nbv-sd 2009-10 with out rs symbol...company profile nava bharat ventures limited (nbv) is a...

COMPANY PROFILE

Nava Bharat Ventures Limited (NBV) is a multi-division company with Rs.1270 crore turnover having business activities in

Power Generation Ferro AlloysSugar and Downstream

ProductsDev. of Infrastructure Projects

Trading MiningSugar Division profile :

• 112 years old plant with new benchmarks in energy conservation

• 3500 TCD sugar plant

• 9 MW power plant

• 20 KLPD Distillery

• One of the few to register with UNFCCC

• ISO 9001 & 14001 certified

• One of the few to implement 5S

PROCESS PROFILE

CANE

SUGAR

CLARIFICATION

EVAPORATION

PAN BOILING

CENTRIFUGALS

SUGAR DRYING

MILLING

BAGASSE

MOLASSES

CO-GEN

DISTILLERY

TREND SETTING PROJECTS IN SUGAR INDUSTRY

Mono Vertical Crystallizer 1982 - 83Microwave probe for batch pan brix control 2003 - 04

AC VF Drives for Sugar Cane Mills 2004 - 06Quintuple 3rd effect vapour for Pan boiling 2005 - 06Vapour Absorption Heat Pump 2005 - 06Clear Juice in place of condensate(In vacuum pans, cont. cfg. & sugar melter)

2006 - 07

Integrated spent wash evaporation 2007 - 08Sulphur free sugar manufacture(Without any extra energy consumption)

2007 - 08

Whole cane milling 2008 - 09Bagacillo floatation cell to improve performance of heat exchangers

2009 - 10

NOTE ON ENERGY CONSERVATION

• Plant capacity utilization

• Consistency in crush rate

• No. of operating days

Apart from energy saving projects, the following factors affect energy

conservation in sugar industry.

The plant operating days were reduced from 187 to 95 during past

four years due to reduced cane availability in the region.

This affected the outcome of energy conservation projects.

However, we succeeded in creating new benchmarks in specific

energy consumption.

ENERGY CONSERVATION TREND

95

137135

150

104

187

85

105

125

145

165

185

205

2004-05 2005-06 2006-07 2007-08 2008-09 2009-10

44.65

37.535.74 36.3

39.44

31.03

21.65 22.4824.24

25.95

30.01

23.51

20

30

40

2004-05 2005-06 2006-07 2007-08 2008-09 2009-10

steam % cane kWh per TC operation days

SPECIFIC ENERGY CONSUMPTION TREND

31

3936

232825

05

1015202530354045

2007-08 2008-09 2009-10

223245

194

100

150

200

250

300

2007-08 2008-09 2009-10

21 % 16 % 51 k kcal

Steam % cane kWh per TC Mcal per TC

Parameter Global NormsGlobal

benchmark as per CII

NBV – SDAchievement

Specific Thermal Energy Consumption

40-41% As per ISSCT proceedings 2005

38.00 % 31.03 %

Specific Electrical Energy consumptionFor sugar plant operations alone

27-28 kWh/ton of caneAs per NFCSF

30 kWh 23.51 kWh

CREATING NEW GLOBAL BENCHMARKS

An unprecedented figure of 29 steam % cane was recorded during TERI audit showing the potential of our encon practices.

31.03

38

0

5

10

15

20

25

30

35

40

steam % cane

30

23.51

0

5

10

15

20

25

30

35

kWh per TC

Global benchmark NBV - SD

IMPROVEMENT OVER GLOBAL BENCHMARK

18 % 22 %

INNOVATIVE PROJECT

General Practice:

Rotary juice screens to remove bagacillo from juice before evaporation.

Limitations with Rotary juice screen:

Separation of bagacillo particles less than 0.32 mm is not possible, which

affects the performance of heat exchangers and quality of sugar.

Innovation:

Incorporated an in-house designed flotation cell to overcome the limitations of the existing system.

2009-10BAGACILLO FLOTATION CELL

Rotary juice screen

Juice heaters(35 – 75 deg.C)

Bagacilloflotation cell

Liming + Sulphitation

Juice Heating(72 – 105 deg.C)

Juice clarification

Vacuum filter

Scum vibroscreenMixed

juiceScumBagacilloMud

Process before

the project

PROCESS FLOW DIAGRAM

BAGACILLO FLOTATION CELL… contd

1. Reduction in heat exchangers cleaning cycles by 57%

2. Reduction in lime and Sulphur consumption percent cane by 0.015 and 0.005 respectively

3. Reduction in sugar loss by 0.025% cane

4. Improvement in sugar quality by 15 ICUMSA

Investment in Rs. Million

Annual Savings inRs. Million

Payback Months

1.2 0.86 17

The Result:

BAGACILLO FLOTATION CELL… contd

Fuel saved : 301 Tons

2009-10

Practice before project:

Feeding high viscous massecuite to the centrifugal machinesProject Description:

Lubricated massecuite with final molasses for reducing the viscosity of the feed.

Result :

Capacity utilization of centrifugal m/cs was improved and resulted in reduction of average running hours by 37.5%.



Payback Months

0.02 0.127 1.90

ENCON PROJECT - 1

MOLASSES AS LUBRICANT

Power saved : 46337.15 kWh

2009-10


MP steam for pan cutover line washing

Project Description:

1st effect vapor is used for washing of pan cutover line

Result:

Reduction of MP steam utilization helped in saving of fuel (bagasse)



Payback Months

0.031 0.030 11.75

CUTOVER LINE WASHING WITH LP VAPOR


ENCON PROJECT - 2


Single Liquor feed line to all pans




Payback Months

0.225 0.306 8.82

2009-10MODIFICATION OF LIQUOR FEED LINES


Provided more feed lines inside the pan .

Result:

Distribution of Liquor has Improved and resulted in reduction of steam consumption due to effective pan boiling

ENCON PROJECT - 3

2009-10

Power saved : 34013 kWh



Payback Months

0.174 0.09 22.40

HIGH EFFICIENCY TRANSFER PUMPS

Practice before project :

Using two no.s of 45 m3/hr pumps with 25 HP motor for boiler feed water transferProject Description:

Replaced the pumps with energy efficient pump of 70 m3/hr with 30 HP motor.

Result:

Power saving by 40 %.

ENCON PROJECT - 4

2009-10


Installed VFD with speed control in closed loop.

Result :

Reduction in power consumption by 12.5 %



Payback Months

0.41 0.13 39

VFD FOR BOILER SA FAN


Using star-delta starter with damper control.

Power saved : 45612 kWh

ENCON PROJECT - 5



Payback Months

2.47 0.31 95

2009-10PHE FOR WASTE HEAT RECOVERY


Using shell & tube heat exchanger for raw juice heating.


Installed PHE for better heat transfer

Result :

Temperature of juice outlet improved by 6 deg.C and resulted in reduction of vapor consumption.

Bagasse saved : 240 MTPower saved : 10400 kWh

ENCON PROJECT - 6

INVOLVEMENT OF EMPLOYEES

Vice PresidentAs Advisor

Plant ManagerCertified Energy Manager

H.O.DMech.

H.O.D C & I

H.O.D Elect.

H.O.D Process

Shop Floor Engineers and Process Technologists

Team leaders

Source of ideas and implementation team

ENERGY CONSERVATION CELL

SN

Encon Idea Year of implementation

Source of idea

AnnualSavings

1 Using common pump for both “B” & “C” seed 2009-10 Chemist

18726 kWh

2 Using syrup instead of hot water for dry seed pump.

2009-10 Chemist 73 Tons Bagasse

3 CJ pump impeller resizing as per present requirement 2009-10

AM &Chemist

9576 kWh

4 Converting in-house available transformer for colony street lightning.

2009-10 Elect.supervisor

5475kWh

5 “C” light Molasses pump ON/OFF control wrt tank level

2009-10 Fitter 12540 kWh

6 Reducing pulley size of final Molasses pump to avoid running of second pump

2009-10 Fitter9200 kWh

INVOLVEMENT OF EMPLOYEESFew of the zero investment projects

SN

Encon Idea Year of implementation

Source of idea

Investment in m Rs.

AnnualSavings

6 Replacing 21 nos. of 40 W bulbs with 1W LED lights at Cont. pans.

2009-10 Elect. Supervisor 0.003

1867kWh

7 Whole cane milling

2008-09Encon cell 0.2003 Rs. 3.818

Million

8 Sulphur free sugar

2007-08Encon cell Nil Rs. 11.849

Million

INVOLVEMENT OF EMPLOYEES

OTHER ENCON PROJECTS

SNProject Name Year Power

saved in m kWh

Bagasse saved in

Tons

Annual Savings in

mRsInvestment

in mRsPayback

in Months

1 Whole cane milling 2008-09 - 3125 3.818 0.2003 0.63

2 Auto on/off control for cooling tower fan with respect to water temperature

2008-09 0.0163 - 0.043 0.01 2.77

3 Mechanical seals for pumps 2008-09 0.0328 - 0.087 0.018 2.48

4 1st vapor for C msc transient heater 2008-09 - 26 0.032 Nil Immediate

5 LED lamps (<5 w) instead of 40 W bulk head fittings

2008-09 0.00015 - 0.0004 0.0003 8.86

6 8 x 20 W CFL instead of lamps of total 640 W.

2008-09 0.0021 - 0.0055 0.0013 2.85

OTHER ENCON PROJECTS

SNProject Name Year Power saved in

m kWh

Bagasse saved

in Tons

Annual Savings in mRs

Investment in mRs

Payback in Months

13 Sulphur free sugar production 2007-08 0.8 8774.5 11.849 Nil Immediate

14 Installation of energy efficient wet scrubber and VFD for ID fans for the boiler.

2007-08 0.816 Nil 2.1522 11.99 66.85

15 Installation of 2 Nos automatic condensate recovery systems

2007-08 Nil 397.4 0.441 0.45 12.24

16 Installation of new fully automated horizontal sugar melter

2007-08 Nil 1625.6 1.804 1.655 11.01

17 Utilization of melt for B2 magma instead of water.

2007-08 Nil 414.7 0.460 Nil Immediate

TOTAL SAVINGS IN LAST THREE YEARS

1.861 m kWh 14963 Tons of bagasse

Rs . 22.82 million

MONITORING AND REPORTING

• PLC based data logging for daily energy monitoring and reporting

• 30 energy meters were installed at all important stations

• 39 flow meters for all process fluids including steam

• Non contact type ultrasonic flow meter for instantaneous monitoring

• Dynamic balancing of all rotating equipment by external agencies

• Annual energy audit by internal as well as external agencies like TERI.

• Displaying daily energy consumption figures in the plant

• Daily report to the top management

IMPLEMENTATION METHODOLOGY

Conceiving encon ideas

Feasibility study & finalization of projects by encon cell in weekly meetings

External audits

Internal audits

Employees

Project design and planning

Project implementation

Gap analysis and review for further improvement

Co-gen plant registered with UNFCCC in the year of 2008.Till date 16135 CERs accumulated and 32005 VERs have been sold.

This year CSTR anaerobic digester erection was completed and to be commissioned shortly

ENVIRONMENT CUM CER PROJECT

CSTR DIGESTER 2009 – 2010

Estimated CO2 Emission Reductions


20000 25

300 – 350 m3/hr of Bio gas can be recovered and used as fuel to distillery boiler

ENVIRONMENT PROJECT – 1

Concrete compost yard to prevent contamination of ground water through percolation

BIOCOMPOST YARD 2009-10

Area Concreted : 4 Acres Investment : Rs.30 million

BEFORE AFTER

INNOVATIVE ENVIRONMENT PROJECS

All bagasse discharge chutes were converted in to PLC based automatic motorized telescopic chutes to avoid flying of bagasse

TELESCOPIC CHUTES 2009-10

Chutes converted: 5 nos. Investment : Rs. 0.6 MillionBEFORE AFTER

ENVIRONMENT PROJECT-3

GI HOOD FOR BAGASSE CONVEYORS 2009-10

Bagasse conveyors are enclosed with GI hood to avoid flying of bagasse

Conveyors covered: 4 Nos. Investment : Rs. 0.3 million

OTHER ENVIRONMENTAL PROJECTS

• 700 saplings planted in and around the factory

• To improve the awareness on avoiding the usage of polythene bags, 400 cotton cloth bags were distributed to employees and surrounding residents.

• Painting and essay writing competitions conducted for school children on environment awareness.

2009-10

2009-10

OTHER ENVIRONMENTAL PROJECTS

• On foot rally and public meetings were conducted in Samalkot with the presence of top management on the eve of world environment day.

1. Converted ETP sludge into bio manure and issued to farmers at free of cost

• 902 MT of sludge in 2009-10• 827 & 248 of sludge in 2008-09 & 2007-08

2. Promoted boiler ash for brick manufacturing

• 2291 MT of ash in 2009-10• 1359 & 3755 MT of ash in 2008-09 & 2007-08

3. Press mud and effluent are used for producing bio compost which minimizes chemical fertilizer consumption

• 3200 MT of bio compost in 2009-10• 6700 & 4800 MT of bio compost in 2008-09 & 2007-08

UTILIZATION OF WASTE

4800

6700

3200

2000

3000

4000

5000

6000

7000

2007-08 2008-09 2009-10

BIO-COMPOST IN MT

ORGANIC FERTILIZER WITH WASTE

Due to reduced opeational days

ETP SLUDGE AS BIOMANURE

902827

248200

400

600

800

1000

2007-08 2008-09 2009-10

ETP sludge as biomanure

31.72

27.18 27.13

26

28

30

32

2007-08 2008-09 2009-10

Lubricant ml/TC

LUBE OIL CONSUMPTION

DAILY ENERGY MONITORING FORMAT

5%

10%

10%22%

2%

11%

5%

25%

10%

Energy conservation measures Quality & raw material management

Analyzing competitors profile Materials management

Manufacturing excellence Technology implementation

Environmental concern Financial management

General administration

TIME SPENT BY TOP MANAGEMENT

TIME SPENT BY TOP MANAGEMENT…contd

Paper presentation on

“Excellence in Energy Management”

in 9th Joint Convention

of STAI & SISSTA at

Chennai Trade Centre

on 19.08.2010

INTERNATIONAL & NATIONAL VISITS

REPLICATION FROM BEST PRACTICES

1. Drip irrigation :

Encouraged farmers in implementing the practice of drip irrigation.

As on date system implemented in 130 acres and the results are

• Reduction in water consumption by 45 %

• Improvement in yield by 20 %

• Reduction in need of fertilizer by 25 %

• Reduction in electrical power consumption by 25 %

Industry got benefited in terms of cane quality

REPLICATION FROM BEST PRACTICES…contd

2. ENERGY EFFICIENT TRANSPORTATION:

About 300 vehicles (Lorries & Tractors) are being used to meet crushing requirement.

Use of efficient vehicles resulted in improved mileage by 0.5 km / ltr

thereby saved 642 lts of fuel per day.

Annual saving : Rs. 2.3 million

Industry got benefited in terms of consistency in cane supply and reduction of transport reimbursement.

FUTURE PROJECTS

1. Planetary gear boxes for new mill, rake elevator and bagasse elevator

Estimated annual power saving : 400,000 kWh

2. Replacing existing two no.s of 160 kW boiler feed water pumps with a 220 kW energy efficient feed water pump and motor


3. Replacing 24 no.s of motors with EFF-1 motors


4. VF drives for common condensate pumps


FUTURE PROJECTS…contd

5. VF drives for ‘C’CVP massecuite and magma pumps


6. VF drive for cooling tower fan


7. Using PHE in series with shell & tube juice heater for waste heat recovery

Estimated fuel savings : 531 Tons

S.N

Non-conformity Corrective action Preventive action

1 No evidence for noise level monitoring for DG sets

Monitored noise levels with the aid of external agency

Schedule for monitoring noise levels prepared.

2 No evidence of identifying applicable legal requirement for storage of LPG gas

Informed to dealers to know the legal requirement

Awareness program conducted for all HODs for identifying legal requirement in their respective depts.

3 No evidence of monitoring particulate matter of sizes 10 micron and 2.5 micron as per APPCB consent

Received reports of January audit and submitted for compliance

Added in Check list

CORRECTIVE & PREVENTIVE ACTIONSFrom ISO 14001 certification

AWARDS AND CERTIFICATIONS

Best Technical Efficiency Award by SISSTA 2010

Excellent Energy Efficient Unit Award by CII 2007,2008 & 2009

Innovative Project Award by CII 2008

Best Performing Cogeneration Factory in Andhra Pradesh by SISSTA

2008

5 S Excellence Award by CII 2007

THANK YOU

nbv-sd 2009-10 with out rs symbol...company profile nava bharat ventures limited (nbv) is a...

Documents