285

First Prize

Sugar

K.C.P SUGAR AND INDUSTRIES CORPORATION LIMITED

Vuyyuru, District Krishna (Andhra Pradesh)

Unit Profile

K.C.P Sugar and Industries Corporation have two sugar factories located at vuyyuru

and lakshmipuram in Andhra Pradesh. The combined capacity of the two factories

put together is 13000 TCD with Co-gen capacities of 20 MW and distillery of 50

KLPD.

Vuyyuru sugar unit was established in the year 1941 with a crushing capacity of 600

TCD. The present crushing capacity is 8500 TCD and this is one of the largest sugar

factories in the country and also one among the most modern. A State of Art

Technology is being continuously tried and incorporated in this plant.

There is a Distillery plant at Vuyyuru Sugar Factory with a capacity of 50 KLPD,

upgraded from 25 KLPD. The plant has been designed to produce bio-ethanol to fall

in line with the government’s policy and to meet the target to reduce the import of

crude oil and save foreign exchange.

The sugar unit at Vuyyuru has a cogeneration plant also to produce 15 MW of power

per day.

286

Energy Consumption

• Bagasse, which is derived from sugar cane crushing as by-product, is being

utilized as boiler fuel. Company has captive power generation of 20 MW

capacity. The exhaust obtained from the power turbines is used for the sugar

manufacturing process.

• The unit was also registered for evolution of carbon credits in the year 2008.

• In sugar industry, electrical and thermal energy consumptions play vital role.

With continuous efforts and successful experiments, the specific thermal and

electrical consumptions were reduced from 3.75 to 3.53 M kCal/ Tonne of sugar

and Electrical energy consumption from 264 to 247 kWh/ Tonne of sugar as

percentage of energy savings are 6.2% and 6.8% respectively.

Downward trend showing energy consumption over last year.

Specific thermal energy consumption Million Kcal/tonne

3.75

3.53

3.4

3.45

3.5

3.55

3.6

3.65

3.7

3.75

3.8

2012-13 2013-14

year

Kc

al/to

nn

e

Specific electrical consumption kwh/tonne

264

247

235

240

245

250

255

260

265

270

2012-13 2013-14

year

kw

h/t

on

ne

287

Energy Conservation Measures Taken

• Replacement of raw juice and imbibitions water batch weighing scales with flow

meters.

• Fully automated continuous pans for A, B and C massecuites.

• Auto star delta starters for all applicable motors.

• Flash heat recovery from condensate.

• PLC based automation aided by AC VF drives.

• Extensive use of energy efficient motors.

• Replacement of all inefficient worm gears with planetary gears and Helical

gearbox.

• Replacement of standard tube lights with CFL.

• Automation of all batch pans.

• Common condensate pumping.

• Mechanical seals for all applicable pumps.

• Usage of wind driven turbo ventilators and day lighting system.

• Installation of effective cooling and condensing system with automation.

• Regenerative type DC drives with interlocking for centrifugal machines.

1. Boiler furnace draft controlled by modifying the draft measuring

transmitters

The draft measuring transmitters line

incorporated condensate pots are modified,

which minimized the noise/ disturbance in signal.

After these were taken into line, noticed the

minimum variation in I.D fan loads as mentioned

below thereby net power saving of average 1.5

MW/day achieved.

Energy saved : 1.5MW/Day Annual saving : Rs. 9.23 Lakh

Investment : Rs. 0.10 Lakh

2. Energy saving by replacing old conventional drier system with

fluidized bed drier system

By replacing old conventional drier system with

fluidized bed drier system with there is an power

saving of 100 kWh and which is free from

environment pollution.

Energy saved : 2.88 Lakh units Annual saving : Rs. 10.25 Lakh

Investment : Rs. 392.3 Lakh

288

3. Energy saving by Installation of suitable (low) capacity pump in

place of higher capacity pump at co-gen

Installation of lower capacity pump for main cooling

water pump for 12 MW TG set at Co-gen plant.

Energy saved : 1.78 Lakh units

Annual saving : Rs. 6.15 Lakh Investment : Rs 1.00 Lakh

4. Energy saving by operating single

compressor and stopping the other

Earlier two compressors were in operation i.e.

boiler compressor 75 HP co-gen & boilers and

150 HP compressor for boiling house. Now,

single compressor i.e. 150 H.P. is in operation

for both boilers and boiling house, with this

there is an power saving of 25 kWh.

Energy saved : 1.00 Lakh units Annual saving : Rs. 3.59 Lakh Investment : Nil

5. Energy saving by Extraction of 12 MW TG SET Bleeding Line

Earlier steam was used from PRDS of 41/7 ata for

distillery operations.

Now, steam from 12 MW TG set 1st extraction is

being used for distillery operations, during the low

crushing rates. With this implementation direct

bleeding from boiler was avoided and increased an

additional power export of 40 kWh to grid.

Energy saved : 1.72 Lakh units Annual saving : Rs. 6.15 Lakh

Investment : Nil

6. Energy saving by Reduced CEP pump speed of 12 MW TG set

Speed of CEP Pump of 12 MW TG set is reduced

Energy saved : 0.144 Lakh units Annual saving : Rs. 0.15 Lakh Investment : Nil

289

7. Energy saving by installation of lotus top roller for last mills.

By installing lotus roller on last mills, juice drainage improved. With this moisture

% Bagasse reduced from 52.00 to 51.00.

Fuel saved : 3000 MT

Annual saving : Rs. 37.50 Lakh Investment : 9 lakhs.

8. Energy saving by By reducing feed water pump delivery pressure

from 64 kg/cm2 to 60 kg/cm2.

Delivery pressure of feed water pump is reduced

from 64 kg/cm2 to 60 kg/cm2, with this there is

steam saving of 0.45 t/hr.

Fuel saved : 3000 MT Annual saving : Rs. 37.50 Lakh

Investment : 9 lakhs

290

ENERGY POLICY

291

Specific Thermal energy

Consumption for Sugar3.32

2.76

0

0.5

1

1.5

2

2.5

3

3.5

2012-13 2013-14

Specific Electrcal Energy

Consumption for Sugar296.75

267.65

250

255

260

265

270

275

280

285

290

295

300

2012-13 2013-14

Second Prize

Sugar

E.I.D PARRY (INDIA) LIMITED

Pudukkottai (Tamil Nadu)

Unit Profile

EID PARRY (INDIA) LTD is a 226 year old company head quartered in Chennai and is

one of the flagship companies of diversified Rs. 243 billon Murugappa group. EID

Parry has its key presence in sugar and related value added products.

Geographically present in south India with its variety of configuration as below.

Energy Consumption

In sugar industry, electrical and thermal energy consumptions play vital role and

continuous efforts and successful experiments, the specific thermal energy

Consumptions were reduced from 3.32 to 2.76 million kCal/tonne of sugar and

electrical energy consumption from 296.75 to 267.65 kWh / tonne of sugar as

percentage of energy savings are 9.81 and 16.87 respectively, further cogeneration

plant auxiliary power consumption has been reduced from 10.19% to 9.05% and

specific steam consumption reduced from 5.49 kg/kW to 5.34 kg/kW.

292

Auxilary Power Consumption for

Power10.19

9.05

8.4

8.6

8.8

9

9.2

9.4

9.6

9.8

10

10.2

10.4

2012-13 2013-14

Specific Steam

Consumption for Power

5.49

5.34

5.25

5.3

5.35

5.4

5.45

5.5

5.55

2012-13 2013-14

z

Energy Conservation Measures Taken

• Plate Heat Exchanger for Raw juice heating

• E Melt Boiler for Sulpher melting

• U siphon for juice heater condensate to avoid condensate pumps

• VFD for Screw Compressor

• Optimum operation of FTP, By recovering maximum exhaust condensate from

sugar process & direct piping to de-aerator from evaporator

• VFD in mechanical spreaders

• Optimum Usage of ACC fans

1. Plate Heat Exchanger for Raw juice heating

Previously raw juice temperature has been increased from 35 Deg. C to 50 Deg.

C at Vapor line juice heater by using 5th evaporator

vapor, further raw juice temperature of 50 Deg. C

is raised to 70 Deg. C by using primary juice heater

with 3rd evaporator vapor. Evaporator condensate

water with 96 deg. C temperature has been sent to

over heat tank for process water requirement by

reducing the temperature.

The Plate type heat exchanger (PHE) has been

introduced to heat the raw juice in between the

Vapor line juice heater and primary juice heater. The PHE has been heated with

Evaporator condensate water with 96 deg. C temperature which was directly

pumped to the over heat tank for process requirement. By introduction of PHE,

the raw juice temp increased from 50 Deg. C to 68 Deg. C before entering to

primary juice heater and reduction of evaporator condensate temperature from

96 Deg. C to 70. Deg. C. with this modification the Unit was able to save 1.6 %

of steam on cane crushed. That is 10497 Tons of steam which resulted in saving

of 3181 MT of bagasse.

2. E Melt Boiler

Sulpher melting was done by using 9 Ata steam from turbine extraction and

return condensate was not able to recover.

293

By providing E Melt boiler for the sulpher melting

total 9 ata steam from turbine extraction has been

eliminated. By which Unit was were able to save 1.5

% of steam on cane crushed. That is 9841 Ton of 9

ata steam has been reduced and which resulted in

saving of 3307 MT of Bagasse.

3. U siphon for juice heater condensate

Two numbers of 5.5 kW condensate pumps were used for Juice heater

condensate to over head tank pumping and

additionally one common 37 kW condensate pump

were used to pump the condensate of Evaporators

to the over head tank.

the Unit has modified the juice heaters condensate

siphon piping and it has been connected to the

common condensate tank and by using the common

condensate pump all condensates were pumped to over head tank. By which the

Unit eliminated two numbers of 5.5 kW condensate pump.

4. VFD for Screw Compressor

Two different Reciprocating Air Compressors were used for Plant Instrumentation

air requirement at 6 kg/sq. cm and ash conveying

air requirement at 4.5 kg/sq. cm. Both were

operated with constant motor speed and loading

and unloading operation.

By providing VFD with Screw compressor for

Instrument air compressor. Further the pressure

controlling system has been introduced from

Instrument compressor air to ash handling system and eliminated ash handling

air compressor. By which the Unit was able to save 42 kW/hr.

5. Optimum operation of FTP, By recovering maximum exhaust

condensate from sugar process & direct piping to deaerator from

evaporator

The condensate water from process was collected in feed water tank of boiler

and it was pumped to deareator using the Feed

water transfer pump (FTP). The FTP was running 24

hrs with power consumption of 45 kW/hr.

By making modification in piping arrangement the

condensate water from the process directly feed to

deareator and the FTP pump was used only for

make up of DM water by which operating hours of

FTP reduced to 4 Hrs per day

294

6. VFD in mechanical spreaders

During Sugar cane crushing, we were using only bagasse as fuel in our boiler,

during running of boiler coal spreader has to run even though no coal feeding to

avoid damage of spreader rotors. Since the

spreaders are connected in constant speed motors

it was running on 1440 rpm and the same was

consuming 3.3 kW/ Hr./ Spreader.

As we were not using coal, the VFD’s of Coal drag

chain feeders kept ideal and the same has been

connected to coal spreader motors and reduced the

rpm to 300 by which the Unit was able to save the power of 2 kW/Hr/Spreader.

Energy Policy