EID/NKM/CIR- 47/ KZ

THEME:

Increase Bio –gas boiler steam

generation

PILLAR JH KK PM QM OTPM SHE E&T DM

LOSS

Q D M S MACHINE Thermax Blr

KEIZEN IDEA

Increase Burner nozzle hole size

BENCH MARK 10 TPH

PROBLEM /PRESENT STATUS

Low steam generation from Bio-gas

boiler

TARGET 12 TPH

START DATE 01.05.16

COUNTER MEASURE

Gas Burner nozzle hole size increase from 3 mm to 5 mm in

all 24 nos.

FINISH DATE 14.05.16

MEMBERS

1.Ravichandran

2. AshokBefore After

ANALYSIS

W1 Low Steam Generation

W2 Low bio gas feed to boiler

W3 Burner nozzle opening size

less

W4 Smaller size of nozzle hole

W5 Poor Design

BENEFITS

1.Steam Generation

increased to 12 THH

2 Monthly cost saving

Rs.10 Lakhs

RESULT H/D PLAN

Plan to implement in

Nestler BoilerROOTCAUSE

Weak Design

P C

Steam Generation (TPH)

10

12

8

9

10

11

12

13

Before After

MT

/ Hr



Tangible Benefit

Bio Gas boiler steam generation increased from 10 TPH to 12 TPH

Annual Cost Saving Rs. 105 Lakhs

Intangible benefits

Entire bio gas utilized in boiler

Reduction in green house emission.

Morale of the employee increased.

Benefits

Environmental Improvement Projects

We have developed Green Belt of more than 35 % of the total factory area.

Zero Effluent discharge system for distillery

Bio-Gas utilized for generating steam for distillery plant requirement.

Augmented the ESP field of the Co-gen boiler to reduce the emission levels to less than 50mg/nm3 though the Pollution control board norm is at 100mg/nm3.

CO2 Generation through Alcoholic Fermentation


Zero Funding Investment Project


Distillery Bio Digester BMSW RO

BMSW Evaporator - IBMSW Evaporator – II & ATFD

&DRUM Dryer

K-Ash Powder

750

KLPD

800

KLPD

400

KLPD

200

TPD

56

TPD

Recovered Permeate & Condensate recycled back to Process

Case Study-4 Zero Liquid Discharge


Present practice:

The distillery is a largest red category industry which has the

Conventional effluent treatment system.

Effluent is rich in Nutrients like N, P & K and other micro nutrients

Conventional method of treating this effluent is mixing with press mud

to produce bio compost which is sold as a fertilizer as well as sold to

cement industries to use as alternative fuel & grinding agent.

Need for change:

With the above technology, we were permitted to operate the plant

only for 270 days a year and we were proposing to operate 365 days a

year

To achieve ZLD with new a concept & technology

To create wealth from waste

NEED FOR THE PRACTICE


First of its kind in the world.

The system can operate for 365 days a year.

The final product is rich in Potash, Nitrogen & Organic carbon.

With this system the plant can achieve complete zero liquid discharge.

This is completely automated, built in a small area and operates with a

closed loop system.

Water is recovered and recycled back to process.

Reduce foreign exchange due to reduction in import of Potash.

Create wealth to nation.

What is taken from soil is given back – Eco system is maintained.

UNIQUENESS OF THE PROJECT


42

Tangible benefits:

Recovering Resources from Industrial Waste – Potash fertilizer

Revenue generation from waste – Rs 4.39 cr

Water and Air pollution are completely eliminated.

Water recovery and recycle thereby reducing the ground water

drawl.

Reduction of use of chemical fertilizer thereby retaining soil quality

and improving organic content of soil.

No of operating days increased by 51 days thereby increase in

revenue.

Intangible benefits :

Employment opportunities

Organizational goals are achieved

Reduce foreign exchange due to import of Potash

Reduction in Green house gas emission

TANGIBLE & INTANGIBLE BENEFIT


43

PRODUCT QUALITY

Govt of India – Fertilizer division – Fertilizer control order has listed this product as “Potash derived from Molasses”


CO2SUCROSE ETHANOL

YEAST

CO2 Generation through Alcoholic Fermentation

Zero Fund investment

project


•Production Capacity: 36 TPD

•Flow rate: 1500 kg/hour.

•Operating Pressure: 20 kg/sq.cm.

•Liquid Temperature: -20 degree Celsius.

•Storage Tank capacity: 50 Tons


CO2 Recovery Plant Details

CO2 After Scrubbing

Alcoholic

Fermentation

Activated Carbon

Tower

Purification

(KMNO4) Tower

Cooler Compressor

Alumina DrierChillierStorage9/6/2017 46E.I.D Parry (India) Ltd, Nellikuppam.

CO2 Recovery System

Rs.250 Lakh/Year


Revenue Generation - CO2

Participation by down the line shop floor personal

in implementing ENCON ideas

S.No. ENCON IdeaYear of

ImplementationSource of Idea

Annual savings

Rs.in Lakh

1Variable Frequency Drive for Cooling

Tower Fan-22014-15

Electrical

Supervisor3.02

2Variable Frequency Drive for DM Water

Transfer Pump2014-15

Electrical

Supervisor0.86

3Sugar recirculation avoided by altering the

grader transfer points.2015-16 Fitter 33.75

4

Usage of first vapour for heating treated

juice reduced by 50 % by adding a new

direct contact heater for second body

vapour.

2015-16 Pan Officer 22.5

5Variable Frequency Drive for condensate

Extraction Pump-22015-16

Electrical

Supervisor2.16

6Injection Header modification by

eliminating separate pump for evaporator2015-16 Shift Chemist 27.27



S.No. ENCON IdeaYear of

Implementation

Source of

Idea

Annual

savings

Rs.in Lakh

7 Reusing of Boiler blow down water 2016-17Shift

Chemist0.86

8

Sugar lumps quantity reduction

during bin cleaning by polishing the

bin internals

2016-17Engg

Supervisor4.86

9ATFD condensate recovery

improvement2016-17

Engg

Supervisor2.64

10Variable Frequency Drive for

Sulphur burnor blower2016-17 Electrician 2.21

11 B Grain pump with VFD 2016-17Shift

supervisor0.66

12

Resizing of sugar common

Condensate pump and eliminated 2

pump operation

2016-17Shift

supervisor6.86

Participation by down the line shop floor personal

in implementing ENCON ideas


Utilization of renewable energy sources

Utilization of Second body vapour condensate heat for VAM Chiller ( 36 tpd ).

Replaced 8 ata steam with heat from 1st body for sugar drying.

For reducing ground water drawl following activities implemented.

Water from bio methinated spent wash recovered through RO and re-circulated for fermentation in distillery around 400 M3/day.

Water recirculation system implemented for water ring vacuum pump and double mechanical seal barrier fluid (240 M3/ day)

Sugar second body condensate water utilized for cogen cooling tower make up. (300 M3 / day)

Utilization of waste material as fuel


Generation of Bio gas from Raw spent wash and running entire distillery ( 38000 m3/

day )

Generation of Organic Potash with high organic Carbon from bio methinated spent

wash ( 25 tpd )

Generation of Carbon di Oxide from distillery fermented for bottling plants ( 36 tpd )

Utilization of heat from 3rd , 4th and 5th body condensate for preheating raw juice

from 35 deg C to 45 deg C

Moisture in the bagasse maintained at the level from 48.50 to 48.27 % on sustainable

basis by optimizing the mill extraction.

Best Practices implemented on energy front in Green

Supply Chain


By reducing shock lime pH, evaporator scaling period is increased from 8 days to 15 days. This has helped in reducing chemical consumption, labour cost and productivity. This practice was deployed in our other units.

Persuaded the coal suppliers to shift importing of coal from Chennai to a nearby port at Karaikal to reduce transportation distance by 200 KM per trip of truck…. Reduction in Diesel consumption by the trucks. ( 27000 tons coal purchased last 3 years ).

Loose Bagasse transportation avoided to the extent possible and insisted on transportation of baled Bagasse. An increase in transportation capacity of truck per trip. 30% reduction in diesel consumption. ( 11000 tons )

Special alloy multi nozzle rollers giving better juice extraction and moisture reduction, resulted improved in Steam bagasse Ratio from 2.25 to 2.26

Farmers were campaigned to cultivate sugar cane nearby factory area near to reduce the transportation distance of 20 km per truck. Reduction in Diesel consumption by the trucks. ( 6.3 lakhs MT last year ).

Nature of non-conformance

The adequacy of disposal of Hazardous waste (Used Batteries) to an authorized collector, whose permit is not detailing collection of used batteries, but “Lead acid Plates, Lead scraps, Ashes & Residue’.

Correction

The Certificates of authorized battery purchaser revived thoroughly before selling.

Corrective action

Used batteries sold through either authorized TNPCB approved vendor or buy back method


Implementation of Corrective / Preventive Actions

from ISO 14001 certification

Nature of non-conformance

The customer complaint handling process of the distillery unit is currently handled manually ,the same can be re-visited and to be addressed through corporate recognized software portal.

Correction

The system followed in other business will extend to Distillery

Corrective action

Customer complaint capturing System incorporated in SAP


Implementation of Corrective / Preventive Actions

From ISO 9001 certification

1. Bagasse dryer for reducing the moisture % Bagasse

2. Condenser modification in evaporator and pan condenser

3. Sugar Common Condensate treatment for boiler feed – Project.

4. VFD for Boiler Feed Pumps (Convert HT to LT Motors)

5. ZLD for Sugar Plant


ENCON projects for next 3 years

1. 23 flow meters for all process fluids including steam

2. DCS based data logging for daily energy monitoring and reporting

3. 35 energy meters were installed at all important stations

4. Utility report is generated on daily basis which captures specific power, steam and water consumption.

5. Internal and external energy audits at regular interval

6. Displaying daily energy consumption figures in the plant

7. Daily report to the top management

8. Equipment running hours are monitored on daily basis to identify idle running/under loading of the machineries


Energy Conservation Monitoring & reporting

• Introduced Real Time Online monitoring of Critical parameters from the Desktop PCs of all Senior Executives

• Hourly SMS auto alerts

• Daily manufacturing report

• SAP generated auto alerts - Plant comparison

• Stock reports from warehouse

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

• Monthly employee productivity linked incentives

Energy savings is our

prime motto


Energy Management monitoring methodology


Energy and Environmental Policy

59

Best Overall Performance of

SUGAR MILL AWARD 2016

Received from Bharatiya Sugar Platinum Award-2016 for the

“Best Distillery” for Distillery

Platinum Award-2016 for the

“Best Technical Efficiency” for

Sugar

Silver Award-2016 for the

“Best Sugar Cane Development”

Awards and Recognitions….

9/6/2017 E.I.D Parry (India) Ltd, Nellikuppam.

http://www.presentermedia.com/index.php?target=closeup&id=7247&categoryid=115&maincat=animsp

60E.I.D PARRY (INDIA)

LTD

Recognition received from our

group for best environmental

project –2016

SISSTA Awarded for best

Environmental focus –

May 2017

CII GREEN-CO Awarded for

best Environmental project &

Useful project – June-2017


RECOGNITION FOR OUR INNOVATION

CII JIPM Kaizen

Competition Award

received in August-2017

National Excellent Energy Efficient Unit Award 2016


629/6/2017 E.I.D Parry (India) Ltd, Nellikuppam.

Documents

18th National Award for - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/General/EID...(Spent wash) Pressmud Bagasse Bio-Compost ... Increase Bio –gas