Energy Auditing of Sugar Industry

Energy Auditing of Co-generation based Sugar plant at M/s Mysore Sugar Company Limited, Mandya

ABSTRACTEnergy audit is designed to determine where, when, why and how energy

is being used. This information can then be used to identify opportunities

to improve efficiency, decrease energy costs and reduce greenhouse gas

emissions that contribute to climate change. Energy audits can also verify

the effectiveness of energy management opportunities (EMOs) after they

have been implemented.

Energy audit is an important tool in transforming the fortunes of any

organisation. This is highly relevant to the sugar industry as it deals with a

renewable energy source and looked upon as rural power house. The

scope for conservation is immense and if properly harnessed can take the

organization to the path of prosperity. Energy audit becomes all the more

important in view of the energy conservation Act 2001 enacted by

Government of India and the proposed New provisions 18A(1), (2) & (3)

to the Boiler Amendment Bill – 2000 (Indian Boilers Act – 1923).

Energy in the form of Electricity has been the prime mover for the overall

progress of any country. Due to rising cost of new generating plants and

severe financial constraints, it is not possible for Electricity Utilities to

outlay more funds in this priority sector. Hence, either the generated

energy has to be used efficiently or reduce the losses by the end users.

Taking the specific case of sugar industry there are wide variations in

energy consumption among different units using comparable technology.

The energy saving potential in sugar sector is estimated to be at least 30%

of its present utilisation, making the sector with the maximum potential in

the country’s economy. The sector can easily be termed as rural power

houses and any conservation here will not only serve the cause of national

economy but also enhance the profitability and stability of the sector. This

M.tech (Energy Systems Management), Sri Jayachamarajendra College of Engineering, Mysore 1


is where the energy audit and energy norms become vital for the sugar

sector as a whole.

It has become the paramount need of the sugar sector at present to become

energy efficient for maximizing their profits as well as to support the

government, in their quest for additional energy resources. Any

augmentation from sugar sector will be a boon to any national economy as

it will not be at the expense of their fossil reserves. Therefore for every

unit in the sugar sector, a self introspection in the form of a detailed

energy audit will do a world of good at this juncture, without waiting for

the intervention of statutes. In this context, sharing of experience based on

the energy audits carried out and the improvement made in some of the

sugar factories in our country will be very useful.

The Energy Audit study was carried out at Mysore Sugar Company

Limited, Mandya, Karnataka. The energy audit was mainly targeted at

identifying practical, sustainable and economically viable energy saving

opportunities in some of main sections of plant, resulting from a detailed

study and analyses of technical parameters.

The plant meets entire power requirement through purchase from KPTCL,

Co-generation, DG sets are used as stand-by. The cost of energy used

during April 2010 to March 2011 works out to ₹ . 1692.00 lacs.

During the study, there was continuous interaction with the plant

personnel; all the recommendations have been thoroughly discussed with

the concerned officials.

This Energy Audit has helped to compile the possible actions to conserve

and efficiently utilize our scarce resources and identify the savings

potential.



Mysore Sugar Company officials have also ensured that they would

utilize, execute and try implementing the recommendations suggested. The

full impact of conducting a energy audit to achieve large savings in energy

cost therefore remains unrealized or prolonged.



List of APPENDICES

Appendix Description Page No.

Appendix-A Layout plan of Mysore Sugar Company 77Appendix-B The present power distribution of My Sugar (Sugar production

area)78

Appendix-C Baggasse based cogeneration power balance 79Appendix-4/1 Details of Power Purchased and Generated for thee period

April 2010 to March 201180

Appendix-5/1 Boiler Specification and Details 82Appendix-5/2 Co-Generation Scheme 83Appendix-5/3 Combustion Efficiency Calculations 84Appendix-5/4 Rated and Operating Parameters of Turbo- Generators, 'A'

& 'B' Mill Steam Drives86

Appendix-5/5 Power Transmission by Different Driving Systems

88

Appendix-6/1 Power Measurement of Centrifugal Pumps 90Appendix-6/2 Design Injection Water Requirements for Pan 93Appendix-6/3 Pressure Drop Calculation for Centrifugal pumps 94Appendix-6/4 Raw Water Balance (Existing) 95Appendix-6/5 Revised Water Balance 96Appendix-6/6 Revised Water Balance 98Appendix-7/1 Lighting Fixture Details 99Appendix-7/2 Lighting Lux Measurement Details 100Appendix-7/3 Replacement of Conventional Electro-magnet Choke with

Electronic Chokes & 40W Fluorescent with CFL 101

Appendix-7/4 Replacement of Conventional Electromagnetic Choke with LED 48” 2000 lumen tube lights

102

Appendix-7/5 Use of Lighting Transformer to Reduce the voltage for lighting Circuit

103



LIST OF ABBREVIATIONS

ACRONYM ABBREVIATION

VFD Variable Frequency Drive

FTL Fluorescent Tube Lights

CFL Compact Fluorescent Lamps

TERI TATA energy research institute

EMO Energy Management opportunities

kL Kilo liter

MT Metric Tons

BMCR Boiler Maximum Continuous Rating

V Voltage

A Current

p.f Power Factor

kW kilo Watt

P Power

kVA kilo Volt Ampere (Active Power)

kVAr Reactive kilo Volt Ampere (Reactive Power)

F Frequency

Hz Hertz

RPM Rotations per minute

kg kilo grams

kWh kilo Watt hour

MD Maximum Demand

FY Financial Year

HP Horse Power

PRDS Pressure Reducing and Distribution System

PCRA Petroleum Conservation research association



LIST OF FIGURES AND TABLES

FIG/TABLE NO.

DESCRIPTION

Fig 3.2 M/s My Sugar Company ltd., Sugar processing flow diagram

Fig 4.7 Pie chart showing the energy consumption profile

Fig 4 / 1 Details of Power Purchased and distributed

Table 4.2 Details of the Sugar production

Table 4.3 Details of Sources of energy

Table 4.4 Details of Specific Electrical Energy Consumption

Table 4.7 Details of Energy consumption

Table 6.3.2 Proposed Water injection pump details

Table 6.3.3 Proposed Raw juice pump details

Table 6.3.4 Proposed Sulphited juice pump details

Table 6.3.5 Proposed Clear juice pump details

Table 6.3.6 Proposed Light molasses pump details

Table 6.5 Details of the temperature measurements

Table A Summary of recommendation



Table of Contents

Chapter Description Page

No.LIST OF APPENDICES 4LIST OF FIGURES AND TABLES 6LIST OF ABBREVIATIONS 5COMPANY PROFILE 9

1 INTORDUCTION1.1 Introduction 111.2 Objective 131.3 Scope 131.4 Methodology and Approach 141.5 Co-generation at Glance 14

2 LITERATURE REVIEW2.1 Energy Savings Toolbox – an Energy audit Manual and Tool 192.2 The Energy Conservation Act 2001 192.3 Guide Books for the National Certificate Examination for Energy managers and Energy Auditors, Second Edition (2005).

20

2.4 PCRA literature (Petroleum Conservation research association) 202.5 Concepts and methodology adapted to Audit Energy 22

3 PROCESS FLOW OF MYSUGAR3.1 General 243.2 Process description 24

4 ENERGY CONSUMPTION PROFILE 4.1 Introduction 334.2 Production Details 334.3 Sources of Energy 334.4 Specific Electrical Energy Consumption 344.5 Cost of Energy 354.6 Total Cost 354.7 Energy Consumption profile 36

ENERGY AUDITING, PROPOSALS AND RECOMMENDATIONS.

5 STEAM GENERATION, DISTRIBUTION & UTILISATION5.1 Facility Description 38



5.2 Observations and Analysis 385.3 Energy Conservation Proposals 40 5.3.1 Proposal-1 :Flash steam recovery from condensate 40

5.3.2 Proposal-2: Replacing the steam drives with DC drives

42

5.3.3 Proposal -3: insulating exposed areas of flanges, valves and pipelines

43

5.3.4 Proposal -4 : insulating exposed areas in steam line 445.4 General 455.5 Energy Conservation in Existing Power Plant 465.6 Guide line for quantifying energy conservation 48

6 PUMPING AND WATER SYSTEM6.1 Facility Description 506.2 Observations and Analysis 506.3 Energy Conservation Proposals and Recommendation 51

6.3.1 Proposal-1 ; Optimization of pan injection cooling water system

51

6.3.2 Proposal-2 ; Right sizing of evaporator injection water pump

53

6.3.3 Proposal-3 ; Right sizing of raw juice pump 546.3.4 Proposal-4 ; Right sizing of Sulphited juice pump 566.3.5 Proposal-5 ; Right sizing of Clear juice pump 576.3.6 Proposal-6 ; Right sizing of light molasses pump 58

6.4 Water System 606.5 Spray Pond 61

7 LIGHTING SYSTEM7.1 Facility Description 657.2 Observations and Analysis 657.3 Energy Conservation proposals and Recommendations 65 7.3.1 Proposal-1 ; Use of 36W Fluorescent tube lights and electronic chokes.

65

7.3.2 Use of LED 48” 2000 lumen tube lights -40 Fluorescent tube lights Replacement

67

7.3.3 Proposal-2 ; Replacement of 200W incandescent lamps with twin fluorescent tube fixtures with electronic choke.

68

7.3.4 Proposal-3 ;Use of lighting voltage controller. 697.4 General 70

CONCLUSION AND SCOPE FOR FUTURE WORK 72

REFERENCES 106



COMPANY PROFILE

The Mysore Sugar Company Limited (Mysugar) is one of the

oldest sugar factories in India. The factory was established in the

early thirties. Initially Mysugar had a capacity of 600 TCD. 0ver the

years the plant has expanded and, presently the plant has a capacity

to crush around 5000 TCD. Mysugar is a Government of Karnataka

Enterprise and the Board of Directors comprise of nominees from

Karnataka State Government and from financial institutions.

Mysugar has its own 35 kL Distillery unit in addition to its own

IMFL bottling plant and arrack unit.

Mysugar is located in the heart of Mandya City and commands a

good cane potential. The agro climatic factors not only favour

intensive cane cultivation but also maintain high sugar content in

the cane over a longer period during the season. Mysugar has

handled about 9 lakhs tonnes of cane during the year. Cane crushing

season usually extends up to nine months and sometimes beyond

that period also.

The subsequent sections of the report highlight the comprehensive

energy audit to identify the energy saving opportunities to minimise

the power and steam requirement of plant.

The Layout plan of Mysore Sugar Company is as shown in

Appendix-A.

The present power distribution of My Sugar (Sugar production

area)is as shown in Appendix-B.

The Baggasse based cogeneration power balance is as shown in

Appendix-C.



Chapter 1



Chapter-1

1.1 IntroductionPower is the most essential input for the industrialization and in the Indian

context, it is indeed the fulcrum on which, the future pace of growth of

development of this country rests. It is estimated that, in India the demand

for electricity is presently growing at a compound rate of over nine (9)

percent which is among the highest in the world. Since achieving

independence, India has multiplied electricity generation by more

than 60 times, which as of now stands at about 89,476 MW. The

approximate share of the installed capacity between Hydro, Thermal and

Nuclear are 22:006 MW, 64,276 MW and 2225 MW respectively. Over

and above that about 970 MW of installed capacity is attributable to non-

conventional energy sources (mostly wind).Though the per capita

electricity consumption in India is at about 338 kWh, the demand for

electricity consumption continues to grow at a rapid rate outstripping the

availability of the same. There is a huge difference between the projected

power demand and the planned generating capacities.

The present shortfall in energy is 11 %, and the shortage in the peaking

capacity is 22 %. In the eighth plan period, as against the targeted capacity

addition of 48,000 MW, only 17,373 MW was added. The projected

capacity addition for the ninth plan period is 57,700 MW, calling

for a total investment of over ₹2500 Billion. In addition to the problems

of installed capacity shortage, there are quite a lot of problems with the

Transmission and Distribution system networks. The transmission and

distribution losses is estimated to be an average of 21 %, owing to poor

reactive power management, too many transformation stages resulting in

high transformer losses, unplanned expansion of distribution system,

improper load distribution, pilferage etc..



India’s involvement in renewable energy movement is being reported to

be the second most extensive in the developing countries, next to China.

In order to meet the growing demand for power, India has added nearly

18000 MW generating capacity through conventional sources besides

1175 MW through renewable energy sources including cogeneration

during the 8th five year plan.

India is currently the largest producer of cane sugar in the world,

accounting for 10% of the world production. Sugar is a growing industry

with the cane area, yield and recovery of sugar increasing over the

decades, though there are cyclic variations from year to year.

The industrial sector in India is a major energy user, accounting for about

48 percent of the commercial energy consumption. The sector has become

increasingly energy intensive overtime, which is partly due to the

investments made in basic and energy intensive industries to achieve self-

reliance. There are wide variations in energy consumption among

different units within the same industry using comparable technology. The

energy saving potential in this Sugar sector is estimated to be 25%,

making it the sector with the maximum potential in the economy.

Energy today has become a key factor in deciding the product cost at

micro level as well as in dictating the inflation and the debt burden at the

macro level. Energy cost is a significant factor in economic activity. On

per with factors of production like capital, land and labor. The imperatives

of an energy shortage situation calls for energy conservation measure,

which essentially mean using less energy for the same level of activity.

Energy Audit attempts to balance the total energy inputs with its use and

serves to identify all the energy streams in the systems and quantifies

energy usage’s according to its discrete function. Energy Audit helps in

energy cost optimization, pollution control, safety aspects and suggests



the methods to improve the operating & maintenance practices of the

system. It is instrumental in coping with the situation of variation in

energy cost availability, reliability of energy supply, decision on

appropriate energy mix, decision on using improved energy conservation

equipment’s. instrumentation’s and technology.

1.2 ObjectivesThis energy audit assumes that the cost of energy used during April 2010

to March 2011 by M/s Mysore Sugar Company Limited works out to

₹ 1692.00 lacs, and it has aimed at obtaining a detailed idea about the

various end use energy consumption activities and identifying,

enumerating and evaluating the possible energy savings opportunities.

The target is to achieve savings in the Steam and electrical energy

consumption .

The objective of the work in M/s Mysore Sugar Company Limited is the

interest in retrofitting the electrical utilities like pump and pumping

system, lighting system and thermal Utilities like boiler, mills , thereby

increasing the overall plant efficiency, increasing output, reducing energy/

steam consumption.

“Every 1unit saved is equal to 2units generated”

1.3 ScopeDetailed Energy Audit aims at identifying priority ordered economically

viable projects that will fulfill the above objectives. It will also arrive at

recommendations regarding maintenance procedures, replacing less

efficient equipment with energy efficient equipments etc. for fulfilling the

energy efficiency objectives.



1.4 Methodology and ApproachThe audit study involved carrying out various measurements and analysis

covering all major energy consuming sections, to realistically assess

losses and potential for energy savings.

The study involved in improving energy use efficiency and identifying

energy saving opportunities at various equipments and processes. The

analyses included simple payback calculations where investment are

required to be made to implement recommendations, to establish their

economic viability.

1.5 Co-gen Plant At GlancePower is the most essential input for industrialization and it is indeed the

fulcrum on which the future pace of growth and development of our

country rests. The demand for power continues to grow at a rapid rate

outstripping the availability and the bagasse based sugar plant

cogeneration holds the promise of narrowing this ever widening gap.

From the very inception the cane sugar factories are equipped for

Cogeneration for generating the steam and power for their captive

consumption. Of late the term “COGENERATION” is used to widely

denote the generation of surplus power for supplying to the Grid or for

selling to any other third party. Cogeneration for the sugar industry has

been a very attractive option in view of the potential for increasing the

financial health of the sugar mill on one hand, and reducing the ecological

damage by promoting the use of renewable fuels like bagasse for power

generation, on the other hand.

The management of Mysugar, having a very progressive outlook, has

realized the potential for Co-generation in Sugar Plants. Considering the



thrust given by the Government of India to this national endeavor and

realizing the contribution they can make to the power deficit Karnataka

State, the management decided to implement Co generation, in the

Mysugar complex at Mandya in the State of Karnataka, along with the

performance and efficiency improvement program, planned for the sugar

mill.

The Co-generation details are as shown below

• Cane crushing capacity (24 Hrs) : 5000 TCD

• Hourly Crushing Capacity : 208.3 TPH&

• Average bagasse percentage on Cane : 32%

• Process steam percentage on cane : 48%

• No. of days of cogeneration plant Operation

- Cane crushing season : 250

- Off-Season : Nil

• No. of boilers installed : Two (2)

• Capacity of each Boiler (MCR) : 80 TPH

• Boiler outlet steam parameters : 66 Kg/Sq.cm(g)

485 +/-5Deg.C

• Fuels used for the Boiler : Bagasse from Sugar Mill

• No. of turbo generators Installed : One (1)

• Turbo generator type and capacity : Double Extraction Cum

Condensing



• Gross Power Generation (kW) : 1x30.0 MW

- Cane Crushing Season : 28000

- Off-Season : Nill

• Power supplied to Sugar Plant (kW)


- Off-season : Nil

• Co-generation Plant Power Consumption (kW)


- Off-season : 0.00

• Net exportable power at 66kV to KEB’s Sub-station (kW)


- Off-season : 0.00

• Net salable energy to grid (Million kwh)

- Cane Crushing Season : 101.71

- Off-season : 0.00

• Bagasse supplied from sugar mill : 341820

During season in (Metric Tonnes / year)

• Steam supply to sugar plant : 580338

(MT/Year)

• Electrical Energy supply to : 32.56

Sugar plant (Million kWh)



• Cost of steam to sugar plant : Nil

( ₹ / Metric Tonne)

• Cost of bagasse from sugar mill : Nil

( ₹/ Metric Tonne)

• Cost of power to KEB ( ₹/kWH) : 3.15 for

2000-2001 with an escalation of 5% every year

• Plant load factor from 2nd year : 90%

• Total works cost ( ₹ In Lakhs) : 6563.22

Note :- Though the Co-generation Plant been erected and commissioned

successfully,due to shortage of fuel the generation of power been not yet

started (i.e the generator synchronization to grid is not yet started). The

bagasse thus comes from the sugar plant and wood chips are used as fuel

to Co-generation boilers and the steam thus generated is pressure reduced

using PRDS system to run the two turbo-generators (each of capacity

2.5MW) of sugar plant. Most of the power requirement of the plant is met

by the power generated by these turbo-generators rest being met by the

power purchase from KPTCL.

Thus the detailed study of energy auditing is confined to the sugar plant.



Chapter 2



Chapter 2

LITERATURE REVIEW

2.1 Energy Savings Toolbox – an Energy audit Manual and Tool [1]

This manual has been developed under the auspices of the Canadian

Industry Program for Energy Conservation (CIPEC), a joint initiative of

Canadian industry and the Office of Energy Efficiency of Natural

Resources Canada. Further, the manual was developed in conjunction

with the provinces and territories.

This Guide promotes the proven Energy Efficient Techniques which are

designed to be utilized as a source of reference by Sugar plant.

The guide provides information on factors affecting energy consumption,

particularly electricity and steam consumption and attention is given to all

thermal and electrical utilities.

This Guide also provides the practical steps to saving energy, saving

money through closer control of mill processes, lighting, heating.

2.2 The Energy Conservation Act 2001. [7]

The Energy Conservation Act implemented by the Bureau of Energy

Efficiency (BEE) a statutory body of India, envisages creation of cadre of

professionally qualified energy managers and auditors with expertise in

energy management, project management, financing and implementation

of energy efficiency projects, as well as policy analysis. It is a law to force

firms to make more profit and not an Act to control and monitor energy

consumption of industry.



2.3 Guide Books for the National Certificate Examination for Energy

managers and Energy Auditors, Second Edition (2005). [2]

Book I – General aspects of energy management and energy audit,

(Chapter 3 – “Energy Management and Audit”, Chapter 5 – “Energy

Action Planning”, Chapter 6 – “Financial Management”, Chapter 8 –

“Energy Monitoring and targeting”).

Book II – Energy Efficiency in Thermal, (Chapter 1 – “Fuel and

Combustion ”, Chapter 2 – “Boiler”, Chapter 3 – “Steam |System”,

Chapter 8 – “Waste heat recovery”).

Book III – Energy Efficiency in Electrical Utilities, (Chapter 1 –

“Electrical System”, Chapter 6 – “Pumps and Pumping System”, Chapter

8 – “Lighting Systems”, Chapter 10 – “Energy Efficient technologies in

Electrical Systems”)

Book IV – Energy performance assessment for equipment & Utility

Systems, (Chapter 1 – “Boilers”, Chapter 7 – “Water Pumps”, Chapter 10

– “Financial analysis”, Chapter 12 – “Application of non-conventional

and renewable energy sources”).

2.5 PCRA literature (Petroleum Conservation research association) [9]

From PCRA literature , the guidelines for quantifying energy conservation

in pumps and lighting system been adapted will conducting the energy

auditing of pumping system and illumination of M/s Mysore Sugar

Company limited and are as follows,

Illumination

• Use of electronic ballast in place of conventional choke saves

energy upto 20%.



• Use of CFL lamp in place of GLS lamp can save energy upto 70%.

• Clean the lamps & fixtures regularly. Illumination levels fall by

20-30% due to collection of dust.

• Use of 36W tubelight instead of 40 W tubelight saves electricity by

8 to 10%.

• Use of sodium vapour lamps for area lighting in place of Mercury

vapour lamps saves electricity upto 40%.

PUMPS

• Improper selection of pumps can lead to large wastage of energy.

A pump with 85% efficiency at rated flow may have only 65%

efficiency at half the flow.

• Use of throttling valves instead of variable speed drives to change

flow of fluids is a wasteful practice. Throttling can cause wastage

of power to the tune of 50 to 60%.

• It is advisable to use a number of pumps in series and parallel to

cope with variations in operating conditions by switching on or off

pumps rather than running one large pump with partial load.

• Drive transmission between pumps & motors is very important.

Loose belts can cause energy loss upto 1-20%.

• Modern synthetic flat belts in place of conventional V-belts can

save 5% to 10% of energy.

• Properly organized maintenance is very important. Efficiency of

worn out pumps can drop by 10-15% unless maintained properly.



2.6 Concepts and methodology adapted to Audit Energy . [20]

The Energy Auditing concepts adapted by The energy and resource

institute formerly known as Tata Energy Research Institute (TERI),

Bangalore, a National laboratory of Central Scientific Institute for

Research.

TERI has conducted many Energy Auditing in Sugar Mills

Based on the above literature survey, the energy auditing of following

equipments of M/s Mysore Sugar company ltd., been carried out.

1. Steam Generation, distribution & utilization.

2. Pump and Water System.

3. Lighting System.



Chapter 3



Chapter-3Process Flow of My Sugar

3.1 General

Sugarcane processing is focussed on the production of cane sugar

(sucrose) from sugarcane. Other products of the processing include

bagasse, molasses, and filtercake. Bagasse, the residual woody fiber of

the cane, is used for several purposes: fuel for the boilers and lime kilns,

production of numerous paper and paperboard products and reconstituted

panelboard, agricultural mulch, and as a raw material for production of

chemicals. Bagasse and bagasse residue are primarily used as a fuel

source for the boilers in the generation of process steam. Thus, bagasse is

a renewable resource. Dried filtercake is used as an animal feed

supplement, fertilizer, and source of sugarcane wax. Molasses is

produced in two forms: inedible for humans (blackstrap) or as an edible

syrup. Blackstrap molasses is used primarily as an animal feed additive

but also is used to produce ethanol, compressed yeast, citric acid, and

rum. Edible molasses syrups are often blends with maple syrup, invert

sugars, or corn syrup.

3.2 Process Description

A simplified process flow diagram for a typical cane sugar production

plant is shown in Figure 3.2. The cane is received at the mill and prepared

for extraction of the juice. At the mill, the cane is mechanically unloaded,

placed in a large pile, and, prior to milling, the cane is cleaned. The

milling process occurs in two steps: breaking the hard structure of the

cane and grinding the cane. Breaking the cane uses revolving knives,

shredders, crushers, or a combination of these processes. For the grinding,

or milling, of the crushed cane, multiple sets of three-roller mills are most

commonly used although some mills consist of four, five, or six rollers in



multiple sets. Conveyors transport the crushed cane from one mill to the

next. Imbibition is the process in which water or juice is applied to the

crushed cane to enhance the extraction of the juice at the next mill. In

imbibition, water or juice from other processing areas is introduced into

the last mill and transferred from mill to mill towards the first two mills

while the crushed cane travels from the first to the last mill. The crushed

cane exiting the last mill is called bagasse. The juice from the mills is

strained to remove large particles and then clarified. In raw sugar

production, clarification is done almost exclusively with heat and lime (as

milk of lime or lime saccharate); small quantities of soluble phosphate

also may be added. The lime is added to neutralize the organic acids, and

the temperature of the juice raised to about 95 degree C (200 degreeF). A

heavy precipitate forms which is separated from the juice in the clarifier.

The insoluble particulate mass, called “mud”, is separated from the limed

juice by gravity or centrifuge. Clarified juice goes to the evaporators

without additional treatment. The mud is filtered and the filter cake is

washed with water.

Evaporation is performed in two stages: initially in an evaporator station

to concentrate the juice and then in vacuum pans to crystallize the sugar.

The clarified juice is passed through heat exchangers to preheat the juice

and then to the evaporator stations. Evaporator stations consist of a series

of evaporators, termed multiple-effect evaporators; typically a series of

five evaporators. Steam from large boilers is used to heat the first

evaporator, and the steam from the water evaporated in the first

evaporator is used to heat the second evaporator. This heat transfer

process continues through the five evaporators and as the temperature

decreases (due to heat loss) from evaporator to evaporator, the pressure

inside each evaporator also decreases which allows the juice to boil at the

lower temperatures in the subsequent evaporator. Some steam is released



from the first three evaporators, and this steam is used in various process

heaters in the plant. The evaporator station in cane sugar manufacture

typically produces a syrup with about 65 percent solids and 35 percent

water. Following evaporation, the syrup is clarified by adding lime,

phosphoric acid, and a polymer flocculent, aerated, and filtered in the

clarifier. From the clarifier, the syrup goes to the vacuum pans for

crystallization.

Crystallization of the sugar starts in the vacuum pans, whose function is

to produce sugar crystals from the syrup. In the pan boiling process, the

syrup is evaporated until it reaches the supersaturation stage. At this

point, the crystallization process is initiated by “seeding” or “shocking”

the solution. When the volume of the mixture of liquor and crystals,

known as massecuite, reaches the capacity of the pan, the evaporation is

allowed to proceed until the final massecuite is formed. At this point, the

contents of the vacuum pans (called “strike”) are discharged to the

crystallizer, whose function is to maximize the sugar crystal removal

from the massecuite. Some mills seed the vacuum pans with isopropyl

alcohol and ground sugar (or other similar seeding agent) rather than with

crystals from the process. From the crystallizer, the massecuite (A

massecuite) is transferred to high-speed centrifugal machines

(centrifugals), in which the mother liquor (termed “molasses”) is

centrifuged to the outer shell and the crystals remain in the inner

centrifugal basket. The crystals are washed with water and the wash water

centrifuged from the crystals.

The liquor (A molasses) from the first centrifugal is returned to a vacuum

pan and reboiled to yield a second massecuite (B massecuite), that in turn

yields a second batch of crystals. The B massecuite is transferred to the

crystallizer and then to the centrifugal, and the raw sugar is separated

from the molasses. This raw sugar is combined with the first crop of



crystals. The molasses from the second boiling (B molasses) is of much

lower purity than the first molasses. It is reboiled to form a low grade

massecuite (C massecuite), which goes to a crystallizer and then to a

centrifugal. This low-grade cane sugar is mingled with syrup and is

sometimes used in the vacuum pans as a “seeding” solution. The final

molasses from the third stage (blackstrap molasses) is a heavy, viscous

material used primarily as a supplement in cattle feed. The cane sugar

from the combined A and B massecuites is dried in fluidized bed or

spouted bed driers and cooled. After cooling, the cane sugar is transferred

to packing bins and then sent to bulk storage. Cane sugar is then generally

bulk loaded to trucks.



Process Flow Diagram of Sugar production in MySugar company Ltd.,

CANE CARRIER

BAGGASE

FILTERATE JUICE

RAW JUICE

HOT RAW WATER

MILK OF LIME LIME STALKER


CANE YARD

MILLS

JUICE WEIGHING TANK

RAW JUICE TANK & PUME

JUICE HEATER

JUICE SULPHITATION

SO2 JUICE &PUMP

CO-GENERATION/ KPC BOLER

A

LIME TANK

SO2 TOWER

SULPHUR BURNER

D


BAGASILO

FILTER CAKE

VAPOURS TO PANS ASMENURE TO FIELDS

VAPOURS TO PANS


JUICE HEATER

FLASH TANK

JUICE CLARIFIER

EVAPORATOR FEEDPUMP

CHATRAPATTIVAPOUR CELL

VAPOUR CELL

EVAPORATOR-1

EVAPORATOR-2

EVAPORATOR-3

A

B

MIXER

CYCLONE

LIME TANK

D


SO2 SYRUP

VAPOUR TO CONDENSER

VAPOUR AND EXHAUST

MASSICUITE


PUG MILL

EVAPORATOR-4

SYRUP EXTRACTIONPUMP

SYRUP SULPHITATION

SO2 SYRUP PUMP

SUPPLY TANK

PAN-A

AIR COOLED CRYSTALIZER

MAGMA

A.A.W MACHINES

B

C

PUG MILL

MOLASSES

E


HOT AIR BLOWER

FINAL MOLASSES TO DISTILLERY

Figure 3.2- M/s My Sugar Company ltd., Sugar processing flow diagram


G.H. CONVEYOR

SUGAR ELEVATOR

SUGAR GRADER

B. CRYSTALLIZER C. CRYSTALLIZER

C

E

SUGAR BAGGING

B. PAN C. PAN

MOLASSESC. CENTRIFUGAL C.A.W

C.A.W MAGMA

C.SEED MIXER

PUG MILLMACHINE PUMP

C. CENTRIFUGAL


Chapter 4



Chapter 4Energy Consumption profile

4.1 Introduction

In this chapter the cane crushing, raw juice, sugar production, the specific energy consumption, sources of fuel and total cost incurred during a fiscal year been tabulated. With these details further energy conservation proposal and recommendation been discussed.

4.2 Production Details

The cane crushing, raw juice and sugar production against each period is shown below,

Table 4.2 : Details of the Sugar production

Year Cane Crushing

M|T

Raw Juice Production

MT

Sugar Production

MT

2009-2010 122563 118825 9067.5

2010-2011 500729 496325 42339

4.3 Sources of Energy

• Electricity

• Bagasse Fuel

• Wood Chip.

Electricity is from KPTCL, Self generation and DG set. Bagasse is used

as fuel in boiler for generation of steam for process utilisation and

electricity generation. The month wise energy consumption from April

2010 to march 2011 is as shown in Appendix – 4/1.



Table 4.3: Details of Sources of energy

Sl. No. Source of Energy Units 2010-2011

1 Electricity kWh

KPTCL Lakh kWh 20.79

Self Generation Lakh kWh 51.24

DG Set Lakh kWh 17

Total 89.03

Av.Unit Rate ₹ .4.6

Cost of Electricity Lakh ₹ 409.54

2 Bagasse MT 153300

Cost of Fuel Lakh ₹ 1533

3 HSD KL 410

Cost of HSD Lakh ₹ 0.17

4 Wood Chip MT 2849.27

Cost of Wood Chip Lakh ₹ 35.01

4.4 Specific Electrical Energy Consumption

Table 4.4 : Details of Specific Electrical Energy Consumption

Year kWh/MT of

Cane Crushing

kWh/MT of

Raw Juice Production

kWh/MT of

Sugar Production

2010-2011 17.8 17.94 210.28



4.5 Cost of Energy

For techno Economic calculation the cost of various resources considered as follows,

• Electrical Charges in kWh

(I) April 2010 to December 2010

a) from 01 unit to 1,00,000 units - ₹ 4.3

b) from 1,00,001 units to consumed units – ₹ 4.6

(II) January 2011 onwards

a) from 01 unit to 1,00,000 units - ₹ 4.6

b) from 1,00,001 units to consumed units – ₹ 4.9

• Demand Charges - ₹ 170.00

• Bagasse Cost - ₹ 1000.00 /MT

• HSD - ₹ 41.58 /liter

• Wood Chip - ₹ 1230 / MT

4.6 Total Cost incurred in Lakhs

• KPTCL - ₹ 123.785.

• Bagasse - ₹ 1533.00.

• Wood Chip - ₹ 35.01.

• HSD - ₹ 0.1705.

-----------------

Total - ₹ 1692.0



4.7 Energy consumption Details

Table 4.7 :Details of Energy consumption

Sources 2010-2011

Lakh Kwh %

KPTCL 20.79 23.35

TG 51.24 57.55

DG 17 19.09

Fig 4.7 – Pie chart showing the energy consumption profile


23.35%

57.55%

19.09%

Energy Consumption Profile

KPTCLTGDG


Chapter 5



Chapter 5

STEAM GENERATION, DISTRIBUTION AND UTILIZATION

5.1 Facility Description

The sugar unit of the plant is equipped with four boilers of which two is of

Texmaco make (40 t/h each) and two is of KCP make (20 t/h each) .all

the boilers are of dumping grate type with pneumatic distribution

.Maximum steam generating pressure of these boilers is 21 kg/cm2 .fuel

used is bagasse. The main auxiliaries of the boilers are ID,FD,SA fan and

feed water pump .the detailed specifications are provided in Appendix-

5/1. Out of 4 boiler only one boiler is in use i.e. KPC boiler of capacity 20

t/h to drive the turbines of Mills, rest of the steam requirement is met from

boilers of co-generation, each of the boiler having a capacity of 80 t/h.

Distribution of steam from the boilers is as shown in Appendix- 5/2.

5.2 Observations and Analysis

A. General – observations

(I) Steam generation of KPC boiler

• Bagasse is used a fuel which has a calorific value of 1960 kcal/kg

• Bagasse is fed into the boilers automatically through conveyors

• Balanced draft in boilers is maintained by operating the ID and FD fan openings

• CO2% percentage in the flue gas varies from 10.8 to 11.75

• It was observed that air infiltration is occurring in KPC Boiler

• At present excess air levels in KPC boiler ranges from 75 to 96%.

This can be brought down to 60% there by increasing the

efficiency by 0.5 to 1% .



• FD fan opening should be adjusted to about 55 to 65% so that

excess air levels can be brought down to 60%

• All the boilers have secondary air fans which is working

satisfactorily

• The boilers blow down TDS was 1800 TDS and the blow down

operations was carried twice in a shift

• The boiler surface temperature was found to be 50°to 60°C.

• The boiler efficiency calculations are provided in Appendix-5/3

(ii) Steam distributions and utilizations

• The high pressure steam generated in boilers are used in TG#1,

TG#2 to generate power and in “A” and “B” mills to drive the

steam turbines. The detailed rated and operating parameters of

“TG, A & B mill turbines” are provided in Appendix -5/4.

• The exhaust steam from TG,A& B mill turbines are fed to

chatrapati vapour cell, raw juice heating sections, 1st body of

Binny and isjeck evaporators

• The vapour coming out of low pressure steam, high pressure

steam is passed through PRDS (approx.2 to 3 t/h) and utilized in

evaporator and chatrapathi cell.

• The vapour coming out of final effect evaporator is at 55°C and it

is condensed in vaccum condenser(2 nos)

• The vapours coming out A,B,C pans are condensed in jet

condenser(11 nos)



• The plant has installed new SS condenser (spray type), which

reduces the cooling water requirement in pan section

• In distillery unit mainly steam is utilized in fermentor,

analyzer,columns,rectifier column, exhaust column and air

benzene recoverable column etc.

• Most places steam pressure gauges are not in working condition.

• Steam leakages at many places in the plant is occurring .

• The management is the process of replacing the chatrapati cell

with kentser vapour cell. This measure will enhance the steam

economy.

• In A and B mill steam turbines should be replaced with DC drive

. this aspect is discussed in proposal section.

• The return condensate is collected in condensate collection tank (2

open ) and hot water tanks. Heavy loss of flash steam is occurring

from the open tanks.

• The condensate is tank surface temperature is high (in the range

of 90 to 97°C) . these tanks should be reinsulated.

• The detailed trap survey has been done and it was found that traps

are working well.

5.3 Energy Conservation proposals and Recommendations

5.3.1 Proposal-1 :Flash steam recovery from condensate

Background



The average condensate collected at hot water tank is around 180m3/h at

temperature of about 95 to 100°C. the tank being open at the top, the flash

steam generated is let out. This steam is utilized and causing damage to the

insulation of pipes, above the tank.

If the flash steam is recovered and utilized in heating of the juice, it will not

only reduce the steam consumption in the first stages heaters and also

condensate can be recovered.

Recommendation

As the return condensate is at considerable pressure and temperature , flash

steam can be recovered by installing a flash steam recovery unit . the flash

steam recovered from the system can be used in the raw juice heaters.

Energy savings

Expected output of flash steam from condensate : 1500kg/h

Expected pressure of flash : 1.5kg/cm² ab

Net savings in bagasse per year : 4250 MT

Cost saving per year : ₹ 42.5lakhs

Cost of flash steam recovery system : ₹ 2.0 lakhs

Simple payback period : 17 days



5.3.2 Proposal-2: Replacing the steam drives with DC drives

Background

This plant has two mills namely A &B. “A” mill has four turbine drives of

600BHP capacity which consumes about 6.5t/h of steam at pressure. “B”

mills has three turbines of 1000BHP capacity which consumes 10 t/h of

steam at 18 kg/cm2.

Normally the efficiency of these turbines are in the range of 35 to 43% .

the low efficiency result these turbines to operate at higher specific steam

consumptions than the power turbines, Appendix-5/5 shows the power

generated at steam turbines shaft and transmitted to a roller shaft through

high and slow speed gear box, open gearing stages, couplings and tail bars.

This lengthy power transmission system result in a very low overall

efficiency of the order of 31%. The over all efficiency of various types of

drives are shown in Appendix – 5/5.

The electric drives(DC motors) for the mills are better placed than steam

drives, in terms of simplicity, better cleanliness, ease of control, readily

adoptable and integration in to any complex system with ease and

flexibility. Above all, overall efficiency of DC drives system system comes

to 51%

The recent technology is hydraulic drives, which gives an overall

efficiency of 58%. But these drives require clean environment for smooth

operations and the cost is high.

Recommendation

Replace the existing steam turbine drives with DC motors drives (600 and

1000 HP), which result in 15% higher efficiency of transmission. The

result in considerable energy savings



Energy savings

Steam consumption in” A” mill steam drives at 16.5 kg/cm² : 6.5 t/h x 4

Pressure : 26 t/h

Steam consumption in “B” mill steam drives at 16.5 kg/cm2 : 10 t/h x 3

: 30 t/h

Total steam consumption : 56 t/h

Energy savings envisaged due to higher : ₹ 152 lakhs

Efficiency of DC drives (15%)

Cost of implementation : ₹ 220 lakhs

Simple payback period : 18 months

5.3.3 Proposal -3: insulating exposed areas of flanges, valves

and pipelines

Background

High pressure lines: many portions of high pressure lines such as valves,

flanges, pipelines near A & B turbines mills, steam headers are exposed to

atmosphere (insulation broken). This result in considerable heat loss

Low pressure lines: in processing sugar juice low pressure steam form

turbine exhaust and vapour from chatrapati cell is used . at many places

connecting pipelines, flanges,valves are uninsulated (or) insulation is

broken . this result in considerable heat loss.



The total surface heat loss from uninsulated flanges, valves and pipe lines

and equipment are tabulated in Appendix-5/6.

Recommendation

By insulating the exposed areas of the flanges, valves and pipelines

Energy savings

Total exposed area : 504+268

: 772mt²

Net energy savings in kcal/h : 578011+59114

: 637125 kcal x 109kcal

Net energy savings per year : 2786 tons/Year

Net savings in bagasse : ₹ 27.86 lakhs

Cost of implementation :₹ 7lakhs

Simple payback period : 3 months

5.3.4 Proposal -4 : insulating exposed areas in steam line

Background

Valves, NRV, flanges and some portion of steam line are exposed to

atmosphere. The uninsulated temperature ranges from 130 °C to 150 °C.

Insulation of some portion of steam balloon has come off and thus

temperature is 120°C.



Recommendation

To reduce heat loss, it is recommended to insulate the surface with glass

wool so as to reduce the surface temperature to 50°C

Energy savings

Total exposed area of steam line : 13.72mt2

Average surface temperature : 127°C

Expected surface temperature after insulation : 50°C

Fuel savings per hour(bagasse) : 11kg

Net energy savings in kcal/h : 15,180

Cost saving per year : ₹ 0.5 lakh

Cost of implementation : ₹ 5000

Simple payback period :1 month

5.4 General

• At the outset the steam and power production areas will be highlighted

before going into the details of energy consumption areas. For steam

production bagasse being the only fuel, it is very important to ensure

that uniform feed of the fuel of not exceeding 50% moisture content is

assured always to the boilers. More than 60% of the factories in India

work with Boiler systems of less than 20 kg/sq.cm pressure rating.

Whatever may be theoperating parameters of the boilers, the need for

maintaining the boilers in excellent health to work at the rated

efficiencies does not require over emphasis. Typically in a well

maintained boiler there is a variation of 0.8% in the efficiency of boiler

for every percentage of moisture variation in bagasse. A moisture level



of 50% in bagasse is generally taken as the benchmark as all the sugar

mills as well as boiler manufacturers adopt this for their designs.

Though bagasse drying can improve boiler efficiency further, it has to

be carefully planned in the heat balance of the plant, while optimizing

the power cycle.

• It is important to take note of the following thumb rules for quantifying

the energy conservation in boiler operations. Every 20°C reduction in

back end temperature: 1.0% increase in boiler efficiency.

• 10% reduction in excess air: 0.4% increase in boiler efficiency.

• 1% reduction in bagasse moisture: 0.8% increase in boiler efficiency.

For 1TPH steam generation with 0.5% increase in boiler efficiency,

there is saving in 3 kg/hr of bagasse.

• For 1 TPH steam generation, by installing flash steam recovery system

for continuous blowdown in boilers, there is a saving of 1.5 kg/hr of

bagasse.

• These figures may vary according to boiler parameters. The above

details will emphasize the need for maintaining optimum operational

conditions required for efficient performance of mills and boilers.

5.5 ENERGY CONSERVATION IN EXISTING POWER

PLANT

CHECK LIST OF KEY FACTORS

• · Improvement in back end gas temperature

• · Rectification of leakage in ducting and the entire flue gas path.



• · Arresting of air / flue gas bypass especially through boiler bank

baffles, economizer flue gas bypass ducting.

• · Proper maintenance of insulation in boiler, furnace, ducting and

piping including fittings.

• · Boiler thermal expansion movement check with respect to supports.

• · Modifications in air / flue gas flow pattern and elimination of ash

accumulation in ducting.

• Minimizing the losses due to boiler drum blow down.

• Arresting water and steam leakage in boiler and piping.

• Improvement / restriction of furnace outlet temperature of flue gas to

avoid slagging in superheater area.

• Introduction of direct spray type desuperheater in superheater assembly

by dividing the superheater into two sections in single stage superheater

design.

• Review of superheater and pressure part supports.

• Addition of long retractable soot blowers in front of superheater.

• Ensuring uniform distribution of controlled quantity of fuel on the

grate.

• Review of the grate design and maintainability.

• Operating the boiler at its rated parameters i.e capacity, pressure and

temperature

• Review of the performance of the existing steam drum internals and

steam drier arrangement.



• Review of the existing heating surface area provided in the boiler.

• Review of the boiler design and space availability with respect to

increase in boiler capacity

• Review of the existing main steam pipe sizing and pipe routing

• Review of the capacity and head of equipment selected such as, ID, FD

& SA fans, boiler feed pumps, etc

• Reduction of unburnt carbon loss in bottom ash and fly ash.

• Review of the dust collector equipment performance.

• Review of boiler operating practices such as furnace cleaning time etc

• Review of boiler water quality and feed water quality.

• Inspection of deaerator and review of its performance.

• Review of HP and LP dozing system capacity and selection.

5.6 GUIDE LINE FOR QUANTIFYING ENERGY

CONSERVATION

• 10°C reduction in back end temperature - 0.6% increase in boiler

efficiency

• 10 % reduction in excess air - 0.4% increase in boiler efficiency

• 1 % reduction in bagasse moisture - 0.8 % increase in boiler efficiency

• For 1.0 TPH steam generation with 0.5 % increase in boiler efficiency,

there is saving of 3 kg/hr of bagasse.

• For 1.0 TPH steam generation, by installing flash steam recovery

system, there is a saving of 1.18 kg/hr of bagasse



Chapter 6



Chapter 6

PUMPING AND WATER SYSTEM


The plant has 43 no. of centrifugal pumps as per the area wise pump details

as shown in Appendix-6/1 and the total power consumption of all the

running pumps is 986 kW, which is about 23% of total power consumption

of sugar plant.


▪ .All most all the pumps are centrifugal pumps.

▪ These pumps used to water and juice.

▪ Transportation of Magma is done through lobe type positive

displacement pumps.

▪ With respect to either flow or head developed most of the Centrifugal

pumps are over sized.

▪ From the Appendix- 6/1 , following pumps are loaded less than 45%

due to either lower rate/head requirement or both as per the process

requirement.

1. Screened Juice pump.

2. Imbibition juice pump-2 (mill-B).

3. Sulphited syrup pump.

4. Syrup extraction pump.

5. Sweet Water pump.



6. Scum pump.

7. Remelt pump.

8. A-light molasses pump.


During the study, all running centrifugal pumps were observed for their

existing operating conditions. The required flow rate and head developed

against rated flow and pressure were studied.

The cooling water flow rate and temperature were also measured at the

inlet and outlet of the various cooling equipment/bearings.

The electrical parameter like V, A, pf, kVA and kW were measured for all

running pump motors.

Energy saving opportunities were identified without effecting the present

process conditions .

The motors required for the right size pumps may obtained from

reshuffling motors from the inventory.

6.3.1 Proposal-1 ; Optimization of pan injection cooling water

system

Background

In the boiling section, there are about 11 pans and two sets (each with 5

bodies) evaporators for concentration of the juice to syrup. Jet type

condensers are used to condense the vapors and create vacuum in the pan

and evaporator bodies.



In this proposal, we are considering only the condensers of pan

evaporators. The amount of cooling water needed to be sent as injection

water is only 5033 cum/hr.

In the existing set up, there are six pumps of rated flow rate of 1000cum/hr

and head of 25 M (6 x 1000 cum/hr) and one pump of rated flow rate of

1400 cum/hr and head of 21M (1x 1400 cum/hr) is being operated. The

quantity of injection water being pumped to the condensers as per pump

rating ( 7 pumps were inline) with the valve full open condition is

7400 cum/hr.

Operating pumps of two different rated head, connected to common

manifold will result in throttling effect and lead to increase power

consumption and non uniform loading of the pumps. This is not a good

engineering practices. The details on design of cooling water requirement,

existing flow rates, the power consumption and percentage loading of all

pan injection water pumps is shown in Appendix – 6/2.

Recommendation

Total design of condenser water required for pans : 5033 cum/hr.

No. of pumps need to be operated is Six : 6 x 1000 cum/hr

= 6000 cum/hr.

3 pumps on each side of 1000 cum/hr of head 25 M to be operated

Hence one pump of 1400 cum/hr pump can be stopped.

Energy saving by switching off one no. of 1400 cum/hr pump

: 76.5 kW

: 76.5 x 24 x 250days



= 4,59,000 kWh/year

With tariff of power/unit @ ₹ 4.60/kWh = 4,59,000 x 4.60

= ₹ 21,11,400/year

6.3.2 Proposal-2 ; Right sizing of evaporator injection water

pump

Background

The vapor from two sets of evaporators (5 bodies per set) is being

condensed using condensers ( each one condenser for one set of

evaporator). The water required for condensers is supplied by centrifugal

pump of following specification,

Capacity : 1400 cum/hr.

Head : 25 M.

Power of motor : 150 kW.

The required flow rate of the pump is 900cum/hr with the head of 18M.

For the flow rate and head, the power required would be 89.18 kW only.

Where the measured power is 118.5 kW. Hence pump have to down sized

to the nearest specification. The details of power requirement for all the

pumps are shown in Appendix – 6/1.

Recommendation

Replacement of existing pump with the specification matching to the

requirement. The energy saved by replacing the right sized pump is

28.75kW.



Table 6.3.2: Proposed Water injection pump details

Pump name Motor

Rate kW

Measured

pump power

kW

Present

loading

Proposed

Q

(cum/hr)

H

(M)

Pump Power

kW

Motor kW

Water injection

pump

150 118.5 79.4 1000 18 111.5 110

Energy savings

Energy saved : 28.75 kW

Power Cost : ₹ 4.6 / Unit.

Energy saved per year : 28.75 x 24 x 250 days

= 1,72,500 units

Cost of energy saving : 28.75 x 4.6 x 24 x 250 days

= ₹ 7,93,500.

Cost of implementation : ₹ 4.5 lakhs

Simple pay back period : 0.6 years

6.3.3 Proposal-3 ; Right sizing of raw juice pump

Background

Raw juice pump is used to pump the raw juice from the juice storage to

juice heater. The actual flow rate is around 220 to 230 cum/hr with a head

of 80 M. The power required by the pump is 22.6kW



Hence the pump be down sized to nearest specification for energy

conservation.

Recommendation

Replacement of present pumps with matching specification.

Table 6.3.3: Proposed Raw Juice pump details

Pump name Motor

Rate kW

Measured

pump power

kW

Present

loading

Proposed

Q

(cum/hr)

H

(M)

Pump Power

kW

Motor

kW

Raw Juice

pump

75 53.7 72 230 57 22.6 30

The energy saved by replacing the right sized pump is 31.1kW.

Energy savings



Energy saved per year : 31.1 x 24 x 250 days

= 1,86,600 units

Cost of energy saving : 31.10 x 4.6 x 24 x 250 days

= ₹. 8,58,360


simple pay back period : 2.1 months.



6.3.4 Proposal-4 ; Right sizing of Sulphited juice pump

Background

Sulphited juice pump is used to pump the sulphited juice from the juice

storage tank to clarifier. The actual flow rate is around 300 cum/hr, for

head of 12M as against pump rated head of 80M. The power required by

the pump is 17.84 kW.


conservation.

Recommendation


Table 6.3.4: Proposed Sulphited juice pump details

Pump name Motor

Rate kW

Measured

pump power

kW

Present

loading

Proposed

Q

(cum/hr)

H

(M)

Pump Power

kW

Motor kW

Sulphited juice

pump

75 46.5 62.3 300 12 17.84 22.5


Energy savings



Energy saved per year : 28.66 x 24 x 250days

= 1,71,960 units



Cost of energy saving : 28.66 x 4.6 x 24 x 250days

= ₹ 7,91,016


simple pay back period : 1.5 months

6.3.5 Proposal-5 ; Right sizing of Clear juice pump

Background

Clear juice pump is used to pump the clear juice from the clarifier to

evaporator. The actual flow rate is around 100 cum/hr (2 pumps being

operated), for head of 13M as against pump rated head of 30M. The power

required by the pump is 6.04 kW/pump.


conservation.

Recommendation


Table 6.3.5: Proposed Clear juice pump details

Pump name Motor

Rate kW

Measured

pump power

kW

Present

loading

Proposed

Q

(cum/hr)

H

(M)

Pump Power

kW

Motor kW

Clear juice

pump

37 22 59.6 100 13 6.44 15.6



The energy saved by replacing the right sized pump (2 No.) is 31.22 kW.

Energy savings




= 1,87,320 units


= ₹ 8,05,476


simple pay back period : 1.5month

6.3.6 Proposal-6 ; Right sizing of light molasses pump

Background

light molasses pump is used to pump molasses from centrifuge to pan from

the molasses storage tank to clarifier. The actual flow rate is around 50

cum/hr per, for head of 21M as against pump rated head of 30M. The

power required by the pump is 5.02 kW.


conservation.

Recommendation




Table 6.3.6: Proposed Light molasses pump details

Pump name Motor

Rate kW

Measured

pump power

kW

Present

loading

Proposed

Q

(cum/hr)

H

(M)

Pump Power

kW

Motor kW

Light molasses

pump

45 10.05 67 50 21 5.2 10


Energy savings




= 46,200 units


= ₹ 2,12,520


simple pay back period : 2.8months

Note: the basis for head calculation for all the above proposals are given in

Appendix – 6/3.



6.4 Water System

As the sugar plant was operating adequate arrangements were been made

for meeting the raw water requirements of the plant. Previously raw water

was being drawn from the nearby Kodanahalli tank, which is getting

charged by the Vishweswarayya Canal. However now required water is

taken from the nearby Holul Tank, through the jack wells sunk in the

'Hebbe Halla' Nalla, which gets fed from the overflow and seepage from

the Holul Tank. Within the Sugar Plant there are Four(-4) Raw water

storage tanks of capacity 3000 Cu.M each, and the water requirements for

the plant is drawn from these tanks. The raw water requirements for the

cooling tower and the other auxiliaries of the Cogeneration plant is

supplied from these existing facilities in the sugar plant. .

Major portion of the water requirement for the condensers of the pan and

evaporator are directly pumped to the sugar plant. The present water

balance of the sugar, co-generation and distillery unit is given in

Appendix -6/4. from the water balance it could be inferred that the plant

consumes more water than the requirement due to uncontrolled water flow

to cooling purpose (bearings and sulphur burning) and short circuit of hot

water in the spray pond. Moreover, the water utility pattern in service area,

like quarters and factory's sanitary requirements seem to higher than the

standards.

In this regard, the water required for the plant is revised based on the

measurements and observation, the details on the revised water balance is

given in Appendix – 6/5.

Recommendation

The water required for various cooling purposes, condenser of the pans,

evaporator s should be optimised for the use of lesser water. The optimum



flow required for condensers are shown in proposal -1. the cooling water

flow to be controlled by trail and error method for pickup more heat to

reaction a differential temperature of 9°C. Also the water required for

quarters and other services should be regulated. Even though the water is

available in plenty. Plant shall take all steps to minimize the consumption

of water in order to mitigate environmental impact due to discharge of

effluent from the factory.

Water Savings

The amount of water that could be saved on implementation of regulating

measures will be around 2184600 cum/yr. Which accounts of 25% of total

water consumption. The detailed of calculation is shown in Appendix-

6/5.

6.5 Spray Pond

Background

Mysore Sugar has a spray pond of following specification to cool the water

from barometric condenser, distillation column condenser, coolers of

bearing and sulfur burner.

Length : 75 m.

Width : 45 m.

Depth : 2.7 m.

Volume : 9121 cum.

No. of Sprayers : 350.

No. of Spray pump : 2 + 1.

Capacity of one pump : 1732 cum/hr.



Spray Capacity : 3464 cum/hr.

The amount of cooling water required to be cooled is in the spray pond as

per the existing operating condition is given in Appendix – 6/6.

As per measurement carried out during the energy audit, the cooling

performance of the spray pond is not satisfactory as the range is only

11°C(in general spray pond have a range of 12- 25°C and approach of 3 –

4°C). The spraying capacity of the pond (as per the pump capacity) is only

3464 cum/hr. The results in decreased efficiency of the spray pond. The

details of the temperature measurements are given below.

Table 6.5: Details of the temperature measurements

Sl No. Description Temp °C

i Hot well temperature 39

ii Pond / cold well temperature 34

iii Dry bulb temperature 27.8

iv Wet bulb temperature 23.04

v Relative humidity (%) 67.8

vi Water temp. at the outlet of spray nozzle 28.5

RANGE(i-ii) 5 °C

APPROACH (ii-iv) 11°C

Recommendation

The following suggestion may be implemented to optimise the

performance of spray pond.



1. Reducing the burnt barometric condenser cooling water quantity to

design value.

2. Segregating the cooling water from distillery unit, bearing cooling and

sulfur burner and using them as cane imbibition water in the mills.

3. Improving performance of the spray nozzles by maintenance /

replacement.



Chapter 7



Chapter -7

LIGHTING SYSTEM


The total Sugar plant has lighting load of around 75 kW |(excluding Co-

generation lighting load of 15 kW) and measured operating load of 54 kW.

The main type of lighting sources is 4' fluorescent tube light, 200W and

100W incandescent lamps, HPSV and halogen lamps. At present there is no

separate lighting transformer. The lighting load is given from feeder F-40

which can be either fed from Co-generation/TG-1/ KPTCL supply. The

data for operating load is given in Appendix – 7/1.


The total operating lighting load of the plant is around 54kW found during

study. The lighting fixture details are given in Appendix – 7/2. The

fluorescent tube lights are used in offices, shift engineer's room and in

production areas. In sugar packaging area 200W incandescent lamps are

used. 100W incandescent lamps incorporated with flameproof fitting being

used in STILL House of distillery. Mill lines and boiler area uses HPSV

(High pressure sodium vapor) lamps and halogen lamps being used.

During the study, the total plant lighting load was measured. The operating

voltage is in the range of 235 – 248 Volts and power factor varies 0.85 to

0.9.


7.3.1 Proposal-1 ; Use of 36W Fluorescent tube lights and

electronic chokes.



Background

Plant has used 40W fluorescent tube lights and copper chokes for all the

tube lights. Use of electronic chokes with 36W fluorescent results in at

least 20-25% energy savings over copper chokes with 40W fluorescent

tube lights for the same level of illumination. The conventional copper

chokes consumes about 15W per lamp as ballast losses, whereas the

electronic choke consumes only 2W per lamp owing to its high frequency

operation.

The electronic choke should be as per IS:13021 with over load/ short

circuit protection and indicator for over load. The other advantages of e-

chokes are,

• Uniform lighting output at variable voltage conditions including

non flickering start.

• Reduction of heat output.

• Minimum fire hazard.

• Enhanced life of lamps due to higher frequency operation.

• The elimination of supply current harmonics and the provision of a

factor of 1.0 without the need for a correction capacitor.

Recommendation

It is proposed to install electronic chokes and 36W fluorescent tubes after

replacing the conventional chokes and 40 W fluorescent tubes. Retrofitting

electronic chokes for those lamps would yield energy savings as given in

Appendix – 7/3.



Energy Savings

Annual energy savings : 7,650 kWh.

Cost of energy : ₹ 32,895/-

Cost of implementation : ₹ 11,250/-

Simple payback period : 4 Months

Or

7.3.2 Use of LED 48” 2000 lumen tube lights -40W Fluorescent

tube lights Replacement

Use of LED tube lights 22W results in at least 75-80% energy savings over

copper chokes with 40W fluorescent tube lights for the same level of

illumination. The main feature of the LED's is No dark areas，no glare, the

light is soft and homogeneous . Other features of LED as follows.

• Power supply of efficiency, low consumption ,steady, unique

design of anti-lighting ,over-currents , over-voltages ,short-circuits

and overloads protection.

• 86-265V Wide voltage design ,simple voltage input model .

• No lead ，mercury and other harmful substances， no noise,no

radiation,no ultraviolet ray, environmental protection and energy

saving.

• Lifespan is more than 40000 hours,30 times than incandescent

lamp's, 6 times than fluorescent lamp's.

• Less maintenance.



Recommendation

It is proposed to LED tube lights 22W after replacing the 40W fluorescent

tube lights. Retrofitting these LEDs would yield energy savings as given in

Appendix – 7/4.

Energy Savings

Annual energy savings : 14, 850 kWh.

Cost of energy : ₹ 68,310/-

Cost of implementation : ₹ 2,36,250/-

Simple payback period : 3years 6 Months.

7.3.3 Proposal-2 ; Replacement of 200W incandescent lamps

with twin fluorescent tube fixtures with electronic choke.

Background

During the study it was observed that around 30 Nos. of 200W

incandescent lamps are being used at various places in plant. Incandescent

lamps have low efficacy and life as compared with fluorescent tube light.

Recommendation

It is proposed to replace all 200W incandescent lamps by twin fluorescent

tube fixtures with e-chokes. Each 200W incandescent lamp gives a lumen

output of 3040, as such they can be replaced by 2 nos of cool day light

36W fluorescent tubes(each having a lumen output of 2450), to get the

same illumination level. The twin fluorescent fixtures with e-chokes

would consumes 76W of power as against 200W by incandescent lamps.

Also the life of fluorescent tubes is 7000 hours as against 1000 hours of



that of 200W incandescent lamps. The proposed retrofitting would yield

energy savings as given below.

Energy Savings


Cost of energy savings : ₹ 86,378/-

Cost of implementation : ₹ 51,000/-

Simple payback period : 0.59 years.

7.3.4 Proposal-3 ;Use of lighting voltage controller.

Background

The incoming voltage to the lighting circuit between 240-245V. By use of

reduced voltage controller set a 210 V in the exclusively in the lighting

circuits, a saving of 15% in the lighting energy consumption is achieved.

The reduction of voltage to the above mentioned levels does not impair the

ability of discharge lamps to strike though an insignificant reduction in

lumen output takes place. Besides, use of lower voltage level leads to

increase in pf and longer life of luminance. Since lighting loads are fed

from feeder F-40, the voltage controller can easily be installed and all

lighting loads can be supplied at the adjusted level of 210V.

Recommendation

It is proposed to install a lighting voltage controller of 90kVA, 3phase ,

50Hz, 415VAC with maximum load / phase capacity of 120amps in

feeder F-40. Based on measured load, the energy saving details are

provided Appendix – 7/6.



Energy Savings


Cost of energy savings : ₹ 1,95,822/-

Cost of implementation : ₹ 2,30,000/-

Simple payback period : 1 year 2 months.

7.4 General

▪ Regular cleaning of lighting fixtures, specially in boiler and mill

areas will help in improvement of illuminance levels.

▪ By power positioning of lighting fixtures mill section, dark patches

observed in some areas could be reduced.

▪ Translucent corrugated sheets provided at the roofs of mill area

should be cleaned for better utilization of daylight.



Conclusion



A Conclusion

Energy audit is a very important tool in transforming the fortunes of any

organisation. Norms should be set and continuously reviewed during the

course of operations, just as any other financial or production or

commercial parameters.

As seen in below Summary table A, there is a huge potential for savings, if

properly harnessed can take any organization to the path of prosperity.

Every unit of power saved and every ton of bagasse saved adds to the

additional revenue of the organisation.

Potential for energy conservation in sugar industry is immense because of

the fast developments that are taking place in the industry as well as the

traditionally conservative outlook of the Industry in India and their present

status. This only a few important areas that has come to light during the

audit of M/s Mysugar. There may be many more areas uncovered by this

report typical to individual units. That the potential for saving is more than

₹282.34 lakhs per annum in one factory has been identified does not

reflect that the same state of affairs will exist in all. It will be different in

different places and there are bound to be concern areas in all places if

honestly looked into, since no one could claim to have reached the state of

perfection.

Therefore it will be prudent for all organisations to set up energy

committees within the organisation, identify lacuna dispassionately and

rectify them immediately. Total commitment, involvement and guidance

of top managements is essential for this and if implemented effectively, it

will usher in prosperity not only to the organisation but also to the

Industry and the Nation at large.



Scope for Future Work

The above study been conducted only for the existing system that is the

equipments of Sugar plant. Once the Co-generation fully (including Coal

Handling Plant) commissioned and put to grid then there is huge

opportunity or future scope for energy auditing of whole plant i.e. Sugar

plant, distillery plant and Co-generation plant.

Summary of Recommendation

Table A: Summary of recommendation

Sl no.

Proposal Annual Saving Potential Cost of immplemn

Simple payback Period

Water Bagasse Elec value ₹.Lakh Years/Month

cum MT L.kWh ₹.Lakh

I STEAM GENERATION, DISTRIBUTION AND UTILIZATION

1 Flash steam recovery from condensate

4250 42.5 2 17 days

2 Replacing the steam drives with DC drives

152 220 18 Months

3 insulating exposed areas of flanges, valves and pipelines

2786 27.86 7 3

Months

4 insulating exposed areas in steam line

0.5 0.05 1 Month

Total Saving 7036 222.86 229.05

II Pumping and Water System



1 Optimization of pan injection cooling water system

4.59 21.11

2 Right sizing of evaporator injection water pump

1.73 7.93 4.5 7 Months

3 Right sizing of raw juice pump

1.87 8.58 1.5 2.1 Month

4 Right sizing Sulphited

juice pump

1.72 7.91 1 1.5 Month

5 Right sizing of Clear

juice pump

1.87 8.05 1 1.5 Month

6 Right sizing of light

molasses pump

0.46 2.13 0.5 2.8 Month

7 Water System 2184600

Total 2184600 12.24 55.71 8.5

II Lighting System

1 Use of 36W

Fluorescent tube lights

and electronic chokes.

0.77 0.33 0.11 4 Months

2 Use of LED 48” 2000

lumen tube lights

-40W Fluorescent tube

lights Replacement

0.15 0.68 2.36 3years 6 Months

3 Replacement of 200W

incandescent lamps

with twin fluorescent

20.09 0.86 0.51 7 Months



tube fixtures with

electronic choke.

4 Use of lighting voltage

controller.

42.57 1.9 2.3 1 year 2 month

Total 63.58 3.77 5.28

Grand Total 2184600 7036 75.82 282.34 242.83



APPENDICES



Appendix-A




Appendix-B


Appendix-C



Appendix-4/1

Details of Power Purchased and Generated for thee period April 2010 to March 2011

Month Power purchased KPTCL (Units)

Power Charges Paid ₹

Power Generated in Units

TG#1 (2.5MW) TG#2 (2.5MW)

April 2010 44316 400899 Nil Nil

May 2010 60012 473427 Nil Nil

June 2010 65160 281537 Nil Nil

July 2010 76896 548482 123800 222800

August 2010 124296 789205 550500 73200

September 193756 1146404 732700 12300

October 224508 1308350 627200 67100

November 263940 1452457 614500 Nil

December 281724 1530039 377600 Nil

January 2011 230544 1402731 770800 Nil

February 257052 1524234 55500 Nil

March 2011 257556 1511717 396400 Nil

Total 20,78,760 1,23,784,82 47,49,000 3,75,400



Fig 4/1: Details of Power Purchased and distributed


01/04/1001/05/10

01/06/1001/07/10

01/08/10September

OctoberNovember

December01/01/11

February01/03/11

0

200000

400000

600000

800000

1000000

1200000

TG#2 (2.5MW)TG#1 (2.5MW)Power purchased KPTCL (Units)

Details of power Purchased and Generated

MySugar Company Limited


Appendix-5/1

Boiler Specification (used to run mill turbine)

1. Make - KCP.

2. No. - 2.

3. Capacity - 20 t/h

4. Working Pressure - 21 Kg/sq cm.

5. Fuel Used - Bagasse.

6. Type of control - 3 element.

7. Fuel cost per ton - Rs.1000.

8. Draft - Balanced Draft

Co-generation Boiler Specification

1. Make - BHEL

2. No. of boilers installed - Two (2)

3. Capacity of each Boiler (MCR) - 80 TPH

4. Boiler outlet steam parameters - 66 Kg/Sq.cm(g)

485 +/-5Deg.C

5. Fuels used for the Boiler - Bagasse from Sugar Mill / wood chip

6. Draft - Forced Draft



Appendix-5/2



Appendix-5/3

Combustion Efficiency Calculation of KPC Boilers

Data

Type of Fuel Bagasse.

Composition of Fuel % Carbon 22.73.

% Hydrogen 3.03.

% Sulphur 0.00.

% Oxygen 23.24

% Moisture 49.5

%Ash 1.5

100

Flue gas Temperature 200 deg C.

CO2 in flue gas 10.5%.

Ambient Air temperature 32 deg C.

Wet Bulb Temperature 26 deg C.

Moisture content in air 0.018 kg/kg of air.

Fuel Calorific Value 1960 Kcal/kg.

Temperature of combustion air 295 deg C.

Excess air in flue gas 96%.

Heat Balance

Particulars Kcal/kg Percentage

Heat Inputs



Through heat value of fuel 1960 87.2Sensible heat in combustion air 289 12.8

Total 2249 100

Heat Output

Dry Flue gas losses 222 9.9

Heat losses due to Hydrogen in fuel 180 8.0

Heat losses due moisture in fuel 327 14.5.

Heat losses due moisture in air 8 0.3

Surface Heat losses 34 1.5

Efficiency 1479 65.8

Total 2250 100



Appendix-5/4

Sheet 1 of 2

Rated Parameters of “A” Mill Turbine

Mill No. Rated HP Rated steam pr (Kg/sqcm)

Rated steam temp (deg C)

Rated Turbine rpm

Mill rpm Yr of mfg

Rated steam con. (t/h)

Make

#1 600 21 340 8000 8 1972 5 Treveni

#2 600 21 340 8000 8 1972 5 Treveni

#3 600 21 340 8000 8 1972 5 Treveni

#4 600 21 340 8000 8 1972 5 Treveni

Operating Parameters of “A” Mill turbine

Mill No. Opt steam pr (Kg/sqcm)

Opt. steam con.(t/h)

operating steam temp (deg C)

Rated Turbine rpm

Mill rpm

#1 15 to 18 6.5 300 5000 5

#2 15 to 18 6.5 300 5000 5

#3 15 to 18 6.5 300 5000 5

#4 15 to 18 6.5 300 5000 5



Appendix-5/4

Sheet 2 of 2

Rated Parameters of “B” Mill Turbine

Mill No. Rated HP Rated steam pr (Kg/sqcm)

Rated steam temp (deg C)

Rated Turbine rpm

Mill rpm Yr of mfg

Rated steam con. (t/h)

Make

#1 1000 18 299 8000 8 1965 8 Treveni

#2 1000 18 299 8000 8 1965 8 Treveni

#3 1000 18 299 8000 8 1965 8 Treveni

Operating Parameters of “B” Mill turbine

Mill No. Opt steam pr (Kg/sqcm)

Opt. steam con.(t/h)

operating steam temp (deg C)

Rated Turbine rpm

Mill rpm

#1 15 to 18 8 to 10 285 4000 to 4500 4.5

#2 15 to 18 8 to 10 285 4000 to 4500 4.5

#3 15 to 18 8 to 10 285 4000 to 4500 4.5




Appendix-5/5

Sheet 1of 2



Appendix-5/5

Sheet 2 of 2


Appendix: 6/1

Power Measurement of Centrifugal Pumps

Sl No. Load Description Rated kW Measured kW % Loading

A. Mill Juice Pump Motors

1 I Mill Juice Pump Motor 1 11.19 6.3 56.3

2 I Mill Juice Pump Motor 2 11.19 6.75 60.32

3 II Mill Juice Pump Motor 11.19 7.32 65.4

4 Screened Juice Pump motor 1 22.38 16.5 73.72

5 Screened Juice Pump motor 2 37.3 13.2 35.4

6 III Mill Juice Pump Motor 7.46 4.8 64.34

7 IV Mill Juice Pump Motor 7.46 6.24 83.65

8 Mill water pump 15 10.05 67

B. Mill Juice Pump Motors

9 BRJP2 30 15.9 53

10 RJP2 11 6.6 59

11 RJP 3 11 12.6 112

12 IJP 1 11 10.5 93.8

13 IJP 2 11 4.26 38

14 IJP 3 11 8.61 77

Spray Pond Pump Motors

15 Spray Pond Pump 2 167 144 86

16 Spray Pond Pump 4 167 154.5 92.5



Pump house

17 Package boiler pump 1 22 11.1 49.6

18 Package boiler pump 4 18.5 8.88 47.6

19 Pan raw water pump 30 21.6 72

20 Factory raw water pump 37 38 102

21 Sugar town drinking water pump

18.5 17.1 92.4

22 Sulphited syrup pump (2 no. Standby)

37.3 15.6 41.8

23 Syrup extraction extraction (1 standby)

22.5 9.9 44

24 Raw Juice pump (1 standby) 75 53.7 72

25 Sulphited Juice pump (1 Standby)

75 46.5 62.3

26 Clear Juice pump 1 37 21.6 58.4

27 Clear Juice pump 2 (Pump 3 Standby)

37 22.5 60.8

28 Vacuum Pump 1 30 21.3 71

29 Vacuum Pump 2 30 21 70

30 Vacuum Pump 3 22 9.9 45

31 Evaporator water injection pump

150 118.5 79.4

32 Sweet water pump 30 13.38 44.6

33 Scum pump 1 11 8.7 77.7



34 Scum Pump 2 11 4.2 37.5

35 Boiler hot water tank pump 3 30 16.14 54

36 Boiler hot water tank pump 1 37 14.7 39.4

37 Remelt pump 1 11 11.46 102

38 Remelt pump 2 11 9.6 35.8

"A" Molasses Pumps

39 Pump 1 (first tank) 15 5.7 38

40 Pump 1 (Second tank) 45 12.9 28.67

41 Pump 2 (Second tank) 29.84 19.5 65.35

"B" Molasses Pumps

42 Pump 1 7.5 4.8 64.3

TOTAL 986.39



Appendix: 6/2

Design Injection Water Requirement for Pan

Sl No. Condenser details No. of SED Condenser

No. of Old type Condenser

Total

1 PAN-A 5 0 5

2 PAN-B 2 1 3

3 PAN-C 2 1 3

4 Evaporator 2 2

TOTAL 11 2 13

a) Cooling Water Required *

PAN-A (SED) = 5 x 432 cum/hr = 2160 cum/hr.

PAN-B (SED) = 2 x 396 cum/hr = 792 cum/hr.

PAN-C (SED) = 2 x 360 cum/hr = 260 cum/hr.

b) PAN-B (Old) ** = 1 x 713 cum/hr = 713 cum/hr.

PAN-C (Old) = 1 x 648 cum/hr = 648 cum/hr

TOTAL = 5033 cum/hr.



Appendix-6/3

Pressure Drop Calculation for centrifugal pump

Sl No.

Description Height (Vertical) , m

Pipe Length. meter

Pipe Dia, meter

No. of valve

No. Of bends

Actual flow rate (cum/hr)

∆P, m

1 Evaporator injection pump

13 12 0.4 1 3 1000 18

2 Raw juice pump

35 20 0.15 2 (one is Non return valve)

3 230 57

3 Sulphited Juice pump

8 70 10 1 3 300 12

4 Clear Juice pump

10 80 8 2 12 100 13

5 A-Light Molasses pump

18 10 6 1 3 50 21



Appendix-6/4

RAW WATER BALANCE (EXISTING)

Sl no. Description Tonnes/Day

1 Inbibition Water 1680

2 Mill and Mill turbine cooling water 1590

3 Sugar Unit wash water 1500

4 Process water for sugar unit 907

5 TG turbine bearing cooling water 1008

6 Distillery unit condenser water 2400

7 Spent wash from distillery 600

8 Quarter 650

9 Factory, sanitary serrvices 100

10 Wind loss and blow down from spray pond 7350

11 Sulphur burner cooling water 242

12 Air compressor and cooling water 240

13 Process water for distillery 500

14 Water for cogeneration 1093

15 Miscellaneous 250

Total 30000



Appendix-6/5

REVISED WATER BALANCE

Sl No. Description cum/day

1 Inbibition Water 1680

2 Make up water for Spray pond 3984

3 Process water to Sugar Unit 907

4 Process water for distillery 500

5 Quarters 200

6 Service water to the factory 100

7 Bearing and cooling water 3264

8 Factory wash 500

9 Spent Wash 600

Total 11735

Note:-

Condenser Cooling Water : 5897 cum/hr

Bearing cooling water : 136 cum/hr

Total : 6033 cum/hr

4% make up water required : 241.32 cum/hr ........................... (i)

Make up condensation water

from pan and evaporators : 75 cum/hr .......................... (ii)

(i)-(ii) : 166 cum/hr



: 166 x 24 = 3984 cum/day

Raw Water Saving Calculation

a. The raw Water received by sugar plant : 17017 cum/day

b. Raw Water received by distillery unit : 2000 cum/day

Total : 19017 cum/day

(This excluding the water required by co-generation)

Usage : 11735 cum/day

Saving : 19017 – 11735

= 7282 cum/day

: 7282 / 19017 = 38%

Total savings : 7282 x 300 = 2184600 cum/yr



Appendix-6/6

REVISED WATER BALANCE

1. Water from the barometric condenser (Pan and evaporator)

: 7400 cum/hr.

2. Cooling Water distillation column condenser (Distillery unit)

: 100 cum/hr.

3. Sulphur burner cooling water : 104 cum/hr.

4. Air Compressors : 10 cum/hr.

5. TG turbine bearing cooling water : 42 cum/hr.

.......................

7656 cum/hr ........................



Appendix -7/1

DETAILS OF MEASURED LIGHTING LOAD AT FEEDER F-40

Sl No.

Particulars 1ɸ Measured Parameters 3ɸ Measured Parameters

V A Pf kVA kW V kVA kW

1 Day Time 245 79 0.9 19.3 17.5 424 57.9 52.5

2 Night Time 240 83 0.85 21.2 18 415 63.6 54

LIGHTING PRACTICES OBDERVATION:

During daytime only necessary lighting were found to be 'ON' in process areas

while street lights were switched 'OFF'. However, the marginal difference in day

and night lighting loads is due to switching 'ON' of the office lighting during

daytime.



Appendix -7/2

Lighting Fixture Details

Particulars Numbers

Fluorescent tube light 150

100W incandescent lamps 50

200W incandescent lamps 30

HPSV lamps 400W 31

HPSV lamps 250 W 58

Metal Halide lamps 250W 12

HPSV lamps 70W 10



Appendix-7/3

Replacement of Conventional Electromagnetic Choke with Electronic Chokes and 40W Fluorescent Tubes with 36W Fluorescent Tubes

There are around 150 nos of fluorescent tube lights with conventional electro-

magnetic chokes. All the 150 are considered for replacement with 36W

fluorescent tubes and electronic chokes.

Power Consumed by Conventional chokes = 15 W

Power Consumed by 40W fluorescent tubes = 40 W

TOTAL POWER I/P = 55 W

Power Consumed by electronic choke = 2 W

Power Consumed by 40 W fluorescent tubes = 36 W


Savings in Power = 55 W – 38W = 22 W

Annual Energy Savings = (17 x 150 x 10 x 300)/1000

(@ 10hrs/day and 300 days per year) = 7650kWh

Annual Cost Savings @ ₹ 4.6/kWh = 7650 x 4.6= ₹ 35190

Cost of implementation = 75 x 150

= ₹ 11, 250

Simple Pay back Period = 4 Months



Appendix-7/4

Replacement of Conventional Electromagnetic Choke with LED 48” 2000 lumen tube lights

There are around 150 nos of fluorescent tube lights with conventional electro-

magnetic chokes. All the 150 are considered for replacement with 36W

fluorescent tubes and electronic chokes.

Power Consumed by Conventional chokes = 15 W

Power Consumed by 40W fluorescent tubes = 40 W


Power Consumed by LED 48” = 22 W

Savings in Power = 55 W – 22W = 33 W

Annual Energy Savings = (33 x 150 x 10 x 300)/1000

(@ 10hrs/day and 300 days per year) = 14, 850 kWh

Annual Cost Savings @ ₹ 4.6/kWh = 14,850 x 4.6= ₹ 68,310

Cost of implementation = 1575 x 150

= ₹ 2, 36, 250

Simple Pay back Period = 3 years 6 Months



Appendix-7/5

Use of Lighting Voltage Transformer to Reduce the Voltage for Lighting Circuit

The total lighting load is fed by feeder F-40. The measurement was carried out

both during day as well as during night time. The measured 3Φ kVA and kW

were as follows,

Period kVA (3Φ) KW (3Φ)

Day 57.9 52.5

Night 63.6 54

Average 60.75 53.25

It is recommended to use a 3Φ, 50Hz, 415VAC, 90 kVA voltage transformer

with maximum load capacity / phase of 120A.

Energy Savings

Average measured power at F-40 = 53.25 kW.

Power saving due to proposal # 1 to 3 = 10.27 kW.

Effective daily consumption of power = 53.25 – 10.27= 42.98 kW

Estimated power saving / day = 42.98 x 0.15 (@15% of effective daily consumption) = 6.45 kW

Annual Cost Savings = 6.45 x 20 x 330

(@ 20hrs/day and 330 days/year) = 42,570 kWh



Annual cost savings(@ Rs.4.6/kWh) = ₹ 1,95,822

Cost of implementation (including cable cost) = ₹ 2,30,000

Simple payback Period = 1 year 2 months



References



BIBLIOGRAPHY AND WEBSITES

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Documents

Energy Auditing of Sugar Industry