E.I.D.-Parry (India) Limited, Pudukottai, Tamilnadu 18th NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT - 2017 1
Murugappa Group Overview 2
E.I.D.- PARRY (INDIA) LIMITED 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 EID PARRY BUSINESS SUGAR DIVISION BIO-PRODUCT DIVISION NUTRA DIVISION SUGAR COGENERATION DISTILLERY TN, KARNATAKA, AP & PONDY 39800 TCD TN, KARNATAKA, AP & PONDY 153 MW TN, KARNATAKA, AP 225 KLPD 3
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 4
ENERGY POLICY 5
Understanding Sugar products Sugarcane Juice Syrup Primary Bagasse Press mud Molasses By Products Value added Products Cogeneration Power plant Organic Manure Alcohol / cattle feed 6
Comparison with global benchmarks Parameters Global Bench mark EID 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) 7
Innovation in Projects Implemented Innovative Ideas Project Description BENEFITS ACHIVED Introduction of additional juice drainage area on mill rollers Effective Utilization of Compressed air by installing air pressure booster. Elimination of re-absorption of juice resulting in reduction of pol % bagasse & Moisture % bagasse Power Saving in Air Compressor operation. Rs. 0.95 Lacs / day Rs. 190.00 Lacs / annum 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 8
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. 9
Innovative Project 01 Loss Reduction Single row Nozzle Drainage nozzles Triple row Nozzle 554 Nozzles Drainage pipe 1662 Nozzles Introduction of additional juice drainage area on mill rollers 10
Pol%bagasse Moisture % Bagasse Innovative Project 01 Loss Reduction Results achieved : 50 4 9. 5 49 4 8. 5 48 47.5 Moisture % Bagasse 49.71 48.45 Moisture % bagasse reduced from 49.71 % to 48.45 % Saving Amount Rs. 70 Lacs for 3 Lacs MT Crushing Before After 2 1.5 1 0.5 0 1.82 Pol % Bagsse 1.38 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 Before After 11
Innovative Project - 02 Power 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. 12
Innovative Project - 02 Power Saving - Air Compressors Replacement of reciprocating compressor by VFD operated screw compressor Savings 1010 units/day Reciprocating Compressor Without VFD Plant Instrumentation Air requirement @ 6.0 Kg/Sq. CM Screw Compressor With VFD Plant Instrumentation Air requirement @ 6.0 Kg/Sq. CM Inst. Air Compressor (Reciprocating) _ With out VFD Ash Handling Air Compressor (Reciprocating) With out VFD Plant Ash handling Air requirement @ 4.50 Kg/Sq.CM 4 Nos Compressors 93 KW 2 Nos 45 KW 2 Nos Power Consumption 3312 units/days Inst. Air Compressor (Screw) With VFD Pressure Regulating Valve Plant Ash handling Air requirement @ 4.50 Kg/Sq.CM 2 Nos Compressors (1No. with standby) 95 KW 2 Nos 13 Power Consumption 2302 units/days
Instrument Air Pressure Reduction Regular Operation Centrifugal area Instrumentation Air requirement @ 6.0 Kg/Sq. CM Innovative Project - 02 Power Saving - Air Compressors Plant Instrumentation Air requirement @ 6.0 Kg/Sq. CM With Pressure Booster Operation Pressure Booster Centrifugal area Instrumentation Air requirement @ 6.0 Kg/Sq. CM Common Plant Instrumentation Air requirement @ 5.0 Kg/Sq. CM Inst. Air Compressor (Screw) With VFD @ 6.0 Kg/Sq. CM Pressure Regulating Valve Plant Ash handling Air requirement @ 4.50 Kg/Sq.CM Power Savings 300 units/day Inst. Air Compressor (Screw) With VFD @ 5.0 Kg/Sq. CM Pressure Regulating Valve Plant Ash handling Air requirement @ 4.50 Kg/Sq.CM 14
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). 15
Innovative Project - 03 (Stopping of vacuum filter operation) Process Failure Mode Effect Analysis (PFMEA) 16
Scheme: Innovative Project - 03 (Stopping of vacuum filter operation) Data: Power Saved Cost Saving Trail Running days = 6221 Kw = Rs.254046/- = 5 Days 17
SPECIFIC ENERGY CONSERVATION 18
Units / Ton SEC REDUCTION PERCENTAGE Sugar - Power 50 Due to Low rate of Cane Crushing & Intermittent stoppage - want of Cane raised out of CHL issues 45 40 35 30 25 20 27.25 27.06 29.04 30.59 13-14 14-15 15-16 16-17 Special Financial Year 27.61 16-17 Main 26.63 17-18 Special Power Consumption / Tones of Cane 25 17-18 Main Plan Global Bench Mark 28 KW / MT 19
% SEC REDUCTION PERCENTAGE Sugar - Steam Due to Low rate of Cane Crushing & Intermittent stoppage 40.00 39.39 39.25 38.00 36.28 36.87 36.93 36.00 34.00 34.86 34 32.00 13-14 14-15 15-16 16-17 Sp 16-17 Financial Year main 17-18 Sp 17-18 Main Plan Steam % on cane crushed Global Bench Mark 34% 20
% SUGAR PLANT PERFORMANCE Reduced rate of crushing based on Cane availability during 2015-16 & 2016-17 4000 3500 3000 2500 2000 3417 2844 2354 2074 3258 2743 1500 13-14 14-15 15-16 16-17 Sp Financial Year 16-17 Main 17-18 Sp Average cane crushed per tons per day 21
MW / HR COGENERATION PLANT PERFORMANCE Power Generation & Export MW / HR 16.00 14.00 12.00 10.00 8.00 13.77 9.17 14.82 9.78 11.31 7.20 10.26 7.64 12.66 8.74 6.00 4.00 2.00 0.00 2012-13 2013-14 2014-15 2015-16 2016-17 YEAR Power generation MW / HR Power export MW / HR 22
% SEC REDUCTION PERCENTAGE Cogen Aux. Power Cogen Auxiliary Power Consumption % On Generation As per STOA from TNEB, power export quantum restricted to < 30 % which resulted in higher Aux Power 12.00 11.00 10.00 9.75 9.63 8.50 @ 16-17 Main 9.00 8.00 9.04 8.44 8.34 8.25 7.00 6.00 13-14 14-15 15-16 16-17 17-18 Sp 17-18 Plan Financial Year 23
Kg of Steam / Kg of Bagasse SEC REDUCTION PERCENTAGE Cogen Steam Fuel Ratio As per STOA from TNEB, power export quantum restricted to < 30 % which resulted in Lower SFR 3.00 2.75 2.50 2.25 2.00 1.75 1.50 2.46 2.46 2.42 2.41 2.47 @ 16-17 Main 2.49 2.55 13-14 14-15 15-16 16-17 17-18 Sp 17-18 Plan Financial Year Steam Fuel (Bagasse) Ratio (Kg of steam/kg of Bagasse) 24
Energy Saving Projects 25
Investment on Encon Projects in the Year 2016-2017 Case Study No Projects Investement (Rs in Lacs) 1 Thermal Saving 6.97 2 Power Saving 5.07 3 Expense 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 Turnover 0.155% 26
Key Energy Saving Projects Implemented in the Year 2016-2017 Description THERMAL SAVINGS Number 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 Description POWER SAVINGS Number 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 27
Energy Conservation Measures taken FY 2016-17 (Thermal) Sl. No. 1 Title of Project Reduction in Hot condensate wastage by changing the Sampling method. Annual Savings (Rs Lacs) Investment (Rs Lacs) 0.85 1.00 2 Improved Thermal Insulation in boiler 6.40 2.97 3 Elimination of vacuum filter operation fromsugar processing 2.54 3.00 4 Alternative Bio mass fuel - Wood Bark 42.95 0.00 Total 52.74 6.97 28
Energy Conservation Measures taken FY 2016-17 (Power) Sl. No. 1 2 3 Title of Project Replaced Worm& worm wheel gear box (30 KW) with helical gear box in Rake carrier (Saving 4.0 Kwh/Hr) Fixed Transparent roof sheet in sugar Godown Lighting load reduced during day time Pneumatic pressure booster is installed to raise the air pressure for Centrifugal machine Instrument air system. Annual Savings (Rs Lacs) Investment (Rs Lacs) 0.80 0.50 0.63 1.00 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 6 Domestic water consumption reduction (50 TPD) 0.54 1.13 29
Energy Conservation Measures taken FY 2016-17 (Power) Sl. No. 7 Title of Project LED Issued to employees during Safety Day Celebration Annual Savings (Rs Lacs) Investment (Rs Lacs) 1.41 0.21 8 WTP flushing water re-usage 0.03 0.05 9 10 Lighting control during Off season (Provided only focus lamps in walk way area) Switch off standby UPS system for DCS to reduce the power loss during Off-season 8.42 0 0.42 0 Total 15.00 5.09 30
Key Energy Management Improvements 2014-2016 Sl. No Financial year Projects Actual Cost Saving (Rs in Lacs) 1 Thermal Saving 58.31 2015-2016 2 Power Saving 20.69 3 Thermal Saving 102.15 2014-2015 4 Power Saving 11.79 31
Encon Team Work & Projects 32
ENERGY CONSERVATION CELL Sr. Vice President As Adviser Resource Leaders Sr. General Manager H.O.D (Engg) H.O.D (Process) H.O.D (Cane) Department Head Engg Process Co-gen * Elect * INST Source of ideas and implementation team Shop Floor Engineers and Process Technologists along with Team Members Note : * Certified Energy Auditor 33
S.N o Financial years 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. Major No: of ENCON Projects Annual savings Rs in Lacs Capital Investment (Rs. In Lacs) 1 2016-2017 6 47.58 4.01 2 3 2015-2016 2014-2015 9 55.62 15.33 6 91.14 45.20 4 2013-2014 3 6.72 3.0 Total 24 201.06 67.54 34
Encon Monitoring Methodology 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 35
Encon Monitoring Methodology Frequency Report Reviewed By Hourly All Energy Consumptions like Shift Engineer Sp. Thermal & Power Consumption for Sugar & Cogen Plant Shift wise All Energy Consumptions like Department Head Sp. Thermal & Power Consumption for Sugar & Cogen Plant Daily All Energy Consumptions like Unit head Sp. Thermal & Power Consumption for Sugar & Cogen Plant Monthly All Energy Consumptions like Sp. Thermal & Power Consumption for Sugar & Cogen Plant Business Group Management Committee (Business head & EID s Function head) 36
Encon Monitoring Methodology Sample Power Monitoring report 37
Road Map for future Encon Activities FY 2017-18 FY 2019-20 Steam % Cane 30 Power/MT cane 22 Steam fuel ratio 2.55 Aux Power % - 8.00 FY 2021-22 Steam % Cane 30 Power/MT cane 20 Steam fuel ratio 2.8 Aux Power % - 7.60 Steam % Cane 34 Power/MT cane 25 Steam fuel ratio 2.5 Aux Power % - 8.25 FY 2018-19 Steam % Cane 32 Power/MT cane 24 Steam fuel ratio 2.55 Aux Power % - 8.10 FY 2020-21 Steam % Cane 30 Power/MT cane 20 Steam fuel ratio 2.8 Aux Power % - 7.80
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 2 Bagasse moisture reduction unit to be provided in the outlet of first & fifth mill. 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 4 1.VLJHReplacing with PHE both series. 2.By providing DCH system in juice heater 50 Lacs 40 Lacs 360 lacs 100 Lacs Reduction in pol% bagasse from 1.35 to 1.00 Reduction in moisture% bagasse from 48.50 to 47.0 Reduction in Power per ton of cane from 29 to 20 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) 6 Baggasse Drying System CF fan, 2 No. Belt Conveyors, Cyclone Chamber, Back Filter and Ducting 15 Lacs Reduction in Power consumption by 15 % 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 1 Introducing 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 5 6 7 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. Introducing Planetary gear box for 5 nos of equipments to save power of 17.5 Units/Hr. 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. Process modification and Introduction of Automation in various areas to save power and steam consumption. 41
Utilization of Waste Materials as fuel Following Waste Bio mass as fuel in our boiler for generating power Till date 12320MT Bio waste fired 1. Match Box Waste 2. Eucalyptus Wood Bark 3. Juliflora Thorns 4. Juliflora Chips 5. Pencil wood waste 6. Wood Industry waste 7. Pressmud 42
Waste utilization 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. 43
Renewable Energy 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. Solar Powered Irrigation pumping system (10 HP) in cane forms are being installed widely in our command area of 25000 acers. 44
Green House Gas Emission Reduction CO 2 Emission Reduction: 500 no Trees planted inside the plant towards the target of 1000 Nos for the year Reduced the Fuel consumption for the same power production by reducing the Specific steam consumption. ( From 5.49 to 5.34 ) Co-Gen Captive power consumption is reduced from 9.75 % to 8.34%. 45
Moving towards digital India Green House Gas Emission Reduction (Paperless office & Diesel Consumption Reduction) By introducing I-Cane software we have created Paperless office for cane management. I-Cane - Plot MAP With Measurement Details 40 % of time spent on traveling by cane staff reduced by this Application usage 46
Green House Gas Emission Reduction (Paperless office & Diesel Consumption Reduction) Pest Affected Field Captured by I-Cane Mobile (Paperless Office) 47
Green House Gas Emission Reduction (Paperless office & Diesel Consumption Reduction) (Paperless Office) I-Cane-Digital Task Scheduler 48
Way forward towards Green House Gas Reduction 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 49
Best Practices Replicated on Energy front in Green Supply Chain 1. Drip irrigation / Micro irrigation for cane cultivation to preserve water & save pumping Electrical Power 50
Best Practices Replicated on Energy front in Green Supply Chain 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 51
Green Supply chain Recycling and Reuse 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. 52
CII AWARD FOR ENERGY MANAGEMENT 2016 & 2014 53
CII AWARD FOR EXCELANT ENERGY MANAGEMENT - 2015 54
NATIONAL ENERGY CONSERVATION AWARD 2014 FROM BUREAU OF ENERGY EFFICIENCY, GOVERNMENT OF INDIA National Level second Prize (Silver Shield) Receiving Shield from Hon ble Minister of Power Mr. PIYUSH GOYAL at New Delhi 55
Group level Best Cogen Award - 2017 56
TPM Awards 57
Best Performing Company Winner in the Sugar Sector for the Dun & Bradstreet Corporate Awards 2016 58
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