19 th National Award for Excellence in Energy Management E.I.D-Parry (India) Limited, Nellikuppam.

Transcription

1 19 th National Award for Excellence in Energy Management 2018 E.I.D-Parry (India) Limited, Nellikuppam. 8/31/2018

2 Murugappa group 28 Business 295 2

3 EID Parry Nellikuppam First sugar plant in India 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 First cane sugar factory in the world to practise TPM 3

4 Our Certifications British Pharmacopeia ISO Halal Accreditations & Certifications ISO US Pharmacopeia Indian Pharmacopeia FSSC /31/2018 8/31/2018 E.I.D-PARRY (INDIA) LIMITED, NELLIKUPPAM 4

5 Understanding Sugar process Sugarcane Juice Syrup Sugar Bagasse Press mud Molasses Primary By Products Value added Products 5 Cogen. Power Plant Organic Manure Alcohol

6 Energy Conservation Activities FY S. No Year of Execution Energy Saving Project Evaporator syrup brix improvement by modifying the juice distribution system. Annual Savings (Rs. In Lakh) Sugar recirculation avoided by altering the grader transfer points Usage of first vapour for heating treated juice reduced by 50 % by adding a new direct contact heater for second body vapour Installation of VFD for condensate Extraction Pump Installation of VFD for Submergible belt conveyor in Cogen both boilers Installation special alloy multi nozzle roller in 4th mill Injection Header modification by eliminating separate pump for evaporator Eliminating sugar grader operation during Raw sugar producction /31/2018 Contd.,

7 Energy Conservation Activities FY S. No Year of Execution Energy Saving Project Annual Savings (Rs. In Lakh) Improvement in refinery input melt brix from 60 to 64 Reduction of steam consumption by 0.1 Ton/Ton of Refined Sugar Output Second body vapor Bleeding for 8 hrs/day to refinery operation - Reduction of steam consumption by 0.15 Ton/Ton of RSO Evaporator syrup brix improvement by challenging the standard operating Procedure Replacement of electric strip heater with hot water coil system in VAM Eliminated 12 KW/hr power consumption Waste Heat Recovery from Sugar second body condensate Utilization of Bio-gas from Bio digester /31/2018 Direct pumping of sugar first body condensate to Cogen deaerator instead of Feed water storage tank Contd.,

8 Energy Conservation Activities FY S. No Year of Execution Energy Saving Project Annual Savings (Rs. In Lakh) Replacement of NK 1503 B centrifugal machine to WK Refinery AHU strip heater system replaced with Condensate coil system Fibrizer Anvil Plate Modification-Power saving Case Study Refinery candle filter lined up in Filter Feed pump with VFD drive Refinery PAN boiling vaccuum generating with body washing Condensate Recovering from ATFD to Dist. Thermax Boiler Case Study-3 Elimination of 5 HP molasse pump (2 Nos.) by introducing one 7.5 HP pump VFD for Cogen Cooling Tower fan /31/2018 Contd.,

9 Energy Conservation Activities FY S. No Year of Execution Energy Saving Project Case Study-2 Annual Savings (Rs. In Lakh) Mill Automation Steam trap capacity resizing in RC column Reboiler Case Study CO2 generation automation B-Massecute Pump VFD installation Air Compressor Header Modification Elimination of intermediate belt conveyor in Refinery Feed Centrifuge Elimination of Slat conveyor during coal operation by introducing new conveyor /31/2018

10 Reduction in Thermal Energy Consumption (Steam % Cane) /31/2018

11 Reduction in Electrical Energy Consumption (KWH / MT of Cane) /31/2018

12 Comparison with global benchmarks Parameters National Bench Mark Global Bench Mark EID Nellikuppam Achievement Specific Thermal Energy Consumption % 38 % As per ISSCT proceedings % Specific Electrical Energy consumption 28 kwh / ton of cane kwh/ton of cane As per NFCSF kwh / ton of cane 8/31/2018

13 A Whopping reduction in Thermal Energy Steam % Cane prior to Implementation % Steam % Cane post to Implementation 33.27% A Saving of 1.42 % of Thermal energy In terms of money.. A saving of Rs.542 Lacs 8/31/2018

14 A Whopping reduction in Electrical Energy / MT of Cane Power/MT of cane prior to Implementation Power/MT of Cane post to Implementation KWH KWH A Saving of 1.44 Units of Electrical energy In terms of money.. A saving of Rs.201 Lacs 8/31/2018

15 Case Study -1 Energy Conservation in Fibrizer E.I.D-PARRY (INDIA) LIMITED 15

16 PROBLEM / PRESENT ISSUES 5 W 1 H METHOD What Where : Power Consumption high : Fibrizer Motor operation (1000 & 1500 KW, HT) When : Cane Cell Opening to maintain Pre. index 92%. Who Which How : Anvil Plate. : Cane travel surface contact is 170 Degree. : Power consumption of the Motors are high E.I.D-PARRY (INDIA) LIMITED 16

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 17

18 BEFORE Anvil Plate Setting: 1.In let opening 292mm; Middle opening: 144mm and cane discharge end 40mm. COUNTER MEASURE DETAILS AFTER 2. Anvil plate surface contact angle : 170 Anvil Plate Setting: 1.In let opening 280mm; Middle opening: 40mm and cane discharge end 500mm. 2. Anvil plate surface contact angle : 85 E.I.D-PARRY (INDIA) LIMITED 18

19 Fibrizer Power / MT of Cane (KWH) Fibrizer Power Consumption Trend Cost benefit Rs Lakhs GOOD

20 Case Study -2 Mill Automation Donnelly chute 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.

21 Analysis of Mill tripping Mill is getting tripped Why? Over load Why? Level controller, reduces the Mill RPM in order maintain the level as per SP Amps control is not there Why? Why? Weak design

22 Theme KAIZEN IDEA BEFORE AFTER Eliminate frequent tripping of Mill 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 Analysis: 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 MILL OPERATED BASED ON DONNELYY CHUTE LVEL MILL OPERATED BASED ON BOTH DC LEVEL & MILL LOAD Counter Measure : New logic is made, considering both DC Level & Amps Pol Loss in Bagasse (%) GOOD

23 IMPLEMENTATION STEPS

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25 IMPLEMENTATION STEPS

26 BENEFITS FROM PQCDSM Cane Crushing Increased 6200 TO 7000 Tons/Day Additional Income Rs.38 Lakhs/Year Pol Loss in Bagasse (%) Ichute jamming decreased 5 to 0 Occurrence Before 0 After 5000 Before After 27

27 Case Study -3 Steam Conservation in ATFD Flash Steam recovering in Agitated Thin Film Drier INTEGRATED EVAPORATOR BMSW EVAPORATOR-II & AGITATED THIN FILM DRYER K-POTTASH AS A FERTILIZER

28 STEAM IN STEAM IN (FLASH VAPOR) POWDER K - BOOST 55 TO 60 Deg.C 74 TO 78 Deg.C Multiple effect evaporator

29 STEAM IN STEAM IN 100Deg.C (0.2 kg/cm2) POWDER K - BOOST SP- 0.4Kg/cm2 (FLASH VAPOR) PCV PID SP- 0.2Kg/cm2 55 TO 60 Deg.C 74 TO 78 Deg.C

30 RE-BOILER

31

32 BENEFITS FROM PQCDSM K Boost Productivity Increased 12 to 15 Tons/Day Additional Income Rs Lakhs/Year Before After Before After 33

33 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 Covered in Case Study 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 Covered in Case Study -5 8/31/2018

34 Case Study -4 Utilization of Renewable Energy Sources CO 2 AUTOMATION IN DISTILLERY FERMENTATION PROCESS MOLASSES FERMENTATION PROCESS CO 2 GENERATION CO 2 PROCESS & STORAGE

35 PROBLEM FACED From the generation of CO 2 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. 36

36 STRATIFICATION OF PROBLEM - CO 2 RECOVERY 5. Once visually confirmed the manhole door was closed and CO 2 passes through the scrubber. CO 2 RECOVERY PLANT 1. MOLASSES filling started CO 2 Loss in visual inspection 4. CO 2 gas generation were observed visually by operator in Manhole door. 3. Slowly pressure buildup in Fermenter 6. In scrubber, purity and pressure has been confirmed, if it reaches the norms then will started the blower and the gas drive to CO 2 recovery plant. FERMENTER 2. Within one hour CO 2 gas generation started CO 2 SCRUBBER 7. This routine process take minimum 3 to 4 hrs to finding the pressure buildup for each fermenter, which leads to loss of CO 2, so unable to recover all the CO 2 generated in fermenter. 37

37 PROBLEM IDENTIFICATION 5 W 1 H METHOD WHY-WHY ANALYSIS What : CO 2 recovery rate not achieved. Where : Fermentation section When : Every day. Who : Fermentation Operator. Which : CO 2 recovery rate low How : Recovery of kgs/day. Why 1 : CO 2 recovery rate from fermentation is low. Why 2 : CO 2 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. 38

38 KAIZEN IDEA SHEET Machine: FERMENTATION SECTION Kaizen Idea: Enhancement of CO 2 BEFORE Recovery AFTER Problem: What Where When Who Which How Why-Why analysis: : CO 2 recovery rate not achieved. : Fermentation section. : Every day. Problem Phenomena: Why 1 Why 2 Why 3 Why 4 Why 5 : Fermentation Operator. : CO 2 recovery rate low. : Recovery of kgs/day. : CO 2 recovery rate from fermentation is low. : CO 2 losses in fermentation operation. : Manual operation of checking & valve operation. : No facility to operate with the pressure based system. : Weak design. Problem: Losses of CO 2 Root Cause: Manual operation. Results: KAIZEN MECHANISM Result: Productivity increased Counter Measure: Automation Additional Revenue of Rs Lakhs/annum. 39

39 WAY FORWARD AUTOMATION IMPLEMENTATION 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 IMPLEMENTATION STEPS FOR AUTOMATION Concept development Approval from Top Management Finalizing the vendor & materials Erection and commissioning 40

40 ACTION TAKEN Provided auto pressure control valve in the CO2 gases outlet line from fermenter. Incorporated automation and interlock system in the fermenter between pressure and level (volume). Once volume increase in fermenter, the CO 2 generation also increased. After automation, pressure reaches to 100 MMWC, the CO 2 outlet valve get automatically open and passed through scrubber. After implementation of automation, Time taken purity & pressure identification in fermenter had reduced from 3-4 hrs to hrs to attain the purity. 41

41 Productivity Increased 22 to 30 Tons/Day BENEFITS FROM PQCDSM Additional Income Rs.58.8 Lakhs/Year Inspection time decreased 3.0 to 0.5 Hrs/Day 42

42 Case Study-5 Condensate Polishing Unit Moving Towards Zero liquid discharge Sugar

43 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.

44 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.

45 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.

46 Design Philosophy Inlet water parameters considered

47 Condensate Polishing Unit Process Flow chart Equilization tank Acticontact tank Clarifier Pressure sand filtration Dual media filtration Ultra filtration

48 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.

49 Advantages of ACTICONTACT design

50 CPU ACTI CONTACT TANK

51 CLARIFIER

52 FILTERS

53 WATER SAMPLES Common condensate 2. Secondary Clarifier outlet 3. UF outlet

54 Treated water parameters Usage of treated water Boiler feed in the place of raw water. Boiler cooling tower. Distillery use.

55 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 8/31/2018

56 TANGIBLE & INTANGIBLE BENEFIT 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. 8/31/

57 Participation by down the line shop floor personal in implementing ENCON ideas S.No. 1 ENCON Idea Sugar recirculation avoided by altering the grader transfer points. Year of Annual savings Implementation Source of Idea Rs.in Lakh Fitter Usage of first vapour for heating treated juice reduced by 50 % by adding a new direct contact heater for second body vapour Pan Officer Variable Frequency Drive for condensate Extraction Pump Electrical Supervisor Injection Header modification by eliminating separate pump for evaporator Shift Chemist Reusing of Boiler blow down water Shift Chemist Sugar lumps quantity reduction during bin cleaning by polishing the bin internals Engg Supervisor /31/2018

58 Participation by down the line shop floor personal in implementing ENCON ideas S.No. ENCON Idea Year of Implementation Source of Idea Annual savings Rs.in Lakh 7 ATFD condensate recovery improvement Engg Supervisor Variable Frequency Drive for Sulphur burnor blower Electrician B Grain pump with VFD Shift supervisor B-Massecute Pump VFD installation Pan Officer Air Compressor Header Modification Engg. Supervisor Elimination of intermediate belt conveyor in Refinery Feed Centrifuge Elimination of Slat conveyor during coal operation by introducing new conveyor Elimination of BC-8 & BC-9 by introducing new coal conveyor Shift Chemist Boiler operator Shift electrician /31/2018

59 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

60 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

61 Energy Conservation Monitoring & reporting flow meters for all process fluids including steam 2. DCS based data logging for daily energy monitoring and reporting 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

62 Energy Management monitoring methodology 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 Energy savings is our prime motto 8/31/2018 Monthly employee productivity linked incentives

63 National Excellent Energy Efficient Unit Award on 2016 & 2017

64 Awards and Recognitions. CII Environmental Best Practice Award-2017 Platinum Award- for the Best Technical Efficiency for Sugar Platinum Award for the Best Distillery for Distillery 8/31/

65 8/31/