06-09-2017
1
18th NATIONAL AWARD FOR
EXCELLENCE IN ENERGY MANAGEMENT - 2017
E.I.D.-Parry (India) Limited,Pudukottai,Tamilnadu
06-09-20172
Murugappa Group Overview
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3
• E.I.D is Over 225 years old, Started in 1788.
• Flagship company of Murugappa Group since
1981, pioneers in extending businesses and value
addition.
• E.I.D Parry is ranked 51 amongst the top 200
Companies in India – Economic Times 2009
survey
E.I.D.- PARRY (INDIA) LIMITED
EID PARRY
BUSINESS
SUGAR
DIVISION
BIO-PRODUCT
DIVISION
SUGAR COGENERATION DISTILLERY
TN,
KARNATAKA, AP
& PONDY
39800 TCD
TN, KARNATAKA,
AP & PONDY
153 MW
TN,
KARNATAKA, AP
225 KLPD
NUTRA
DIVISION
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Pudukottai Unit Milestone
Green field project commissioned in 2000
Integrated sugar complex with a crushing
capacity of 4500 TCD, 19.50 MW
Cogeneration Power Plant
We have ISO 14001, OHSAS 18001, ISO
9001 certified by DNV
Highest cane crushed 9.21 Lakhs MT in
2011-12 with a sugar recovery of 9.51%
First TPM practicing company in cane
sugar manufacturing industry
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ENERGY POLICY
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6
Understanding Sugar products
Sugarcane Juice Syrup
Bagasse Press mud Molasses
CogenerationPower plant
Organic Manure Alcohol / cattle feed
Primary
By Products
Value added
Products
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ParametersGlobal Bench
markEID –Achievement
Specific Thermal
Energy Consumption
26-34 %
As per ISSCT
proceedings 2013
36.94 %
Steam / ton of cane
(Main season)
Specific Electrical Energy
consumption
27-28 kWh/ton of
cane
As per NFCSF
27.61
kWh / ton of cane
(Main season)
Comparison with global benchmarks
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Innovative Ideas Project Description BENEFITS
ACHIVED
Introduction of additional
juice drainage area on
mill rollers
Elimination of re-absorption
of juice resulting in
reduction of pol % bagasse
& Moisture % bagasse
Rs. 0.95 Lacs / day
Rs. 190.00 Lacs /
annum
Effective Utilization of
Compressed air by
installing air pressure
booster.
Power Saving in Air
Compressor operation.
Rs. 0.05 Lacs / Day
Rs. 10.40 Lacs /
annum
Elimination of sub
process through Process
Modification
Elimination of Vacuum Filter
Operation in Sugar Process
Rs. 0.51 Lacs / Day
Rs. 2.55 Lacs for 5
days operation
Innovation in Projects Implemented
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Innovative Project – 01
Loss reduction
Objectives:
To reduce losses by eliminating juice re-absorption in
milling operation.
Action Plan:
Improve juice drainage area in mill rollers by introducing
additional juice drainage nozzles.
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554
Nozzles
Introduction of additional juice drainage area on mill rollers
Innovative Project – 01
Loss Reduction
Single row Nozzle Triple row Nozzle
Drainage
nozzles
Drainage
pipe 1662
Nozzles
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Moisture % Bagasse
49.71
48.45
47.5
4 8
4 8 . 5
4 9
4 9 . 5
5 0
Before After
Mois
ture
%
Bagasse
Pol % Bagsse
1.821.38
0
0.5
1
1.5
2
Before After
Pol%
bagasse
Results achieved :
•Moisture % bagasse reduced from 49.71
% to 48.45 %
•Saving Amount Rs. 70 Lacs for 3 Lacs
MT Crushing
• Pol % bagasse reduced by 0.44 % which
resulted in recovery of 351 MT of Sugar
savings for 3 Lac Crushing.
• Savings amount Rs. 120 Lacs
Innovative Project – 01
Loss Reduction
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Innovative Project - 02Power Saving - Air Compressors
Objectives:
Power conservation in utilities ( Air compressor)
Action Plan:
1. Replacing existing 4nos of lower capacity Reciprocating Air
Compressors (138 kw) with 2 no higher capacity Screw Air
Compressor (95 kw).
2. Providing VFD for screw compressors.
3. Operating air compressor at low air pressure and boosting pressure
with help of pressure booster where ever high pressure required.
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Inst. Air Compressor
(Reciprocating) _ With out VFD
Ash Handling Air
Compressor
(Reciprocating)
With out VFD
Plant Instrumentation
Air requirement
@ 6.0 Kg/Sq. CM
Plant
Instrumentation
Air requirement
@ 6.0 Kg/Sq. CM
Plant Ash handling
Air requirement
@ 4.50 Kg/Sq.CM
Inst. Air
Compressor
(Screw) With
VFD
Pressure
Regulating
Valve
Replacement of reciprocating compressor
by VFD operated screw compressor
Innovative Project - 02
Power Saving - Air Compressors
Reciprocating Compressor
Without VFDScrew Compressor With VFD
Power Consumption – 3312 units/days Power Consumption – 2302 units/days
Savings 1010
units/day
Screw Compressor With VFD
Power Consumption – 3312 units/daysPower Consumption – 3312 units/daysPower Consumption – 3312 units/days Power Consumption – 2302 units/daysPower Consumption – 3312 units/days
2 Nos Compressors
(1No. with standby)
95 KW – 2 Nos
4 Nos Compressors
93 KW – 2 Nos
45 KW – 2 Nos
Plant Ash handling
Air requirement
@ 4.50 Kg/Sq.CM
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Instrument Air Pressure Reduction
Plant
Instrumentation
Air requirement
@ 6.0 Kg/Sq. CM
Plant Ash handling
Air requirement
@ 4.50 Kg/Sq.CM
Inst. Air
Compressor
(Screw) With
VFDPressure
Regulating
Valve
Regular Operation
Pressure
BoosterCommon Plant
Instrumentation
Air requirement
@ 5.0 Kg/Sq. CM
Plant Ash handling
Air requirement
@ 4.50 Kg/Sq.CM
Inst. Air
Compressor
(Screw) With
VFD Pressure
Regulating
Valve
Centrifugal areaInstrumentation
Air requirement
@ 6.0 Kg/Sq. CM
With Pressure
Booster Operation
Innovative Project - 02
Power Saving - Air Compressors
Power Savings
300 units/day
@ 6.0 Kg/Sq. CM
@ 5.0 Kg/Sq. CM
Centrifugal area Instrumentation
Air requirement
@ 6.0 Kg/Sq. CM
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Innovative Project - 03
(Stopping of vacuum filter operation)
Objectives:
To conserve energy in vacuum filter area by diverting muddy juice to mill.
Action Plan:
1. Diverting muddy juice to mill section to mix with bagasse to extract juice.
2. Stopping of vacuum filter operation ( vacuum pump, filtrate pump, mud
mixer drive, bagacillo blower and filter drum).
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Process Failure Mode Effect Analysis (PFMEA)
Innovative Project - 03
(Stopping of vacuum filter operation)
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Power Saved = 6221 Kw
Cost Saving = Rs.254046/-
Trail Running days = 5 Days
Innovative Project - 03
(Stopping of vacuum filter operation)Scheme:
Data:
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SPECIFIC ENERGY CONSERVATION
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Power Consumption / Tones of Cane
27.2525
26.6327.6130.59
29.0427.06
20
25
30
35
40
45
50
13-14 14-15 15-16 16-17
Special
16-17
Main
17-18
Special
17-18
Main Plan
Financial Year
Un
its
/ To
n
Due to Low rate of Cane Crushing & Intermittent
stoppage - want of Cane raised out of CHL issues
Global Bench Mark – 28 KW / MT
SEC REDUCTION PERCENTAGE
Sugar - Power
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Due to Low rate of Cane Crushing & Intermittent stoppage
Steam % on cane crushed
Global Bench Mark – 34%
39.39
34.8634
36.2836.87
39.25
36.93
32.00
34.00
36.00
38.00
40.00
13-14 14-15 15-16 16-17 Sp 16-17
main
17-18 Sp 17-18
Main PlanFinancial Year
%SEC REDUCTION PERCENTAGE
Sugar - Steam
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Average cane crushed per tons per day
3417
27432844
23542074
3258
1500
2000
2500
3000
3500
4000
13-14 14-15 15-16 16-17
Sp
16-17
Main
17-18
Sp
Financial Year
%
Reduced rate of crushing based on Cane availability during 2015-16 & 2016-
17
SUGAR PLANT PERFORMANCE
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Power Generation & Export
MW / HR
13.7714.82
11.3110.26
12.66
9.179.78
7.20 7.648.74
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
2012-13 2013-14 2014-15 2015-16 2016-17
YEAR
MW
/ H
R
Power generation MW / HR Power export MW / HR
COGENERATION PLANT
PERFORMANCE
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9.048.44
9.759.63
8.348.25
6.00
7.00
8.00
9.00
10.00
11.00
12.00
13-14 14-15 15-16 16-17 17-18 Sp 17-18 PlanFinancial Year
%
As per STOA from TNEB, power export quantum restricted to < 30 %
which resulted in higher Aux Power
Cogen Auxiliary Power Consumption % On Generation
8.50 @
16-17 Main
SEC REDUCTION PERCENTAGE
Cogen Aux. Power
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Steam – Fuel (Bagasse) Ratio (Kg of steam/Kg of Bagasse)
2.46 2.46 2.42 2.41 2.49 2.55
1.50
1.75
2.00
2.25
2.50
2.75
3.00
13-14 14-15 15-16 16-17 17-18 Sp 17-18 PlanFinancial Year
Kg
of
Ste
am /
Kg
of
Bag
asse
As per STOA from TNEB, power export quantum restricted to <
30 % which resulted in Lower SFR
2.47 @
16-17 Main
SEC REDUCTION PERCENTAGE
Cogen – Steam Fuel Ratio
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Energy Saving Projects
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Case Study
NoProjects
Investement
(Rs in Lacs)
1 Thermal Saving 6.97
2 Power Saving 5.07
3Expense for Training and Development of
our own staff and suppliers.5.23
4 Total Investment 17.27
5 Turnover of unit 11162
6% Investment on Encon projects on
Turnover0.155%
Investment on Encon Projects in the Year
2016 - 2017
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THERMAL SAVINGS
DescriptionNumber
of projects
Annual
Savings (Rs Lacs)
Investment
(Rs Lacs)
Savings With Investment 3 9.79 6.97
Savings Without Investment 1 42.95 0
Total 4 52.74 6.97
POWER SAVINGS
DescriptionNumber
of projects
Annual
Savings (Rs Lacs)
Investment
(Rs Lacs)
Savings With Investment 8 6.16 5.09
Savings Without Investment 2 8.84 0
Total 10 15.00 5.09
Key Energy Saving Projects Implemented
in the Year 2016 - 2017
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Sl.
No
.
Title of ProjectAnnual Savings
(Rs Lacs)
Investment
(Rs Lacs)
1Reduction in Hot condensate wastage by
changing the Sampling method.0.85 1.00
2 Improved Thermal Insulation in boiler 6.40 2.97
3Elimination of vacuum filter operation
from sugar processing2.54 3.00
4 Alternative Bio mass fuel - Wood Bark 42.95 0.00
Total 52.74 6.97
Energy Conservation Measures taken
FY 2016-17 (Thermal)
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Sl.
No.Title of Project
Annual Savings
(Rs Lacs)
Investment
(Rs Lacs)
1
Replaced Worm& worm wheel gear box (30
KW) with helical gear box in Rake carrier
(Saving 4.0 Kwh/Hr)
0.80 0.50
2
Fixed Transparent roof sheet in sugar
Godown – Lighting load reduced during day
time
0.631.00
3
Pneumatic pressure booster is installed to
raise the air pressure for Centrifugal
machine Instrument air system.
1.20 0.67
4 VFD Installed for unsulphited syrup pump 1.04 0.68
5 LED Lightings in plant area 0.51 0.85
6Domestic water consumption reduction (50
TPD)0.54 1.13
Energy Conservation Measures taken
FY 2016-17 (Power)
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Sl.
No.Title of Project
Annual Savings
(Rs Lacs)
Investment
(Rs Lacs)
7LED Issued to employees during Safety Day
Celebration 1.41 0.21
8 WTP flushing water re-usage 0.03 0.05
9
Lighting control during Off season
(Provided only focus lamps in walk way
area)
8.42 0
10Switch off standby UPS system for DCS to
reduce the power loss during Off-season0.42 0
Total 15.00 5.09
Energy Conservation Measures taken
FY 2016-17 (Power)
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Sl. No Financial year Projects
Actual
Cost Saving
(Rs in Lacs)
1
2015-2016
Thermal Saving 58.31
2 Power Saving 20.69
3
2014-2015
Thermal Saving 102.15
4 Power Saving 11.79
Key Energy Management Improvements
2014 - 2016
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Encon Team Work & Projects
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Sr. Vice President
As Adviser
Sr. General Manager
Shop Floor Engineers and Process Technologists along with Team Members
Source of ideas and implementation team
Engg Process Co-gen * Elect * INST
Department Head
H.O.D
(Engg)
H.O.D
(Process)
H.O.D
(Cane)
Resource Leaders
Note : * Certified Energy Auditor
ENERGY CONSERVATION CELL
Sr. Vice President
As Adviser
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S.N
oFinancial years
Major No: of
ENCON
Projects
Annual
savings Rs in
Lacs
Capital
Investment
(Rs. In Lacs)
1 2016-2017 6 47.58 4.01
22015-2016
9 55.62 15.33
32014-2015
6 91.14 45.20
4 2013-2014 3 6.72 3.0
Total 24 201.06 67.54
Involvement of Employees in
implementing Encon Projects
Power & Energy saving related major & minor projects of 873 Nos. received from
176 employees and implemented 640 Nos.
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• Introduced Real Time Online monitoring system to control the plant critical operating parameters from the Desktop PCs of all Senior Executives
• Cane crushing details is being sent to all HOD’s through CMS based Hourly SMS
• PROMIS capturing all the production details an hourly basis and generated daily production report
• SAP Generated auto alerts - Plant comparison, Stores & Warehouse reports, Inventory, R&M
Budget Vs Actual
• Trend charts from QA- Incoming raw material & In process- Weekly compliance report
Encon Monitoring Methodology
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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)
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Encon Monitoring Methodology
Sample Power Monitoring report
FY 2017-18
•Steam % Cane – 34
•Power/MT cane – 25
•Steam fuel ratio – 2.5
•Aux Power % - 8.25
FY 2019-20
•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
Resources planned for accomplishing Targets
S.No. Equipment Cost Deliverables
1 1. 4th mill all three roller pitch has to be changed from 40 to 30
including scrapper, Trash plate with triple nozzle lotus roller
2. 3rd mill all three roller pitch has to be changed from 40 to 30
including scrapper, Trash plate with triple nozzle lotus roller
50
Lacs
Reduction in pol%
bagasse from 1.35
to 1.00
2 Bagasse moisture reduction unit to be provided in the outlet of
first & fifth mill.
40
Lacs
Reduction in
moisture% bagasse
from 48.50 to 47.0
3 1. Auto de-hooking system for cane unloader 2 nos
2. Provide planetary gear box with VFD system - Mills, Rake
carrier, Feeder table, Cane carrier, Lime tank, B Vacuum Xlr
3. Automation of cooling tower
4. Injection pump automation
5. VFD for cane preparatory devices
6. Rope coupling for 5 mills
360
lacs
Reduction in Power
per ton of cane from
29 to 20
4 1.VLJHReplacing with PHE both series. 2.By providing DCH
system in juice heater
100
Lacs
Reduction in Steam
% cane from 38.5 to
30
Road Map for future Encon Activities
Resources Planned for accomplishing Targets
S.No. Equipment Cost Deliverables
5 Planetary Gear Boxes For Bagasse
Drum feeder –
5 No, (5.5.KW, 5 to 40 RPM)
15 Lacs Reduction in Power consumption by
15 %
6 Baggasse Drying System – CF fan, 2
No. Belt Conveyors, Cyclone Chamber,
Back Filter and Ducting
250 Lacs Increase in Steam Fuel ratio from
2.5 to 2.8 thereby reducing fuel cost
or cost of power production.
7 Energy Conservation System:
50 tph Boiler Feed Pump 12 lacs
Reduction in In-house Power
consumption.
8 100 CFM, 6kgf, Screw Compressor 7.5 Lacs Reduction in In-house Power
Consumption
9 Addional capacity in APH 25 Lacs To recover waste heat from the Flue
Gas (From 150 Deg C to 140 deg
C).
Road Map for future Encon Activities
06-09-2017
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Road Map for 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 additional
capacitor banks.
Harmonic reduction in all power centers by providing Harmonic filters to
improve power quality.
5Introducing Planetary gear box for 5 nos of equipments to save power of
17.5 Units/Hr.
6
Introduction of Auto Hydraulic de-hooking system to eliminate operation
of one no of 25 KW motor for 2 nos cane unloaders to save power of 14
Units/Hr.
7Process modification and Introduction of Automation in various areas to
save power and steam consumption.
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Utilization of Waste Materials as fuel
1. Match Box Waste
2. Eucalyptus Wood Bark
3. Juliflora Thorns
4. Juliflora Chips
5. Pencil wood waste
6. Wood Industry waste
7. Pressmud
Following Waste Bio
mass as fuel in our boiler
for generating power
Till date 12320MT Bio
waste fired
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43
1) Treated water from ETP is used for cane irrigation and Trees plantation
around the factory.
2. Co-Gen boiler Ash is utilized as manure in Cane fields.
• RO Reject water / Boiler Blow down water is used for boiler Ash
quenching in place of raw water.
Waste utilization
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Waste materials from forest is
used as fuel to maximize the
power generation at Co-Gen. We
generated 2.86 million units in
the last run.
Renewable Energy
Solar Powered Irrigation pumping system (10 HP) in cane forms are being installed widely in our command area of 25000 acers.
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CO2 Emission Reduction:
• 500 no Trees planted inside the plant towards the target of 1000 Nos for theyear
• Reduced the Fuel consumption for the same power production by reducingthe Specific steam consumption. ( From 5.49 to 5.34 )
• Co-Gen Captive power consumption is reduced from 9.75 % to 8.34%.
Green House Gas Emission Reduction
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Moving towards digital India
• By introducing I-Cane software we have created Paperless office for cane management. I-Cane - Plot MAP – With Measurement Details
Green House Gas Emission Reduction(Paperless office & Diesel Consumption Reduction)
40 % of time spent on traveling by cane staff reduced by this Application usage
06-09-2017
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Pest Affected Field – Captured by I-Cane Mobile(Paperless Office)
Green House Gas Emission Reduction(Paperless office & Diesel Consumption Reduction)
06-09-2017
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(Paperless Office)
I-Cane-Digital Task Scheduler
Green House Gas Emission Reduction(Paperless office & Diesel Consumption Reduction)
06-09-2017
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1) Zero Ground water drawl
2) Plantation of Trees – 1000 Trees / Year
3) Utilizing Renewable Energy (Solar Power for Effluent Treatment Plant, Cane Cultivation Etc)
4) Ensuring Emission test for vehicles entering in to Factory premises
Way forward towards Green House Gas
Reduction
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1. Drip irrigation / Micro irrigation for cane cultivation to preserve water & save
pumping Electrical Power
Best Practices Replicated on Energy front in
Green Supply Chain
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2. Encouraging Cane cultivation closer to factory to reduce the Cane transport for reducing diesel consumption.
3. By using daily tracker S/W we have identified that 60% of cane staff time is wasted in traveling between Cane field and Office. By Implementation I-Cane Software (Satellite mapping, machine based management system) effectively the necessity of travel to office is drastically reduced to 20% this resulted in significant reduction in Petrol/Diesel for Cane Staff vehicles
Best Practices Replicated on Energy front in
Green Supply Chain
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1) Sugar process water requirement is met with vapour condensate from cane juice.
So, ground water drawl for Sugar Process is Nil.
2) Excess condensate water is cooled in Fan-less cooling Tower and used for
Greenery development inside the factory.
Green Supply chain – Recycling and Reuse
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CII AWARD FOR
ENERGY MANAGEMENT – 2016 & 2014
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CII AWARD FOR
EXCELANT ENERGY MANAGEMENT - 2015
06-09-2017
55
Receiving Shield from
Hon’ble Minister of Power
Mr. PIYUSH GOYAL at New
Delhi
National Level
second Prize
(Silver Shield)
NATIONAL ENERGY CONSERVATION AWARD 2014
FROM BUREAU OF ENERGY EFFICIENCY,
GOVERNMENT OF INDIA
06-09-2017
56
Group level Best Cogen Award - 2017
06-09-2017
57
TPM Awards
06-09-2017
58
Best Performing Company Winner in the
‘Sugar’ Sector for the Dun & Bradstreet Corporate
Awards 2016
06-09-2017
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06-09-2017
60606 September 2017