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EID Parry, Nellikuppam

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EID Parry, Nellikuppam 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 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. E.I.D PARRY (INDIA) LTD 2 2 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 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 tons metricCane in 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 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 Consumption Trend 7.6 7.4 7.4 7.2 7.1 7.1 7.0 GOOD 6.8 6.6 / MT of Cane (KWH) Cost benefit 6.4 6.4 Rs 37.11 Lakhs 6.2 Fibrizer Power 6.0 5.8 2014-15 2015-16 2016-17 2017-18 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.
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