21-09-2019
PARTICIPANTS : S.VIJAYAN – Manager (Process) K.BHAKIYARAJ – Manager (Process) K.THIRUNAVUKKARASU – Manager (Engg)
VISION: “Enriching & Energizing lives by creating Value added products from AGRICULTURE (Sugar)” 1
ABOUT OUR GROUP
32,000 Employees | 28 Businesses | One Group
• EID Parry is the flagship company of the Murugappa Group • 228 years old!! • Pioneers in: - Sugar from 1842. - Distillery from 1848. - Sanitary ware from 1906. - Fertilizers from 1906. - Sugar Based confectionery from 1914. - Biogas and Bio earth 1987. - Bio-pesticides from 1995. - Co-generation Power for GRID from 1997. - Algal Neutraceuticals from 1997 - Branded sugar from 2004.
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ABOUT OUR FACTORY
➢ Our Nellikuppam unit was set-up the country's first sugar plant established First cane in year – 1842 & Distillery operation started on year – 1848. sugar factory in ➢ A fully integrated complex with Sugar, Refinery, Co-Gen, Distillery, Fertilizer world to plant & CO2 Production. practise TPM SUGAR CO-GEN FERTILIZER PLANT 7500 Tons Crushing / 24.5 Mega Watt Hr 45 Tons/Day Day
REFINERY DISTILLERY CO2 PLANT 190 Tons Sugar/Day 75 Kilo Ltrs / Day 30 Tons/Day
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OUR CERTIFICATIONS ARE UNIQUE IN INDIA
We are the first Indian sugar company having Pharma Licenses & Quality E.I.D PARRY (INDIA) LTD 4
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RECAP OF CONVENTIONAL SYSTEM SUGAR & DISTILLERY
SUGAR CANE MILLING SECTION JUICE CLARIFICATION FILTERATION EVAPORATION SYRUP CLARIFICATION BY-PRODUCTS
BAGASSES PRESSMUD FINAL PRODUCT GRADING CENTRIFUGATION CRYSTALLIZATION
COGEN-POWER BACK TO SOIL MOLASSES FERMENTATION DISTILLATION ALCOHOL
POTASH RICH BMSW EVAPORATOR-II & ATFD INTEGREATED EVAPORATOR BMSW RO PLANT BIO-DIGESTER BIO-GAS BOILER FERTILIZER E.I.D PARRY (INDIA) LTD 5
FOOD, BEVERAGES AND CONFECTIONARY CUSTOMERS
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PHARMA CUSTOMERS
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ENERGY CONSERVATION ACTIVITIES – FY 2016-17
Year of Annual Savings S. No Energy Saving Project Execution (Rs. In Lakh)
Improvement in refinery input melt brix from 60 to 64 – Reduction of steam consumption 1 2016-17 37.40 by 0.1 Ton/Ton of Refined Sugar Output.
Second body vapor Bleeding for 8 hrs/day to refinery operation - Reduction of steam 2 2016-17 56.10 consumption by 0.15 Ton/Ton of RSO.
3 2016-17 Evaporator syrup brix improvement by challenging the standard operating Procedure 208.89
Replacement of electric strip heater with hot water coil system in VAM – Eliminated 12 4 2016-17 3.45 KW/hr power consumption
5 2016-17 Waste Heat Recovery from Sugar second body condensate 104.13
6 2016-17 Utilization of Bio-gas from Bio digester 104.90
Direct pumping of sugar first body condensate to Cogen deaerator instead of Feed water 7 2016-17 105.27 storage tank
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ENERGY CONSERVATION ACTIVITIES – FY 2017-18
Year of Annual Savings S. No Energy Saving Project Execution (Rs. In Lakh)
8 2017-18 Replacement of NK 1503 B centrifugal machine to WK 1500 16.70
9 2017-18 Refinery AHU-35000 strip heater system replaced with Condensate coil system 1.30
10 2017-18 Fibrizer Anvil Plate Modification-Power saving 37.11
11 2017-18 Refinery candle filter lined up in Filter Feed pump with VFD drive 1.30
12 2017-18 Refinery PAN boiling vaccuum generating with body washing 2.51
13 2017-18 Condensate Recovering from ATFD to Dist. Thermax Boiler 27.38
14 2017-18 Elimination of 5 HP molasse pump (2 Nos.) by introducing one 7.5 HP pump 1.00
15 2017-18 VFD for Cogen Cooling Tower fan 1.30
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ENERGY CONSERVATION ACTIVITIES – FY 2017-18
Year of Annual Savings S. No Energy Saving Project Execution (Rs. In Lakh)
16 2017-18 Mill Automation 50.00
17 2017-18 Steam trap capacity resizing in RC column Reboiler 44.37
18 2017-18 CO2 generation automation 58.80
19 2017-18 B-Massecute Pump VFD installation 1.34
20 2017-18 Air Compressor Header Modification 9.06
21 2017-18 Elimination of intermediate belt conveyor in Refinery Feed Centrifuge 9.54
22 2017-18 Elimination of Slat conveyor during coal operation by introducing new conveyor 4.30
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ENERGY CONSERVATION ACTIVITIES – FY 2018-19
Year of Annual Savings S. No Energy Saving project Implementation Rs. in Lakh
23 2018-19 Installed just adequate capacity high efficiency Cooling water PumpCovered at cogen in case. study - 1 38.46
24 2018-19 Energy saving projects by Utilization of Waste Heat recovery Covered in case study - 2 122.0
25 2018-19 Sugar recirculation avoided by altering the grader transfer points. 3.38
Usage of first vapour for heating treated juice reduced by 50 % by adding a new direct 26 2018-19 2.25 contact heater for second body vapour.
27 2018-19 Installation of VFD for condensate Extraction Pump-2 2.16
28 2018-19 Installation of VFD for Submergible belt conveyor (Both Boiler) 1.29
29 2018-19 Installation special alloy multi nozzle Lotus roller in 4th mill Covered in case study - 3 279.27
30 2018-19 Injection Header modification by eliminating separate pump for evaporator 18.56
31 2018-19 Eliminating sugar grader operation during Raw sugar production 0.23
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REDUCTION IN THERMAL ENERGY CONSUMPTION (STEAM % CANE)
50
45
40.89
40.54
40.33
39.90 39.39
40 38.56
38.00
35.22
34.69
33.68
33.50
% 33.27 35 33.18
30
25
20 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 Series1 40.89 40.54 40.33 39.90 39.39 38.56 38.00 35.22 34.69 33.68 33.50 33.27 33.18
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REDUCTION IN ELECTRICAL ENERGY CONSUMPTION (KWH / MT OF CANE)
40.00
35.00
30.58
30.18
29.58
29.30 28.72
30.00 28.30
26.00
25.98
25.15
24.74
24.51
23.71 23.57
% 25.00
20.00
15.00
10.00 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 Series1 30.58 30.18 29.58 29.30 28.72 28.30 26.00 25.98 25.15 24.74 24.51 23.71 23.57
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COMPARISON WITH GLOBAL BENCHMARKS
National Global Bench EID – Nellikuppam Parameters Bench Mark Mark Achievement
38 % Specific Thermal As per 38-40 % Energy Consumption ISSCT proceedings 33.18 % 2005
Specific Electrical 28 27-28 kWh/ton of 23.57 Energy consumption kWh / ton of cane kWh / ton of cane cane As per NFCSF
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A Whopping reduction in Thermal Energy A Whopping reduction in Electrical Energy / MT of Cane Steam % Cane prior to Power/MT of cane prior to Implementation 33.68 % Implementation 24.74 KWH
Steam % Cane post to GOOD Power/MT of Cane Implementation 33.18% post to Implementation 23.57 KWH
• A Saving of 0.50 % of Thermal energy • A Saving of 1.17 Units of Electrical energy
In terms of money ….. In terms of money ….. • A saving of Rs.196.88 Lacs • A saving of Rs.145.90 Lacs
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CASE STUDY - 1
Encon activity carried out in TG cooling water system
Objective : For Electrical energy saving
3 ➢ Installed a 3000 M / hr low head pump to cater to the requirement of both condenser & Lube oil system instead of 3 low efficiency high head pumps (3 x 1500 3 M / hr).
3 ➢ Installed a separate booster pump of 400 M / hr, 12 m head capacity to cater to the requirement of Lube oil system exclusively.
Tangible benefits : Eliminated running of two cooling water pumps leading to a Power saving of 5400 Units/day.
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WHY – WHY ANALYSIS
Power consumption high in TG cooling tower Why?
Numbers of pump running is high Why?
Pressure required for the process is inadequate Why?
Due to low efficiency of pump
Root Cause : Low pump efficiency & high consumption of power
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PREVIOUS SCHEME OF TG COOLING TOWER
To meet the cooling water requirement of TG Condenser and lube oil system, 3 x 200 KW pumps of each 1500 M3 /hr Elevation flow and 32 Mtr head were operating. 15Mtr
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MODIFIED SCHEME OF TG COOLING TOWER
Tangible benefits : Eliminated running of two cooling water pumps leading to a Power saving of 5400 Units/day.
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BENEFITS - PQCDSM
POWER CONSUMPTION 16000 14400 Cost savings 14000 Rs. 38.46 Lakhs per year 12000
10000 9000
8000
GOOD Units/Day 6000
4000 Investment 2000 of 16 lakhs
0 Before After
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CASE STUDY -2 Case Study -1 PROJECT 1: Energy saving projects by Utilization of Waste Heat recovery
Previous scheme Modified Scheme
• Heat evolved through Exothermic reaction is lost • The exothermic heat is reused for melting the to the cooling tower. sulphur. • Fresh Live steam is used for melting the • No external energy required for operating the sulphur. system.
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PROJECT 2: Steam Economy improvement through Direct Contact Heaters
Previous scheme Direct contact heater Modified scheme 1. Secondary juice heating with 3rd , 2nd & 1st body vapour - 70 to 103 degC. 2. Syrup heating with 4th body vapour - 60 to 75 degC 3. Clarified syrup heating with 3rd vapour – 70 to 90 degC
Tubular Heater DCH Direct contact heater
Steam 1 2 3 4 5
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BENEFITS - PQCDSM
STEAM CONSUMPTION Cost savings 600 Rs. 122.0 Lakhs per year 500 400
300 GOOD Tons/day 200
100 Investment of 0 40.0 lakhs Before After Series1 504 408
Tangible benefit achieved : 96 MT /day of Steam saving and corresponding reduction in cooling tower heat load & steam reduction in juice heating
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CASE STUDY -3
Installation of special alloy triple nozzle lotus roller to reduce Bagasse moisture and improve boiler efficiency
CANE CANE HANDLING MILL-0 MILL-1 MILL-2 MILL-3 MILL-4 PREPARATION
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WHY – WHY ANALYSIS
Moisture % Bagasse is high-(Fuel for Boiler) Why?
Re- absorption high Why?
Poor juice draining Why?
Less opening for juice drainage Why?
More number of nozzles not possible in Cast iron conventional roller
Root Cause : Less number of nozzles with weak MOC
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COUNTER MEASURE DETAILS
BEFORE AFTER No of Longitudinal pipe : 16 No of Longitudinal pipe : 20 No of Nozzles per pipe : 35 No of Nozzles per pipe : 35 No of Nozzles per hole : 3 No of Nozzles per hole : 3 Nozzle diameter in mm : 5 Nozzle diameter in mm : 5 Total no of Nozzles : 1680 Total no of Nozzles : 2110 Juice draining area in Sq.M : 0.033 Juice draining area in Sq.M : 0.041
16 PIPES 20 PIPES
TOTAL NOZZLE: 1680 TOTAL NOZZLE: 2110
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MULTI NOZZLES IN THE TOP ROLLER
IMAGE SHOWING TOP ROLLER
Top roller with 2100 nozzles
Output Bagasse from roller
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BENEFITS - PQCDSM
Cost savings Bagasse Moisture% Steam Fuel RatioRs. 279.27 2.22 51 Lakhs2.20 per year 50.5 2.2 50.5 2.18 50 2.16
49.5 2.14 % 2.12
Moisture % Moisture 49 GOOD 2.10 GOOD 48.5 2.1 48.5 2.08 48 2.06 2.04 47.5 Before After Before After Investment of 45 Lakhs
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WEALTH FROM WASTE PROJECTS EARNINGS BEFORE INTEREST, TAXES, DEPRECIATION & AMORTIZATION IMPROVEMENT – WEALTH FROM WASTE CONCEPT PROJECTS Recovering CO2 gas from fermentation process – Completed in 2015
Excess bagasse to paper industries – Completed in 2016
Zero liquid discharge system in Distillery – Completed in 2017
Impure alcohol into Bio Fuel – Completed in 2018 Covered in case study - 4
Conversion of Pressmud into carbon rich Fertilizer (Biochar) - Trial process going on
Extraction of furnace oil from Distillery effluent - Pilot plant erection under progress by ICT - Mumbai
Biogas into CPG – Yet to start.
Conversion of CO2 gas into Dry ICE - Discussion going on for feasibility
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UNDERSTANDING THE PROCESS
Propanol & Methanol & After Aldehydes Esters Butanol Di-acetal IMPURE ALCOHOL Fermentation 9.5 – 10% alcohol Recovery column Kaizen Area To Fermentation 75000 ltrs/day
ENA PRODUCT 96.5% alcohol Effluent to ETP 45000 ltrs/day
Analyzer Pre-Rectifier Hydro-Purifier Rectifier Simmering EXTRA NEUTRAL ALCOHOL IMPURE ALCOHOL column column column column column STORAGE TANK STORAGE TANK
ETHANOL – 99.8%
Evaporator column Molecular Sieve Bed-A Molecular Sieve Bed-B ETHANOL STORAGE TANK
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UNDERSTANDING OF IMPURE ALCOHOL
➢ This is the byproduct from the distillery, to improve the product quality the impurities are separated in various stages. ➢ Impure alcohol is nothing but ethyl alcohol with the concentration of 95.0%. ➢ It consist of impurities likes Acetaldehyde, Acetone, Methanol, n-Propanol, 2-Butanol, Iso-butanol, Iso amyl Alcohol, diacetal etc., ➢ This impure alcohol is unfit for the production breweries & human consumption. ➢ This is used in varied applications mainly that used to producing Perfumes, acetic anhydride & esters derived products.
EXTRA NUTRAL IMPURE ALCOHOL ALCOHOL
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THEME SELECTION ❑ Design of Impure alcohol drawl - 5 % from the day production. (3750 Total Storage capacity – 43.70 LL ltrs/day) ❑ Year 2016-17 sale volume reduced, with help of supplier Impure alcohol Allotted capacity – 3.00 LL drawl % further reduced. ❑ The impurity drawl is not able to bring it less than 2% which leads to Impure Alcohol stock – 10.54 LL quality issue in final product. Capacity occupied – 25 % of total storage ❑ At one point of stage which was exhausted the factories storage space and leads to difficulty in storing main products like Extra Neutral Alcohol/Ethanol. 5 % → 2%
6 IS PRODUCTION vs SALES 25
5 20 4 15 3 10 2
Qty Qty in LL 1 5 0 0 2014-15 2015-16 2016-17 2017-18 2018-19 Prod 4.84 5.10 3.90 1.91 3.33 Sales 3.15 2.86 1.64 0.88 0.01 Cumm 4.84 9.94 13.84 15.75 19.08
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ANALYSIS & DEVELOPMENT OF THE SOLUTION
5 W 1 H METHOD WHY-WHY ANALYSIS What : Non sale of Impure alcohol. Why 1 : Distillery - Extra Neutral Alcohol production stopped. Where : Distillery warehouse. Why 2 : Storages tanks in warehouse got full with When : Every day. ENA/AA/IS. Why 3 : No sale order for impure alcohol. Who : Warehouse In-Charge. Which : Impure alcohol Storage. Why 4 : No market demand for the impure alcohol consumption. How : 1500 ltrs/day. Why 5 : Closer of all industrial consumers.
Root Cause: No market demand for the impure alcohol consumption.
Counter measure: Change in process or new technology to be adopted
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STEPS FORWARD
Impure Alcohol Feed
ETHANOL PRODUCT
ETHANOL LAB SCALE PLANT IN M/S. PRAJ INDUSTRIES - PUNE
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ISSUE IN PRODUCT COLOUR
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WHY – WHY ANALYSIS
Yellow colour in Ethanol product Why? Feed material itself carrying the yellow colour Why?
Impurities from distillation is leads to colour precipitation Why?
Presence of Di-Acetal impurities
Root Cause : No facility to separate the impurities of Di-Acetal from Impure Alcohol.
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STEPS IMPLEMENTED
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DESIGN DATA OF ACTIVATED CARBON BED
Inlet S.No DESCRIPTION UOM DATA 1 Height of bed mm 3240
Top mesh 2 Dia of bed mm 1350 Carbon 3 Volume m3 4.6 feeding point 4 Working pressure Kgs/cm2 18.5 5 Working temp deg C 140 6 Material of construction Mild steel Activated Carbon area 7 Thickness mm 12 8 Activated carbon Kgs 500 9 Carbon bed height mm 2.1 10 Feed rate ltrs/hr 2000 Bottom mesh Manhole 11 Mesh Angle ring grating door 12 Carbon replacement frequency Year 1 13 Regeneration steam requirement Kgs 1200 Outlet 14 Steam Pressure Kgs/cm2 3.5 15 Steam temperature deg C 145
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AFTER KAIZEN IMPLEMENTATION
Propanol & Methanol & After Aldehydes Esters Butanol Di-acetal IMPURE ALCOHOL Fermentation 9.5 – 10% alcohol Recovery column
To Fermentation
ENA PRODUCT 96.5% alcohol Effluent to ETP
Analyzer Pre-Rectifier Hydro-Purifier Rectifier Simmering EXTRA NEUTRAL ALCOHOL IMPURE ALCOHOL column column column column column STORAGE TANK STORAGE TANK 10.54 LL consumed in within a month
Activated Carbon Bed Evaporator column Molecular Sieve Bed-A Molecular Sieve Bed-B ETHANOL STORAGE TANK
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ACHIVEMENT FOR THE PROCESS CHANGE ➢ Based on the report we have applied for the permission in COMMISSIONER OF PROHIBITION AND EXCISE – CHEPAUK, CHENNAI.
➢ After getting the permission we have started consuming impure alcohol from APRIL-2018 to MARCH-2019
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BENEFITS - PQCDSM Revenue Generation Losses Rs.10.41 during With investment of Crore last conversion Rs.2.25 Lakhs Year increased We have 3.0 to 6.0 % achieved
On time delivered the There is no quality allotted quantity of 50 complaints received LL during the Financial from our customer year Apr-18 to Mar-19 0 M/S.BPCL-Karur. without any penalty
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TANGIBLE & INTANGIBLE BENEFIT The principle behind the practice is wealth from waste concept.
Tangible benefits: ➢ Recovering Resources from Industrial Waste. ➢ Revenue generation from waste – Rs.10.41 Cr. ➢ Poor marketing of impure spirit is now managed in all over distillers in TN. ➢ Storage concern has been avoided & able to store the good quality of ENA / ETHANOL. ➢ By this we can able to produce both ENA & Ethanol at a time.
Intangible benefits : ➢ Reduction in crude oil import will increase the revenue generation for the government. ➢ Organizational goals are achieved. ➢ Saves the environmental pollution that exhaust gases of ethanol are much cleaner, its burns more cleanly (Complete combustion)
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RECOGNITION FOR OUR INNOVATION
Received winner award from our Platinum award received from Received winner award in 35th group chairman for best operation SISTA for the best distillery - 2018 TPM Kaizen Competition – 2019 & excellence project – 2018 in Breakthrough Category
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REPLICATION POTENTIAL WITHIN THE SECTOR
➢ We have already replicated this in our other unit which is located in Sivagangai-Tamilnadu & Sankili, Srikakulam district, AP & Haliyal-Karnataka.
➢ The plant was operated on 26th Oct-18 & 5th Feb-2019 with production of 200000 litres Ethanol from Impure Spirit. ➢ Likewise some of the distilleries are like M/s. Dharani sugars, M/s.Thiru Arooran Sugars are started the processing of mixing their impure spirit with rectified spirit with 30 : 70 ratio.
E.I.D PARRY (INDIA) LTD – SIVAGANGAI,TN E.I.D PARRY (INDIA) LTD – SANKILI, AP
Contact person : Mr.C.Aruchamy Contact person : Mr.V.Sivakumar Designation : Sr.Manager-Distillery Designation : Manager-Distillery Contact No. : +91 99529 47380 Contact No. : +91 91211 68695
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ENCON PROJECTS FOR NEXT 3 YEARS
1. Bagasse dryer for reducing the moisture % Bagasse
2. Increase bio gas boiler capacity from 12 TPH to 15 TPH.
3. Condenser modification in evaporator and pan condenser
4. Sugar Injection water Treatment– Project.
5. Furnace oil from distillery effluent (Spent wash)
9/21/2019
ENERGY CONSERVATION MONITORING & REPORTING
1. 23 flow meters for all process fluids including steam
2. DCS based data logging for daily energy monitoring and reporting
3. 35 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
9/21/2019
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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 • Monthly employee productivity linked incentives
9/21/2019
TRUTH BEHIND OUR SUCCESS
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