Presenter K.E. Kesavan., DGM Engineering T.S.Balasubramanian., AGM Inst E. Rajendran., Sr. Manager-Mech K. Bhagyaraj., Manager-Process

VISION: “Enriching & Energizing lives by creating Value added products from AGRICULTURE (Sugar)” 1 ABOUT OUR GROUP

32,000 Employees | 28 | One Group

• EID Parry is the flagship company of the • 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.

E.I.D PARRY () LTD 2 2 ABOUT OUR FACTORY

➢ Our 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

E.I.D PARRY (INDIA) LTD 3 OUR CERTIFICATIONS ARE UNIQUE IN INDIA

We are the first Indian sugar company having Pharma Licenses & Quality E.I.D PARRY (INDIA) LTD 4 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

E.I.D PARRY (INDIA) LTD 6 6 PHARMA CUSTOMERS

E.I.D PARRY (INDIA) LTD 7 ENERGY CONSERVATION ACTIVITIES

Year of Annual Savings S. No Energy Saving Project Execution (Rs. In Lakh)

1 2017-18 Replacement of NK 1503 B centrifugal machine to WK 1500 16.70

2 2017-18 Refinery AHU-35000 strip heater system replaced with Condensate coil system 1.30

3 2017-18 Fibrizer Anvil Plate Modification-Power saving 37.11

4 2017-18 Refinery candle filter lined up in Filter Feed pump with VFD drive 1.30

5 2017-18 Refinery PAN boiling vaccuum generating with body washing 2.51

6 2017-18 Condensate Recovering from ATFD to Dist. Thermax Boiler 27.38

7 2017-18 Elimination of 5 HP molasse pump (2 Nos.) by introducing one 7.5 HP pump 1.00

8 2017-18 VFD for Cogen Cooling Tower fan 1.30

9 2017-18 Mill Automation 50.00

10 2017-18 Steam trap capacity resizing in RC column Reboiler 44.37

E.I.D PARRY (INDIA) LTD 8 ENERGY CONSERVATION ACTIVITIES

Year of Annual Savings S. No Energy Saving Project Execution (Rs. In Lakh)

11 2017-18 CO2 generation automation 58.80

12 2017-18 B-Massecute Pump VFD installation 1.34

13 2017-18 Air Compressor Header Modification 9.06

14 2017-18 Elimination of intermediate belt conveyor in Refinery Feed Centrifuge 9.54

15 2017-18 Elimination of Slat conveyor during coal operation by introducing new conveyor 4.30

16 2018-19 Installed just adequate capacity high efficiency Cooling water Pump at cogen. 38.46

17 2018-19 Energy saving projects by Utilization of Waste Heat recovery 196.88

18 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 19 2018-19 2.25 contact heater for second body vapour.

20 2018-19 Installation of VFD for condensate Extraction Pump-2 2.16

E.I.D PARRY (INDIA) LTD 9 ENERGY CONSERVATION ACTIVITIES

Year of Annual Savings S. No Energy Saving Project Execution (Rs. In Lakh)

21 2018-19 Installation of VFD for Submergible belt conveyor (Both Boiler) 1.29

22 2018-19 Installation special alloy multi nozzle Lotus roller in 4th mill 279.27

23 2018-19 Injection Header modification by eliminating separate pump for evaporator 18.56

24 2018-19 Eliminating sugar grader operation during Raw sugar production 0.23

25 2018-19 Evaporator syrup brix improved by modifying the juice distribution system 226.20

26 2019-20 B & C Melter tank lifting to 12 Mts for gravity flow and to eliminate Pump 3.36

27 2019-20 Fibrizer anvil plate further modification-Power saving 37.11

28 2019-20 Cane Kicker drive gearbox and motor replaced by energy efficient unit 1.04

29 2019-20 Mill Automation 38.00

30 2019-20 Installation of VFD for Sulphur furnace blower 1.26

•E.I.D PARRY (INDIA) LTD •10 REDUCTION IN THERMAL ENERGY CONSUMPTION (STEAM % CANE) Steam % Cane 40.00 39.00 38.00 37.00 36.00 35.00 34.00 33.00 32.00 31.00 30.00 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20 Steam % Cane 39.39 38.56 38.00 35.22 34.69 33.68 33.50 33.27 33.04 32.81

E.I.D PARRY (INDIA) LTD 11 REDUCTION IN ELECTRICAL ENERGY CONSUMPTION (KWH / MT OF CANE) Power per Ton of Cane 30.00 29.00 28.00 27.00 26.00 25.00 24.00 23.00 22.00 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20 PPTC 28.72 28.30 26.00 25.98 25.15 24.74 24.51 23.71 23.57 23.40

E.I.D PARRY (INDIA) LTD 12 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 32.81 % 2005

Specific Electrical 28 27-28 kWh/ton of 23.40 Energy consumption kWh / ton of cane kWh / ton of cane cane As per NFCSF

E.I.D PARRY (INDIA) LTD 13 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 33.50 % Implementation 24.51 KWH

Steam % Cane post to GOOD Power/MT of Cane Implementation 32.81% post to Implementation 23.40 KWH

• A Saving of 0.69 % of Thermal energy • A Saving of 1.11 Units of Electrical energy

In terms of money ….. In terms of money ….. • A saving of Rs. 226.15 Lacs • A saving of Rs. 243 Lacs

E.I.D PARRY (INDIA) LTD 14 Case Study -1Case Study-1

Evaporator syrup brix improved by modifying the juice distribution system “To reduce the energy consumption in Sugar Manufacturing Process”

E.I.D-PARRY (INDIA) LIMITED, 8/13/2020 15 NELLIKUPPAM Analysis of high steam consumption in evaporators

Steam consumption high Why? Syrup concentration low Why?

Evaporator tube scaling Why?

Evaporator starved for juice Why?

Improper juice distribution

E.I.D-PARRY (INDIA) LIMITED, 8/13/2020 16 NELLIKUPPAM Kaizen Mechanism

Before After

E.I.D-PARRY (INDIA) LIMITED, 8/13/2020 17 NELLIKUPPAM Benefit Steam Consumption in % / MT of Cane crush 33.5

33.5 32.81 33 GOOD

32.5

32 Before After

E.I.D-PARRY (INDIA) LIMITED, 8/13/2020 18 NELLIKUPPAM Benefit in PQCDSM

Cane crushing per day 7000

6800 6 % increase 6600 GOOD

6400 Cane in metric tons metric in Cane

6200 BEFORE AFTER CANE CRUSHING 6477 6840 PER DAY

E.I.D-PARRY (INDIA) LIMITED, 8/13/2020 19 NELLIKUPPAM Benefit in PQCDSM

Evaporator outlet syrup concentration 61 60 59 58 57 56 11 % increase GOOD 55 54 53

Syrup concentrationSyrup 52 51 BEFORE AFTER Evaporator outlet 54 60 syrup concentration

E.I.D-PARRY (INDIA) LIMITED, 8/13/2020 20 NELLIKUPPAM Benefit in PQCDSM

Energy cost 36 GOOD

34 5.7 % Reduction Amount Amount crores in

32 BEFORE AFTER COST SAVING 35.28 33.28

E.I.D-PARRY (INDIA) LIMITED, 8/13/2020 21 NELLIKUPPAM Result

Amount saved on account of reduction in evaporator steam consumption by improving the syrup concentration

Rs 226 lakhs annually

E.I.D-PARRY (INDIA) LIMITED, 8/13/2020 22 NELLIKUPPAM Case Study -2

Energy Conservation in Fibrizer

E.I.D-PARRY (INDIA) LIMITED 23 PROBLEM / PRESENT ISSUES 5 W – 1 H METHOD What : Power Consumption high

Where : Fibrizer Motor operation

When : Cane Cell Opening to maintain Preparatory Index %.

Who : Anvil Plate.

Which : Cane hitting plates is around 170 Degree.

How : Power consumption is 7.1 KW/Ton of Cane

E.I.D-PARRY (INDIA) LIMITED 24 WHY- WHY ANALYSIS

➢ Why 1 : Power Consumption high in Fibrizer motors

➢ Why 2 : Loading of cane in-between anvil plate to hammer

➢ Why 3 : Added number of impact plates in anvil plate.

➢ Why 4 : Anvil plate wrap angle is 170 degree.

➢ Why 5 : As per OEM Recommendation

Root Cause : ➢ High impact rib plates in anvil plate.

E.I.D-PARRY (INDIA) LIMITED 25 COUNTER MEASURE DETAILS BEFORE AFTER Anvil Plate Setting: Anvil Plate Setting: 1.In let opening 292mm; Middle opening: 144mm and cane discharge end 40mm. 1.In let opening 280mm; Middle opening: 40mm and cane discharge end 500mm. 2. Anvil plate rib plate angle : 170 ° 2. Anvil plate rib plate : 85 °

E.I.D-PARRY (INDIA) LIMITED 26 Fibrizer Power / MT of Cane (KWH) 5.8 6.0 6.2 6.4 6.6 6.8 7.0 7.2 7.4 7.6 2014-15

7.4 Fibrizer Power Consumption Trend Rs 37.11 Rs Costbenefit 2015-16

7.1 Lakhs 2016-17

7.1 2017-18

6.4 GOOD Case Study -3

Mill Automation

Problem Definition

• Earlier, Mill automation was carried out, based on Donnelly chute level and not considering its motor’s current.

• So when we try to put the mill in level control mode, it gets tripped due to over load.

• Hence the mills could not taken auto. 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 Why?

Amps control is not there Why?

Weak design KAIZEN IDEA

Theme BEFORE AFTER

Eliminate frequent tripping of Mill

Problem: What: Mill is getting tripped When: Operating in Level CTRL mode MILL OPERATED Where: Mill 1 BASED ON BOTH DC LEVEL Who: Load / Amps CTRL is not available MILL OPERATED BASED & MILL LOAD Which: Every day ON DONNELYY CHUTE LVEL How much: 5 Occurrence Counter Measure : New logic is made, considering both DC Level & Amps Analysis: 2 GOOD

Why 1: Mill is getting tripped 1.8 1.65 1.55

1.6 1.39

Why 2: Over load (Amps is more) 1.35 1.4 Why 3: Level CTLR reduces the RPM to 1.2 Pol Loss in Bagasse (%) get good extraction 1 0.8 Why 4: Amps control is not there 0.6 Why 5: Weak design 2014-15 2015-16 2016-17 2017-18 30 30 IMPLEMENTATION STEPS

IMPLEMENTATION STEPS BENEFITS FROM PQCDSM

Additional Income Ichute jamming Cane Rs.38 decreased Crushing Lakhs/Year 5 to 0 Increased Occurrence 6200 TO 6477 2

Tons/Day 1.8 1.65 1.55

1.6

1.39 1.35 1.4 6 1.2 5 8000 Pol Loss in Bagasse (%) 1 5 7500 0.8 4 6477 0.6 3 7000 2014-15 2015-16 2016-17 2017-18 2 6500 6200 1 6000 0 0 5500 Before After

5000 Before After

34 34 Case Study-4

Condensate Polishing Unit

A Process change in Effluent Treatment system

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 35 Condensate Polishing Unit Process Flow chart

Equilization tank

Acticontact tank

Clarifier

Pressure sand filtration

Dual media filtration

Ultra filtration

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 36 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.

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 37 Design Philosophy

Inlet water parameters considered

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 38 CPU – ACTI CONTACT TANK

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 39 CLARIFIER

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 40 FILTERS PSF & DMF

ULTRA FILTERS

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 41 WATER SAMPLES

1 2 3

1. Common condensate

2. Secondary Clarifier outlet

3. UF outlet E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 42 Treated water parameters

Usage of treated water ✓ Boiler feed in the place of raw water .

✓ Boiler cooling tower.

✓ Distillery use.

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 43 WATER BALANCE WITH CPU

Condensate Polishing Unit

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 45 USAGE OF CPU WATER

Water from CPU @ 1200 m3/day

DMF outlet 500-550 m3/day UF outlet 650 -700 m3/day

Cogen - Cooling tower 250-300 Fermentation process 300 -350 m3/day m3/day

Distillery - Cooling tower 200 -250 m3/day Cogen boiler feed water 300-350 m3/day

Sugar - Descaling 50 m3/day

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 46 REUSED WATER QUANTITY

During off season Condensate Polishing Unit

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 47 RESULT

Raw water consumption (m3/day)

1400 1200 1200

1000

800

600

400 Quantity in m3/day 200 50 0 Treated Effluent Discharge (m3/day) Before After 1600 1444 1400

1200

1000

800

600

Quantity in m3/day 400 244 200

0 Before After

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 48 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 & Moving towards Zero Effluent Discharge

8/13/2020 E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 49 BenefitBenefit from from Condensate Condensate PolishingPolishing Unit Unit

Return On Investment ????

E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 50 TANGIBLE & INTANGIBLE BENEFIT

Tangible benefits:

➢ Recovering Resources from sugar Condensate

➢ Effluent water discharge 83% eliminated.

➢ Water recovery and recycle thereby reducing the ground water

drawl.

Intangible benefits :

➢ Employment opportunities

➢ Organizational goals are achieved

➢ Morale of the employee increased.

51 E.I.D. PARRY (INDIA) LIMITED,NELLIKUPPAM 51 Case Study-5 CO2 Generation through Alcoholic Fermentation

Zero investment project

YEAST

CO2 SUCROSE ETHANOL CO2 Recovery Plant Details

• Production Capacity: 36 TPD • Flow rate: 1500 kg/hour. • Operating Pressure: 20 kg/sq.cm. • Liquid Temperature: -20 degree Celsius. • Storage Tank capacity: 50 Tons CO2 After Scrubbing CO2 Recovery System

Alcoholic Activated Carbon Cooler Compressor Fermentation Tower

Storage Chillier Alumina Drier Purification (KMNO4) Tower Revenue Generation - CO2

Rs.250 Lakh/Year 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

56 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-.

➢ 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 ENCON PROJECTS FOR NEXT 3 YEARS

1. Bagasse dryer for reducing the moisture % Bagasse

2. Increase bio gas boiler capacity from 10 TPH to 15 TPH.

3. Condenser modification in evaporator and pan condenser

4. Sugar calandria tube renewal for steam conservation

5. Furnace oil from distillery effluent (ICT project)

8/13/2020 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

8/13/2020 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

8/13/2020 TRUTH BEHIND OUR SUCCESS

E.I.D PARRY (INDIA) LTD 61