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© Confederation of Indian Industry© Confederation of Indian Industry
E.I.D. Parry (I) ltdPudukkottai
S. Murugesan – Dy. General Manager (Engg)P. Shanmugam – Dy. General Manager (Process) B.Natarajan– Sr Manager(Mech)
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
20182
Pudukottai Unit Milestone
➢ Green field project commissioned in 2000
➢ Integrated sugar complex with a crushing
capacity of 4500 TCD, 19.50 MW
Cogeneration Power Plant
➢ We have ISO 14001, OHSAS 18001, ISO
9001 certified by DNV
➢ Highest cane crushed 9.21 Lakhs MT in
2011-12 with a sugar recovery of 9.51%
➢ First TPM practicing company in cane
sugar manufacturing industry. We have
completed Assessment audit by JIPM.
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
20183
Power Consumption / Tones of Cane
27.25 27.06 28.0428.84
25.73 2520
25
30
35
40
45
50
13-14 14-15 15-16 16-17 17-18 18-19 Plan
Un
its
/ To
n
Financial Year
Due to Low rate of Cane Crushing & Intermittent stoppage -
want of Cane raised out of CHL issues
Global Bench Mark – 28 KW / MT
SEC REDUCTION PERCENTAGE Sugar - Power
1. Sp. Energy Consumption in last 5 years
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
20184
Due to Low rate of Cane Crushing & Intermittent stoppage
Steam % on cane crushed
Global Bench Mark – 34%
39.39
36.2836.87
38.38
34.6534
32.00
34.00
36.00
38.00
40.00
13-14 14-15 15-16 16-17 17-18 18-19 Plan
%
Financial Year
SEC REDUCTION PERCENTAGE
Sugar – Steam % on cane
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
20185
9.04 8.44
9.75 9.63 8.848.25
6.007.008.009.00
10.0011.0012.00
13-14 14-15 15-16 16-17 17-18 18-19 Plan
%
Financial Year
As per STOA from TNEB, power export quantum restricted to < 30 %
which resulted in higher Aux Power
Cogen Auxiliary Power Consumption % On Generation
SEC REDUCTION PERCENTAGE
Cogen Aux. Power
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
20186
Steam – Fuel (Bagasse) Ratio (Kg of steam/Kg of Bagasse)
2.46 2.46 2.42 2.41 2.492.55
1.501.752.002.252.502.753.00
13-14 14-15 15-16 16-17 17-18 18-19 Plan
Kg
of S
tea
m /
Kg
of
Ba
ga
sse
Financial Year
As per STOA from TNEB, power export quantum
restricted to < 30 % which resulted in Lower SFR
SEC REDUCTION PERCENTAGE
Cogen – Steam Fuel Ratio
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
20187
ParametersGlobal Bench
mark
National
Bench mark
EID –
Achievement
Specific Thermal
Energy
Consumption
38 %
As per ISSCT
proceedings 2013
38-40 % Steam
on Cane
34.65 %
Steam on cane
Specific
Electrical Energy
consumption
27-28 kWh/ton of
cane
As per NFCSF
28 kWh/ton of
cane
25.73
kWh / ton of
cane
Comparison with Global & National Benchmarks
2. Information on Competitors, National &Global benchmark
© Confederation of Indian Industry© Confederation of Indian Industry
FY 2017-18
•Steam % Cane – 34.65
•Power/MT cane – 25.73
•Steam fuel ratio – 2.44
•Aux Power % - 8.84
FY 2019-20
•Steam % Cane – 30
•Power/MT cane – 22
•Steam fuel ratio –
2.55
•Aux Power % - 8.00
FY 2020-21
•Steam % Cane – 30
•Power/MT cane – 20
•Steam fuel ratio – 2.8
•Aux Power % - 7.80
FY 2018-19
•Steam % Cane – 32
•Power/MT cane – 24
•Steam fuel ratio – 2.55
•Aux Power % - 8.10
FY 2021-22
•Steam % Cane – 30
•Power/MT cane – 20
•Steam fuel ratio – 2.8
•Aux Power % - 7.60
Road Map for future Encon Activities
© Confederation of Indian Industry© Confederation of Indian Industry
Case Study
NoProjects
ActualCost Saving (Rs in Lakhs)
1 Thermal Saving 58.31
2 Electrical Saving 18.29
Key Energy Management Improvements 2015 - 2016
9
31 August
2018
3a. Energy Saving projects implemented in FY 2015-16
© Confederation of Indian Industry© Confederation of Indian Industry
31 August
201810
Energy Conservation Measures takenFY 2015-16(Thermal)
1031 August 2018
Sl.No.
Title of ProjectAnnual Savings(Rs Lakhs)
Investment (Rs Lakhs)
1Turbine Condensate heating by excessheat at suagar plant
20.44 9.00
2Lotus under feed roller instead of grovedunder feed roller with hole provided
1.25 5.00
3 Alternative Bio mass fuel 31.36 0.00
4 Elimination of Sugar Reprocess 5.26 0.00
Total 58.31 14.00
© Confederation of Indian Industry© Confederation of Indian Industry
31 August
201811
Energy Conservation Measures takenDuring FY 2015-16
(Electrical)
1131 August 2018
Sl.No.
Title of ProjectAnnual Savings
(Rs Lakhs)Investment (Rs Lakhs)
1Stopping Feed transfer pump for DM water make up to Deareator
0.42 0.00
2 VFD for 3rd mill juice pump 1.21 0.65
3 Planetary gear for B3 XLR 2.89 4.35
4ETP outlet pump power consumption reduction based on level mode operation
0.75 0.05
51st body condensate Pump size change for power consumption reduction
2.01 0.10
6 VFD provided for Injection water pump no1 5.03 0.00
7Instrument air set point reduction during cogen stand alone running.
1.31 0.00
© Confederation of Indian Industry© Confederation of Indian Industry
31 August
201812
Energy Conservation Measures takenDuring FY 2015-16
(Electrical)
1231 August 2018
Sl.No.
Title of ProjectAnnual Savings
(Rs Lakhs)Investment (Rs Lakhs)
8Rain water horvesting in WTP roof to reduce the Bore water reduction
0.09 0.00
9CFL lamp issued for all staffs during their birth day function
0.51 0.25
10 Planetary gear for 5th rake carrier 0.70 4.35
11 VFD for 4th mill juice pump 1.21 0.65
12 VFD for 5th mill juice pump 2.01 0.65
13 Planetary gear box for C Melt 0.70 4.35
14Turbine Condensate heating by excess heat at sugar plant
2.41 2.10
15 Elimination of Sugar Reprocess 1.85 0.00
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201813
Case Study
NoProjects
Actual
Cost Saving
(Rs in Lacs)
1 Thermal Saving 52.74
2 Electrical Saving 13.68
Key Energy Management Improvements
2016 - 2017
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201814
THERMAL SAVINGS
DescriptionNumber
of projects
Annual
Savings (Rs Lacs)
Investment
(Rs Lacs)
Savings With Investment 3 9.79 6.97
Savings Without Investment 1 42.95 0
Total 4 52.74 6.97
Electrical SAVINGS
DescriptionNumber
of projects
Annual
Savings (Rs Lacs)
Investment
(Rs Lacs)
Savings With Investment 8 4.83 5.09
Savings Without Investment 2 8.85 0
Total 10 13.68 5.09
0.11 % Investment for ENCON project on Turn over
Key Energy Management Improvements
2016 - 2017
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201815
Sl.
No
.
Title of ProjectAnnual Savings
(Rs Lacs)
Investment
(Rs Lacs)
1Reduction in Hot condensate wastage by
changing the Sampling method.0.85 1.00
2 Improved Thermal Insulation in boiler 6.40 2.97
3Elimination of vacuum filter operation
from sugar processing2.54 3.00
4 Alternative Bio mass fuel - Wood Bark 42.95 0.00
Total 52.74 6.97
Energy Conservation Measures taken
FY 2016-17 (Thermal)
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201816
Sl.
No.Title of Project
Annual Savings
(Rs Lacs)
Investment
(Rs Lacs)
1
Replaced Worm& worm wheel gear box (30
KW) with helical gear box in Rake carrier
(Saving 4.0 Kwh/Hr)
0.80 0.50
2
Fixed Transparent roof sheet in sugar
Godown – Lighting load reduced during day
time
0.631.00
3
Pneumatic pressure booster is installed to
raise the air pressure for Centrifugal
machine Instrument air system.
1.20 0.67
4 VFD Installed for unsulphited syrup pump 1.04 0.68
5 LED Lightings in plant area 0.51 0.85
6Domestic water consumption reduction (50
TPD)0.54 1.13
Energy Conservation Measures taken
FY 2016-17 (Electrical)
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201817
Sl.
No.Title of Project
Annual Savings
(Rs Lacs)
Investment
(Rs Lacs)
7LED Issued to employees during Safety Day
Celebration 1.41 0.21
8 WTP flushing water re-usage 0.03 0.05
9
Lighting control during Off season
(Provided only focus lamps in walk way
area)
8.42 0
10Switch off standby UPS system for DCS to
reduce the power loss during Off-season0.42 0
Total 13.68 5.09
Energy Conservation Measures taken
FY 2016-17 (Electrical)
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201818
Case Study
NoProjects
Actual
Cost Saving
(Rs in Lacs)
1 Thermal Saving166.23
2 Electrical Saving 13.86
Key Energy Management Improvements
2017 - 2018
3c. Energy Saving projects implemented in FY 2017-18
0.15 % Investment for ENCON project on Turn over
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201819
THERMAL SAVINGS
DescriptionNumber
of projects
Annual
Savings (Rs Lacs)
Investment
(Rs Lacs)
Savings With Investment 2 166.23 9.00
Savings Without Investment 0 0 0
Total 2 166.23 9.00
Electrical SAVINGS
DescriptionNumber
of projects
Annual
Savings (Rs Lacs)
Investment
(Rs Lacs)
Savings With Investment 7 4.86 4.67
Savings Without Investment 2 9.00 0
Total 9 13.86 4.67
Key Energy Management Improvements
2017 - 2018
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201820
Sl.
No
.
Title of ProjectAnnual Savings
(Rs Lacs)
Investment
(Rs Lacs)
1 Sugar dryer modification 35.93 1.50
2Bio fuel Preparation equipment fabrication
and modification130.30 7.50
Total 166.23 9.00
Energy Conservation Measures taken
FY 2017-18 (Thermal)
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201821
Sl.
No.Title of Project
Annual Savings
(Rs Lacs)
Investment
(Rs Lacs)
1 Fibrisor anvil modification 8.76 0
2Raw water pump level based auto to avoid
water recirculation0.23
0.25
3 Automation in Pan vacuum pump 1.69 0.25
4 Planetary gear for B melter 0.44 0.45
5Vapor condensate pump stopped by piping
modification - during off season hydro test0. 21 0.10
Energy Conservation Measures taken
FY 2017-18 (Electrical)
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201822
Sl.
No.Title of Project
Annual Savings
(Rs Lacs)
Investment
(Rs Lacs)
6 ETP equipments in VFD duirng offseason 0.24 0.00
7Planetary Gear box provided in B seed
XLR1.33 2.50
8 VFD in syrup pump 0.58 0.72
9 Cooling Water Holding quantity reduction 0.59 0.40
Total 13.86 4.67
Energy Conservation Measures taken
FY 2017-18 (Electrical)
© Confederation of Indian Industry© Confederation of Indian Industry
4. Innovative Projects implemented1. Fibrizer anvil modification
Source of idea – Team leader
Replication potential – Sister units also practicing
© Confederation of Indian Industry© Confederation of Indian Industry
Fibrizer Anvil Plate Modification
180 degree double anvil plate ( Before) 90 degree Single anvil plate ( After )
Power consumption
- 6.5Kwh/ton of cane
Power consumption
- 5.5Kwh/ton of
cane
© Confederation of Indian Industry© Confederation of Indian Industry
One Point Lesson Sheet
© Confederation of Indian Industry© Confederation of Indian Industry
26
26000
22000
20000
22000
24000
26000
28000
Before After
Kwh Power savings per day 4000Kwh * Rs
4.0 per Kwh
Rs.16000 per
day savings
Fibrazer anvil modification
© Confederation of Indian Industry© Confederation of Indian Industry
2. Fuel preparation and handling at Co-GenJulie Flora Chips Preparing M/C
© Confederation of Indian Industry© Confederation of Indian Industry28
2. Fuel preparation and handling at Co-GenReaper wood Preparing M/C
Repper wood and Plyboard waste preparation with wood chipping machine is
not possible.
Existing Cane trash cutting machine is modified with additional strengthened
knifes along with locally fabricated feeding conveyor.
© Confederation of Indian Industry© Confederation of Indian Industry29
2. Fuel preparation and handling at Co-GenFuel Feeders Stranthining
Problem faced with bio fuel
1. Frequent Belt failure
2. Frequent Drum feeders
jamming
3. Frequent Screw feeders
jaming
Action taken
1. Belt scrapers removed
during Bio fuel handing
2. Drum feeders spikes
height raised.
3. Fuel proper preparation
confirmed
© Confederation of Indian Industry© Confederation of Indian Industry30
2. Fuel preparation and handling at Co-Gen
Description Qty
Wood Bark 7308.21
Julia flora wood 12816.60
Eucalyptus wood 907.67
Matchstick waste 563.42
Casurina Wood 4770.34
Play Board Waste 754.32
Saw Dust 638.30
Ground Nut shell 1535.32
Char coal dust 3547.60
Reapper wood 2145.40
Mixed Wood 1266.21
Total 36253.38
1. 204 Lac Unit Power
generated by Bio mass
2. 17000 Mt Raw Sugar
Processing done with out
Coal
© Confederation of Indian Industry© Confederation of Indian Industry
3. Sugar Drying System Modification
8/31/2018 31
© Confederation of Indian Industry© Confederation of Indian Industry8/31/2
018 32
Steam Pr – 0.6 kgf
Steam temp – 102 Deg CSteam Pr – 1.2 kgf
Steam temp – 115 Deg C
AfterBefore
Steam Saving :1 TPH
Cost Saving : 35.93 Lacs
Sugar Drying System Modification
© Confederation of Indian Industry© Confederation of Indian Industry31-08-2018
33
Waste materials from forest is
used as fuel to maximize the
power generation at Co-Gen.
We generated 20.62 million
units in the last run.
Renewable Energy
Solar Powered Irrigation pumping system (10 HP) in cane forms are being installed widely in our command area of 25000 acers.
5. Utilisation of renewable energy sources
© Confederation of Indian Industry© Confederation of Indian Industry31-08-2018
34
1. Waste Oil and Grease
2. Cotton Waste
3. Match Box Waste
4. Eucalyptus Wood Bark
5. Juliflora Thorns
6. Juliflora Chips
7. Pencil wood waste
8. Wood Industry waste
Following Waste Bio mass
as fuel in our boiler for
generating power
Till date 36298 MT Bio
waste fired
6. Utilisation of waste material as fuel
© Confederation of Indian Industry© Confederation of Indian Industry31-08-2018
35
1) Treated water from ETP is used for cane irrigation and Trees
plantation around the factory.
2. Co-Gen boiler Ash is utilized as manure in Cane fields.
• RO Reject water / Boiler Blow down water is used for boiler Ash
quenching in place of raw water.
Waste utilization
© Confederation of Indian Industry© Confederation of Indian Industry
- Information on GHG Inventorisation and public disclosure
7. GHG Inventorisation
CO2 Emission Reduction:
• 500 no Trees planted inside the plant towards the target of 1000 Nos forthe year
• Reduced the Fuel consumption for the same power production byreducing the Specific steam consumption. ( From 5.49 to 5.34 )
• Co-Gen Captive power consumption is reduced from 9.75 % to 8.34%.
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201837
Moving towards digital India
• By introducing I-Cane software we have created Paperless office for cane management. I-Cane - Plot MAP – With Measurement Details
Green House Gas Emission Reduction(Paperless office & Diesel Consumption Reduction)
40 % of time spent on traveling by cane staff reduced by this Application usage
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201838
Pest Affected Field – Captured by I-Cane Mobile(Paperless Office)
Green House Gas Emission Reduction(Paperless office & Diesel Consumption Reduction)
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201839
(Paperless Office)
I-Cane-Digital Task Scheduler
Green House Gas Emission Reduction(Paperless office & Diesel Consumption Reduction)
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201840
1) Zero Ground water drawl
2) Plantation of Trees – 1000 Trees / Year
3) Utilizing Renewable Energy (Solar Power for Effluent Treatment Plant, Cane Cultivation Etc)
4) Ensuring Emission test for vehicles entering in to Factory premises
Way forward towards Green House
Gas Reduction
© Confederation of Indian Industry© Confederation of Indian Industry
“Yield Improvement is defined as increasing yield per unit area with available resources
and Technology transfer thru farmers training and field demonstrations “.
In Pudukottai Unit , Cane cultivation is drastically reduced due to, Low yield , High cost of production
,Eratic rainfall distribution , water scarcity resulted in limited horizontal growth of area expansion
.Hence , vertical growth of increasing yield per unit area is only way forward to retain farmers and
sustainable cane supply and Sugar production to factory .
40.4236.50
32.3327.22
32.54 33.80 30.75 29.62 30.75 30.90 29.18
45
37
26
16
28 3023 21
25 2420
15.00
25.00
35.00
45.00
55.00
2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17
Yield Reduction Trend (2006-17)
Avg Yield Mt/Ac Above 40 Mt in %
8671034
1301
868
1248
941
617474
661
980
418
0
200
400
600
800
1000
1200
1400Rain Fall Trend (Mm)
year
27234
20828 2183319347 19708
2492127521
19247
10997 103817884
0
10000
20000
30000Cane Cultivation Area Trend (Ac)
Area (Ac) 2 per. Mov. Avg. (Area (Ac))
41
Definition of yield improvement
© Confederation of Indian Industry© Confederation of Indian Industry
Yield based grouping
and selection of farmers
Conducting scientific
study on yield
improvement
Identification of root
cause analysis
Action plan
Matrix for cane yield Vs number of farmers
42
Yield Range
MT
2015-16 2016-17 2017-18
No of
Farmers
No of
acre
No of
Farmers
No of
acre
No of
Farmers
No of
acre
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201843
1. Drip irrigation / Micro irrigation for cane cultivation to preserve water &
save pumping Electrical Power
Best Practices Replicated on Energy front in
Green Supply Chain
© Confederation of Indian Industry© Confederation of Indian Industry31-08-2018
44
2. Encouraging Cane cultivation closer to factory to reduce the Cane transport for reducing diesel consumption.
3. By using daily tracker S/W we have identified that 60% of cane staff time is wasted in traveling between Cane field and Office. By Implementation I-Cane Software (Satellite mapping, machine based management system) effectively the necessity of travel to office is drastically reduced to 20% this resulted in significant reduction in Petrol/Diesel for Cane Staff vehicles
Best Practices Replicated on Energy front in
Green Supply Chain
© Confederation of Indian Industry© Confederation of Indian Industry31-08-2018
45
1) Sugar process water requirement is met with vapour condensate from cane
juice. So, ground water drawl for Sugar Process is Nil.
2) Excess condensate water is cooled in Fan-less cooling Tower and used for
Greenery development inside the factory.
Green Supply chain – Recycling and Reuse
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201846
Sr. Vice President
As Adviser
Sr. General Manager
Shop Floor Engineers and Process Technologists along with Team Members
Source of ideas and implementation team
Engg Process Co-gen * Elect * INST
Department Head
H.O.D
(Engg)
H.O.D
(Process)
H.O.D
(Cane)
Resource Leaders
Note : * Certified Energy Auditor
ENERGY CONSERVATION CELL
Sr. Vice President
As Adviser
9. Team work, Employee Involvement & Monitoring
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201847
S.N
oFinancial years
Major No: of
ENCON
Projects
Annual
savings Rs in
Lacs
Capital
Investment
(Rs. In Lacs)
1 2017-2018 11 180.09 27.17
2 2016-2017 6 47.58 4.01
3 2015-2016 9 55.62 15.33
4 2014-2015 6 91.14 45.20
5 2013-2014 3 6.72 3.0
Total 35 381.15 81.30
Involvement of Employees in
implementing Encon Projects
Power & Energy saving related major & minor projects(Kaizens) of 873 Nos.
received from 176 employees and implemented 640 Nos.
© Confederation of Indian Industry© Confederation of Indian Industry
TPM Progress
TPM Model Machine selection
TPM Kick off
TPM Health checkup – CII TPM club India
JIPM First stage assessment
JIPM Second stage assessment
TPM Excellence award
TPM Consistency l Award
TPM Declaration by management
May 2014
Apr 2015
May 2017
Aug 2018
Dec 2018
Mar 2019
Jan 2021
May 2014
48
© Confederation of Indian Industry© Confederation of Indian Industry 49
1st Stage Assessment Audit by JIPM
© Confederation of Indian Industry© Confederation of Indian Industry31-08-2018
50
• Introduced Real Time Online monitoring system to control the plant critical operating parameters from the Desktop PCs of all Senior Executives
• Cane crushing details is being sent to all HOD’s through CMS based Hourly SMS
• PROMIS capturing all the production details an hourly basis and generated daily production report
• SAP Generated auto alerts - Plant comparison, Stores & Warehouse reports, Inventory,
R&M Budget Vs Actual
• Trend charts from QA- Incoming raw material & In process- Weekly compliance report
Encon Monitoring Methodology
© Confederation of Indian Industry© Confederation of Indian Industry31-08-2018
51
Encon Monitoring Methodology
Frequency Report Reviewed By
Hourly All Energy Consumptions like
Sp. Thermal & Power Consumption for Sugar & Cogen Plant
Shift Engineer
Shift wise All Energy Consumptions like
Sp. Thermal & Power Consumption for Sugar & Cogen Plant
Department Head
Daily All Energy Consumptions like
Sp. Thermal & Power Consumption for Sugar & Cogen Plant
Unit head
Monthly All Energy Consumptions like
Sp. Thermal & Power Consumption for Sugar & Cogen Plant
Business Group Management Committee (Business head & EID’s Function head)
© Confederation of Indian Industry© Confederation of Indian Industry31-08-2018
52
Encon Monitoring Methodology
Sample Power Monitoring report
© Confederation of Indian Industry© Confederation of Indian Industry
On Going Projects : Future Encon activities:
1. Pol % Bagasse reduction by Partial Diffusion
2. Pilot Project for blowing Non cane by Pelleting and Blowing
S.No. Name of the Project Status
1. Pol % Bagasse reduction by Partial Diffusion 2nd Phase Trials in Progress.
2. Pilot Project for blowing Non cane by Pelleting and Blowing
In Progress. Trials planned for 29 and 30th
of this month.
© Confederation of Indian Industry© Confederation of Indian Industry
Pol % Bagasse reduction by Partial Diffusion
© Confederation of Indian Industry© Confederation of Indian Industry
Cutter
Blower-Man Cooler
Air
Flow
Cut
trash
FlowCutter
© Confederation of Indian Industry© Confederation of Indian Industry
Resources planned for accomplishing Encon Targets
S.No. Equipment Cost Deliverables
1 1. 4th mill all three roller pitch has to be changed from 40 to 30
including scrapper, Trash plate with triple nozzle lotus roller
2. 3rd mill all three roller pitch has to be changed from 40 to 30
including scrapper, Trash plate with triple nozzle lotus roller
50
Lacs
Reduction in pol%
bagasse from 1.35
to 1.00
2 Bagasse moisture reduction unit to be provided in the outlet of
first & fifth mill.
40
Lacs
Reduction in
moisture% bagasse
from 48.50 to 47.0
3 1. Auto de-hooking system for cane unloader 2 nos
2. Provide planetary gear box with VFD system - Mills, Rake
carrier, Feeder table, Cane carrier, Lime tank, B Vacuum Xlr
3. Automation of cooling tower
4. Injection pump automation
5. VFD for cane preparatory devices
6. Rope coupling for 5 mills
360
lacs
Reduction in Power
per ton of cane from
29 to 20
4 1.Replacing Present Shell and Tube type VLJH with PHE both
series.
2.By providing DCH system in juice heater
100
Lacs
Reduction in Steam
% cane from 38.5 to
30
Future Encon Activities
© Confederation of Indian Industry© Confederation of Indian Industry
Resources planned for accomplishing Encon Targets
S.No. Equipment Cost Deliverables
5 Planetary Gear Boxes For Bagasse
Drum feeder –
5 No, (5.5.KW, 5 to 40 RPM)
15 Lacs Reduction in Power consumption by
15 %
6 Baggasse Drying System – CF fan, 2
No. Belt Conveyors, Cyclone Chamber,
Back Filter and Ducting
250 Lacs Increase in Steam Fuel ratio from
2.5 to 2.8 thereby reducing fuel cost
or cost of power production.
7 Energy Conservation System:
50 tph Boiler Feed Pump 12 lacs
Reduction in In-house Power
consumption.
8 100 CFM, 6kgf, Screw Compressor 7.5 Lacs Reduction in In-house Power
Consumption
9 Addional capacity in APH 25 Lacs To recover waste heat from the Flue
Gas (From 150 Deg C to 140 deg
C).
Future Encon Activities
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201858
Future Encon Activities
1Introducing VFD for 7 Equipments (150 KW) to save power of 35
Unit/Hr.
2 Introducing Solar street lights (20 Nos.) to save power of 40 Unit/Hr.
3
4
Improving of power factor from 0.9 to 0.95 lag by providing additionalcapacitor banks.
Harmonic reduction in all power centers by providing Harmonic filters to
improve power quality.
5Introducing Planetary gear box for 5 nos of equipments to save power of
17.5 Units/Hr.
6
Introduction of Auto Hydraulic de-hooking system to eliminate operation
of one no of 25 KW motor for 2 nos cane unloaders to save power of 14
Units/Hr.
7Process modification and Introduction of Automation in various areas to
save power and steam consumption.
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201859
CII AWARD FOR
ENERGY MANAGEMENT – 2017, 2016 & 2014
© Confederation of Indian Industry© Confederation of Indian Industry31-08-
201860
Receiving Shield from
Hon’ble Minister of Power
Mr. PIYUSH GOYAL at New
Delhi
National Level
second Prize
(Silver Shield)
NATIONAL ENERGY CONSERVATION AWARD 2014
FROM BUREAU OF ENERGY EFFICIENCY,
GOVERNMENT OF INDIA