65
E.I.D-Parry (India) Limited, Nellikuppam. 19 th National Award for Excellence in Energy Management 2018 8/31/2018
E.I.D-Parry (India) Limited,
Nellikuppam.
19th National Award for
Excellence in Energy Management 2018
8/31/2018
Murugappa group
295
28 Business
2
EID Parry – Nellikuppam
First sugar plant in India
First cane sugar
factory in the
world to practise
TPM
Sugar Plant
7500 Tons cane
crushing per day
Refinery 170
Tons sugar per
day
Distillery 75
Kilo litres per
day
Co-Generation
24.5 MW/Hr
3
Our Certifications
Accreditations
&
Certifications
ISO 9001-2008
FSSC 22000
Halal
Indian Pharmacopeia
US Pharmacopeia
British Pharmacopeia
8/31/2018 4E.I.D-PARRY (INDIA) LIMITED,
NELLIKUPPAM
ISO 14001
8/31/2018
5
Understanding Sugar process
Sugarcane Juice Syrup
Bagasse Press mud Molasses
Cogen .
Power PlantOrganic Manure Alcohol
Primary
By Products
Value added
Products
Sugar
Energy Conservation Activities – FY 2015-16
Contd.,8/31/2018
S. NoYear of
ExecutionEnergy Saving Project
Annual Savings
(Rs. In Lakh)
1 2015-16Evaporator syrup brix improvement by modifying the juice distribution system.
220.50
2 2015-16 Sugar recirculation avoided by altering the grader transfer points. 33.80
3 2015-16Usage of first vapour for heating treated juice reduced by 50 % by adding a new direct contact heater for second body vapour.
22.50
4 2015-16 Installation of VFD for condensate Extraction Pump-2 2.16
5 2015-16 Installation of VFD for Submergible belt conveyor in Cogen both boilers 1.29
6 2015-16 Installation special alloy multi nozzle roller in 4th mill 279.27
7 2015-16Injection Header modification by eliminating separate pump for evaporator
27.27
8 2015-16 Eliminating sugar grader operation during Raw sugar producction 2.27
Energy Conservation Activities – FY 2016-17
8/31/2018
S. NoYear of
ExecutionEnergy Saving Project
Annual Savings
(Rs. In Lakh)
9 2016-17Improvement in refinery input melt brix from 60 to 64 – Reduction of steam consumption by 0.1 Ton/Ton of Refined Sugar Output.
37.40
10 2016-17Second body vapor Bleeding for 8 hrs/day to refinery operation -Reduction of steam consumption by 0.15 Ton/Ton of RSO.
56.10
11 2016-17Evaporator syrup brix improvement by challenging the standard operating Procedure
208.89
12 2016-17Replacement of electric strip heater with hot water coil system in VAM – Eliminated 12 KW/hr power consumption
3.45
13 2016-17 Waste Heat Recovery from Sugar second body condensate 104.13
14 2016-17 Utilization of Bio-gas from Bio digester 104.90
15 2016-17Direct pumping of sugar first body condensate to Cogen deaerator instead of Feed water storage tank
105.27
Contd.,
Energy Conservation Activities – FY 2017-18
8/31/2018
S. NoYear of
ExecutionEnergy Saving Project
Annual Savings
(Rs. In Lakh)
16 2017-18 Replacement of NK 1503 B centrifugal machine to WK 1500 16.70
17 2017-18Refinery AHU-35000 strip heater system replaced with Condensate coil system
1.30
18 2017-18 Fibrizer Anvil Plate Modification-Power saving 25.97
19 2017-18 Refinery candle filter lined up in Filter Feed pump with VFD drive 1.30
20 2017-18 Refinery PAN boiling vaccuum generating with body washing 2.51
21 2017-18 Condensate Recovering from ATFD to Dist. Thermax Boiler 27.38
22 2017-18Elimination of 5 HP molasse pump (2 Nos.) by introducing one 7.5 HP pump
1.00
23 2017-18 VFD for Cogen Cooling Tower fan 1.30
Contd.,
Case Study-1
Case Study-3
Energy Conservation Activities – FY 2017-18
8/31/2018
S. NoYear of
ExecutionEnergy Saving Project
Annual Savings
(Rs. In Lakh)
24 2017-18 Mill Automation 38.00
25 2017-18 Steam trap capacity resizing in RC column Reboiler 44.37
26 2017-18 CO2 generation automation 58.80
27 2017-18 B-Massecute Pump VFD installation 1.34
28 2017-18 Air Compressor Header Modification 9.06
29 2017-18Elimination of intermediate belt conveyor in Refinery Feed Centrifuge
9.54
30 2017-18Elimination of Slat conveyor during coal operation by introducing new conveyor
4.30
Case Study-2
Case Study-4
Reduction in Thermal Energy Consumption
(Steam % Cane)
8/31/2018
40
.89
40
.54
40
.33
39
.90
39
.39
38
.56
38
.00
35
.22
34
.69
33
.68
33
.50
33
.27
20.00
25.00
30.00
35.00
40.00
45.00
50.002006-0
7
2007-0
8
2008-0
9
2009-1
0
20
10-1
1
2011-1
2
2012-1
3
2013-1
4
2014-1
5
2015-1
6
2016-1
7
20
17-1
8
Reduction in Electrical Energy Consumption
(KWH / MT of Cane)
8/31/2018
30.5
8
30.1
8
29.5
8
29.3
0
28.7
2
28.3
0
26.0
0
25.9
8
25.1
5
24.7
4
24.5
1
23.7
1
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
50.002006
-07
2007
-08
2008
-09
2009
-10
2010
-11
2011
-12
2012
-13
2013
-14
2014
-15
2015
-16
2016
-17
2017
-18
ParametersNational
Bench Mark
Global Bench
Mark
EID –
Nellikuppam
Achievement
Specific Thermal
Energy Consumption 38-40 %
38 %
As per
ISSCT proceedings
2005 33.27 %
Specific Electrical Energy
consumption
28
kWh / ton of
cane
27-28 kWh/ton of
cane
As per NFCSF
23.71
kWh / ton of cane
Comparison with global benchmarks
8/31/2018
• A Whopping reduction in Thermal Energy
• A Saving of 1.42 % of Thermal energy
• In terms of money …..
• A saving of Rs.542 Lacs
Steam % Cane prior to
Implementation 34.69 %
Steam % Cane post to
Implementation 33.27%
8/31/2018
• A Whopping reduction in Electrical Energy / MT of Cane
• A Saving of 1.44 Units of Electrical energy
• In terms of money …..
• A saving of Rs.201 Lacs
Power/MT of cane prior
to Implementation 25.15 KWH
Power/MT of Cane
post to Implementation 23.71 KWH
8/31/2018
E.I.D-PARRY (INDIA) LIMITED 15
Energy Conservation in Fibrizer
Case Study -1
E.I.D-PARRY (INDIA) LIMITED 16
PROBLEM / PRESENT ISSUES
5 W – 1 H METHOD
What : Power Consumption high
Where : Fibrizer Motor operation (1000 & 1500 KW, HT)
When : Cane Cell Opening to maintain Pre. index 92%.
Who : Anvil Plate.
Which : Cane travel surface contact is 170 Degree.
How : Power consumption of the Motors are high
E.I.D-PARRY (INDIA) LIMITED 17
WHY- WHY ANALYSIS
➢ Why 1 : Power Consumption high in Fibrizer motors
➢ Why 2 : Loading of cane in-between anvil plate to hammer
➢ Why 3 : High contact surface in anvil plate to hammer.
➢ Why 4 : Anvil plate setting 292; 144 ; 40mm.
➢ Why 5 : As per OEM Recommendation
Root Cause :
➢ High contact surface in anvil plate to hammer. OEM Design.
E.I.D-PARRY (INDIA) LIMITED 18
Anvil Plate Setting: 1.In let opening 292mm; Middle opening: 144mm and cane discharge end 40mm.
2. Anvil plate surface contact angle : 170 °
BEFORE
COUNTER MEASURE DETAILSAFTER
Anvil Plate Setting:
1.In let opening 280mm; Middle opening: 40mm and cane discharge end 500mm.
2. Anvil plate surface contact angle : 85 °
7.4
7.1
7.1
6.4
5.8
6.0
6.2
6.4
6.6
6.8
7.0
7.2
7.4
7.6
2014-15 2015-16 2016-17 2017-18
Fib
rize
r P
ow
er/
MT
of
Ca
ne
(KW
H)
GOOD
Fibrizer Power Consumption Trend
Cost benefit Rs 25.97 Lakhs
Problem Definition
• The purpose of mill automation is
– To get good extraction and
– high-through put
• To get good extraction we have to maintain 30% level in Donnelly chute.
• So initially mill automation was carried out based on Donnelly chute level (i.e.) when the level > 30%, RPM will increase and pushes down the bagasse, and when the level <30% the RPM will decrease and try to maintain 30%
• But, when we try to maintain 30%, the motor is getting over loaded and tripped. Because the motor load is not considered.
• Hence the mills could not taken auto.
Case Study -2
Mill Automation
Donnelly chute
Analysis of Mill tripping
Mill is getting tripped
Over load
Level controller, reduces the Mill RPM in order maintain the level as per SP
Amps control is not there
Weak design
Why?
Why?
Why?
Why?
2323
Theme
Eliminate frequent tripping of Mill
Analysis:
Problem:What: Mill is getting tripped
When: Operating in Level CTRL mode
Where: Mill 1
Who: Load / Amps CTRL is not available
Which: Every day
How much: 5 Occurrence
Why 1: Mill is getting tripped
Why 2: Over load (Amps is more)
Why 3: Level CTLR reduces the RPM to
get good extraction
Why 4: Amps control is not there
Why 5: Weak design
Counter Measure :New logic is made, considering both DC Level & Amps
23
GOOD
KAIZEN IDEA
BEFORE AFTER
MILL OPERATED BASED
ON DONNELYY CHUTE LVEL
MILL OPERATED
BASED
ON BOTH DC LEVEL
& MILL LOAD
1.6
5
1.5
5
1.3
9
1.3
50.6
0.8
1
1.2
1.4
1.6
1.8
2
2014-15 2015-16 2016-17 2017-18
Pol Loss in Bagasse (%)
IMPLEMENTATION STEPS
IMPLEMENTATION STEPS
Cane Crushing Increased
6200 TO 7000Tons/Day
Additional Income
Rs.38 Lakhs/Year
Ichute jamming
decreased 5 to 0
Occurrence
2727
BENEFITS FROM PQCDSM
1.6
5
1.5
5
1.3
9
1.3
5
0.6
0.8
1
1.2
1.4
1.6
1.8
2
2014-15 2015-16 2016-17 2017-18
Pol Loss in Bagasse (%)5
00
1
2
3
4
5
6
Before After
6200
7000
5000
5500
6000
6500
7000
7500
8000
Before After
Flash Steam recovering in Agitated Thin Film Drier
Case Study -3
Steam Conservation in ATFD
INTEGRATED EVAPORATOR BMSW EVAPORATOR-II & AGITATED THIN FILM DRYER K-POTTASH AS A FERTILIZER
Multiple effect evaporator
FEED @ 55 TO 60 Deg.C OUT @ 74 TO 78 Deg.C
(FLASH VAPOR)
POWDER K - BOOST
STEAM IN
STEAM IN
100Deg.C
(0.2 kg/cm2)
FEED @ 55 TO 60 Deg.C OUT @ 74 TO 78 Deg.C
POWDER K - BOOST
(FLASH VAPOR)
STEAM IN
STEAM IN
PID SP- 0.2Kg/cm2
SP- 0.4Kg/cm2
PCV
RE-BOILER
Additional Income
Rs.31.28 Lakhs/Year
K Boost Productivity Increased 12
to 15 Tons/Day
3333
BENEFITS FROM PQCDSM
12
15
0
2
4
6
8
10
12
14
16
Before After
0
31.28
0
5
10
15
20
25
30
35
Before After
Environmental Improvement Projects
1. We have developed Green Belt of more than 35 % of the total factory area.
2. CO2 generation through automationn Case Study-4
3. Bio-Gas utilized to generate steam for distillery plant requirement.
4. Augmented the ESP field of the Co-gen boiler to reduce the emission levels to
less than 50mg/nm3, though the Pollution control board norm is at
100mg/nm3.
5. Condensate Polishing Unit in Sugar (To achieve zero water Drawl from bore well)
6. Energy Sources
8/31/2018
Covered in Case Study -4
Covered in Case Study -5
CO2 AUTOMATION IN DISTILLERY
FERMENTATION PROCESS
MOLASSES FERMENTATION PROCESS
CO2 GENERATION CO2 PROCESS & STORAGE
Case Study -4
Utilization of Renewable Energy Sources
363636
PROBLEM FACED
• From the generation of CO2 gases in fermentation, cant able to achieve the
recovery rate for the calculated yield of molasses to alcohol conversion.
• Because of manual control & observation, the time & sensing may vary by
person to person will result in production loss.
• There is no stranded system & format to identify the pressure and purity.
• Uncertainty will leads to losses in the production.
• Which creates an Green House gas emission.
3737
7. This routine process take minimum 3 to 4 hrs to finding the pressure
buildup for each fermenter, which leads to loss of CO2, so unable to
recover all the CO2 generated in fermenter.
1. MOLASSES filling started
FERMENTER
2. Within one hour CO2 gas generation
started
3. Slowly pressure buildup in Fermenter
4. CO2 gas generation were observed
visually by operator in Manhole door.
5. Once visually confirmed the manhole door was
closed and CO2 passes through the scrubber.
CO2 SCRUBBER
STRATIFICATION OF PROBLEM - CO2 RECOVERY
6. In scrubber, purity and
pressure has been
confirmed, if it
reaches the norms
then will started the
blower and the gas
drive to CO2 recovery
plant .
CO2 RECOVERY PLANT
CO2 Loss in visual inspection
38
PROBLEM IDENTIFICATION
What : CO2 recovery rate not achieved.
Where : Fermentation section
When : Every day.
Who : Fermentation Operator.
Which : CO2 recovery rate low
How : Recovery of 22000 kgs/day.
Why 1 : CO2 recovery rate from fermentation is low.
Why 2 : CO2 losses in fermentation operation
Why 3 : Manual operation of checking & valve operation.
Why 4 : No facility to operate with the pressure based system.
Why 5 : Weak design.
5 W 1 H METHOD WHY-WHY ANALYSIS
39
KAIZEN IDEA SHEET
BEFORE
Additional
Revenue of Rs.
58.8
Lakhs/annum.
AFTER
What : CO2 recovery rate not
achieved.
Where : Fermentation section.
When : Every day.
Who : Fermentation Operator.
Which : CO2 recovery rate low.
How : Recovery of 22000 kgs/day.
Problem:
Why-Why analysis:
Problem Phenomena:
Why 1 : CO2 recovery rate from fermentation is low.
Why 2 : CO2 losses in fermentation operation.
Why 3 : Manual operation of checking & valve operation.
Why 4 : No facility to operate with the pressure based system.
Why 5 : Weak design.
Machine: FERMENTATION SECTION Kaizen Idea: Enhancement of CO2
Recovery
Results:
Counter Measure: Automation
Problem: Losses of CO2
Root Cause: Manual operation.
Result: Productivity increased
KAIZEN MECHANISM
4040
➢ Concept development
➢ Approval from Top Management
➢ Finalizing the vendor & materials
➢ Erection and commissioning
Had a brain storming section with our management…
➢ Concluded & took forward with the upgradation of system with the
automation of pressure control value & interlock system.
➢ Everything would be displayed in Control Room, no man will affect
with harmful gases.
➢ The cost of the automation will be approx. Rs.15 Lakhs
WAY FORWARD – AUTOMATION IMPLEMENTATION
40
IMPLEMENTATION STEPS FOR AUTOMATION
4141
ACTION TAKEN
• Provided auto pressure control valve in the CO2 gases outlet line from fermenter.
• Incorporated automation and interlock system in the fermenter betweenpressure and level (volume).
• Once volume increase in fermenter, the CO2 generation also increased.
• After automation, pressure reaches to 100 MMWC, the CO2 outlet valve getautomatically open and passed through scrubber.
• After implementation of automation, Time taken purity & pressure identificationin fermenter had reduced from 3 - 4 hrs to 0.5 – 1.0 hrs to attain the purity.
4242
BENEFITS FROM PQCDSM
Productivity Increased 22 to 30 Tons/Day
Additional Income
Rs.58.8 Lakhs/Year
Inspection time
decreased 3.0 to 0.5 Hrs/Day
Moving Towards Zero liquid discharge
Sugar
Condensate Polishing Unit
Case Study-5
Main Source of Effluent
• Excess condensate from boiling House
• Blow down and excess water from Cooling tower.
• Effluent from vessels testing and cleaning – Evaporator
• Floor washings.
What Triggered us
• When plant capacity scaled up to 7000 TCD
enormous volume of excess condensate .
• Though sufficient lands was available continuous
usage couldn’t been ensured due to nearby coastal
area.
• More drawl of ground water for our other unit
operations like distillery and power plant.
Actions planned and implemented
• Separation of Lean Effluent -Excess condensate from
evaporator was separated
• Common condensate cooling system.
• Monitoring of cooled condensate characters.
• Treatment of excess condensate in a pilot plant to
arrive at a commercial scheme.
• Based on the trials and the outputs, decided to go with
a MBBR treatment scheme.
Design Philosophy
Inlet water parameters considered
Condensate Polishing UnitProcess Flow chart
Equilization tank
Acticontact tank
Clarifier
Pressure sand filtration
Dual media filtration
Ultra filtration
Usage of Aerobic bio film treatment system ACTICONTACT
✓ ACTICONTACT is the trade name of aerobic bio film treatment unit.
✓ Selection of the fixed-bed or moving-bed type is based on factors such as loading
rate, wastewater components and treatment objective.
✓ Three times higher BOD loading rate can be achieved than with conventional
activated sludge systems and large settling tank is not necessary.
Advantages of ACTICONTACT design
CPU – ACTI CONTACT TANK
CLARIFIER
FILTERS
WATER SAMPLES
1. Common condensate
2. Secondary Clarifier outlet
3. UF outlet
1 2 3
Treated water parameters
Usage of treated water✓ Boiler feed in the place of raw water .
✓ Boiler cooling tower.
✓ Distillery use.
8/31/2018
Benefit from Condensate Polishing Unit
✓ Boiler feed in the place of raw water .
✓ Cogeneration Plant cooling tower Make up.
✓ Distillery Cooling Tower make up.
✓ Usage of domestic purpose
Zero water Drawl
& Zero Effluent Discharge
57
Tangible benefits:
➢ Recovering Resources from sugar Condensate
➢ Effluent water discharge completely 50 % reduced.
➢ Water recovery and recycle thereby reducing the ground water
drawl.
Intangible benefits :
➢ Employment opportunities
➢ Organizational goals are achieved
➢ Reduction in Green house gas emission
➢ Morale of the employee increased.
TANGIBLE & INTANGIBLE BENEFIT
8/31/2018
Participation by down the line shop floor personal
in implementing ENCON ideas
8/31/2018
S.No. ENCON IdeaYear of
ImplementationSource of Idea
Annual savings
Rs.in Lakh
1Sugar recirculation avoided by altering the grader transfer points.
2015-16 Fitter 33.75
2Usage of first vapour for heating treated juice reduced by 50 % by adding a new direct contact heater for second body vapour.
2015-16 Pan Officer 22.5
3Variable Frequency Drive for condensate Extraction Pump-2
2015-16 Electrical
Supervisor 2.16
4Injection Header modification by eliminating separate pump for evaporator
2015-16 Shift Chemist 27.27
5 Reusing of Boiler blow down water 2016-17 Shift Chemist 0.86
6Sugar lumps quantity reduction during bin cleaning by polishing the bin internals
2016-17 Engg Supervisor 4.86
Participation by down the line shop floor personal
in implementing ENCON ideas
8/31/2018
S.No. ENCON IdeaYear of
ImplementationSource of Idea
Annual savings
Rs.in Lakh
7 ATFD condensate recovery improvement 2016-17 Engg Supervisor 2.64
8Variable Frequency Drive for Sulphur burnor blower
2016-17 Electrician 2.21
9 B Grain pump with VFD 2016-17 Shift supervisor 0.66
10 B-Massecute Pump VFD installation 2017-18 Pan Officer 1.34
11 Air Compressor Header Modification 2017-18 Engg. Supervisor 9.06
12Elimination of intermediate belt conveyor in Refinery Feed Centrifuge
2017-18 Shift Chemist 0.66
13Elimination of Slat conveyor during coal operation by introducing new conveyor
2017-18 Boiler operator 4.30
14Elimination of BC-8 & BC-9 by introducing new coal conveyor
2017-18 Shift electrician 1.58
Best practices on energy front implemented
through our associates
1. Persuaded the coal suppliers to shift importing of coal from Chennai to a
nearby port at Karaikal to reduce transportation distance by 200 KM per trip of
truck…. Reduction in Diesel consumption by the trucks.
2. Loose Bagasse transportation avoided to the extent possible and insisted on
transportation of baled Bagasse. An increase in transportation capacity of truck
per trip. 30% reduction in diesel consumption.
3. Special alloy multi nozzle rollers giving better juice extraction and moisture
reduction, resulted improved in Steam bagasse Ratio.
4. Farmers were campaigned to cultivate sugar cane nearby factory area near to
reduce the transportation distance of 20 km per truck. Reduction in Diesel
consumption by the trucks.
8/31/2018
ENCON projects for next 3 years
Bagasse dryer for reducing the moisture % Bagasse
Increase bio gas boiler capacity from 12 TPH to 15 TPH.
Condenser modification in evaporator and pan condenser
Sugar Injection water Treatment– Project.
8/31/2018
Energy Conservation Monitoring & reporting
1. 23 flow meters for all process fluids including steam
2. DCS based data logging for daily energy monitoring and reporting
3. 35 energy meters were installed at all important stations
4. Utility report is generated on daily basis which captures specific power, steam
and water consumption.
5. Internal and external energy audits at regular interval
6. Displaying daily energy consumption figures in the plant
7. Daily report to the top management
8. Equipment running hours are monitored on daily basis to identify idle
running/under loading of the machineries
8/31/2018
• Introduced Real Time Online monitoring of Critical
parameters from the Desktop PCs of all Senior Executives
• Hourly SMS auto alerts
• Daily manufacturing report
• SAP generated auto alerts
- Plant comparison
• Stock reports from warehouse
• Trend charts from QA
• Incoming raw material
• In process
• Weekly compliance report
• Monthly employee productivity linked incentives
Energy savings is
our prime motto
Energy Management monitoring methodology
8/31/2018
National Excellent Energy Efficient Unit Award on 2016 & 2017
65
Platinum Award for the
“Best Distillery” for Distillery
Platinum Award- for the “Best
Technical Efficiency” for Sugar
Awards and Recognitions….
CII Environmental Best Practice Award-2017
8/31/2018
668/31/2018
