e.i.d. parry (i) ltd pudukkottai - green business centre · 2018. 9. 13. · eid – achievement...

© 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.


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


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


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


Cogen Aux. Power


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


Cogen – Steam Fuel Ratio


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


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


FY 2020-21





FY 2018-19





FY 2021-22





Road Map for future Encon Activities


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


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


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


31 August

201812

Energy Conservation Measures takenDuring FY 2015-16

(Electrical)

1231 August 2018

Sl.No.


(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


201813

Case Study

NoProjects

Actual

Cost Saving

(Rs in Lacs)

1 Thermal Saving 52.74


Key Energy Management Improvements

2016 - 2017


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)



Total 10 13.68 5.09

0.11 % Investment for ENCON project on Turn over


2016 - 2017


201815

Sl.

No

.


(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)


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


FY 2016-17 (Electrical)


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




201818

Case Study

NoProjects

Actual

Cost Saving

(Rs in Lacs)

1 Thermal Saving166.23



2017 - 2018

3c. Energy Saving projects implemented in FY 2017-18

0.15 % Investment for ENCON project on Turn over


201819

THERMAL SAVINGS

DescriptionNumber

of projects

Annual

Savings (Rs Lacs)

Investment

(Rs Lacs)


Savings Without Investment 0 0 0

Total 2 166.23 9.00

Electrical SAVINGS

DescriptionNumber

of projects

Annual

Savings (Rs Lacs)

Investment

(Rs Lacs)



Total 9 13.86 4.67


2017 - 2018


201820

Sl.

No

.


(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


FY 2017-18 (Thermal)


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




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




4. Innovative Projects implemented1. Fibrizer anvil modification

Source of idea – Team leader

Replication potential – Sister units also practicing


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


One Point Lesson Sheet


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


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.


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


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


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


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


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


- 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%.


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


201838

Pest Affected Field – Captured by I-Cane Mobile(Paperless Office)



201839

(Paperless Office)

I-Cane-Digital Task Scheduler



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


“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


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


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


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


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


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


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.


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


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


51


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


Department Head

Daily All Energy Consumptions like


Unit head

Monthly All Energy Consumptions like


Business Group Management Committee (Business head & EID’s Function head)


52


Sample Power Monitoring report


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.


Pol % Bagasse reduction by Partial Diffusion


Cutter

Blower-Man Cooler

Air

Flow

Cut

trash

FlowCutter


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


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).



201858


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.


201859

CII AWARD FOR

ENERGY MANAGEMENT – 2017, 2016 & 2014


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

e.i.d. parry (i) ltd pudukkottai - green business centre · 2018. 9. 13. · eid – achievement...

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