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13th NATIONAL AWARD FOR EXCELL EXC ELLENC ENCE E IN ENERG ENERGY Y MAN MANAGE AGEMEN MENT T - 201 2012 2
Contents Company Profile Process Profile Trend setting projects Reduction in SEC & Global benchmarking Innovative & encon projects Involvement of employees Environmental concern Awards and accolades
Contents Company Profile Process Profile Trend setting projects Reduction in SEC & Global benchmarking Innovative & encon projects Involvement of employees Environmental concern Awards and accolades
Company profile
Company profile
Corporate with a conscience
Integrated sugar complex 114 years old
The state-of-the-art technology “Integrated Sugar Complex”
Sugar division profile
1897 - Established as Gur Refinery,
1902 - Commencement of Distillery production
1943 - Conversion to sugar manufacturing unit from cane – 230 TCD
1980 - Acquired by Nava Bharat Ventures Ltd. – 1500 TCD
2008 – One of very few to register with UNFCCC in the sector
2011 - OHSAS 18001 certified – 4000 TCD
2012 –Ethanol plant commissioning
Process profile
Integrated sugar complex
Process flow chart CO-GEN POWER PLANT
MILLING
BAGASSE
ORGANIC MANURE
FILTER CAKE
ENA
RAW JUICE
CLARIFICATION CANE EVAPORATION
SPENT WASH
PAN BOILING
RECTIFIED SPIRIT
ETHANOL MOLASSES
CENTRIFUGALS
SUGAR
Trend setting projects
Trend setting projects Mono Vertical Crystallizer
1982 ‐ 83
Microwave probe for batch pan brix control
2003 ‐ 04
AC VF Drives for Sugar Cane Mills
2004 ‐ 06
Quintuple 3rd effect vapour for Pan boiling
2005 ‐ 06
Vapour Absorption Heat Pump
2005 ‐ 06
Clear Juice in place of condensate for pans, cfg & sugar melter
2006 ‐ 07
Integrated spent wash evaporation
2007 ‐ 08
Manufacturing Sulphur free sugar without extra energy
2007 ‐ 08
Whole cane milling
2008 ‐ 09
Bagacillo floatation cell
2009 ‐ 10
Recirculation of condensate for VAHP
2010 ‐11
Mechanical circulators for ‘A’ continuous pan
2010 ‐11
Installation of Vibro screens for Raw juice
2011 – 12
Energy conservation
2011‐12
Though the bolder grain sugar production has been increased from 47 to 55% during last crushing season, the encon efforts helped us to sustain the previous year’s energy consumption levels.
Reduction in SEC & global benchmarking
Reduction in SEC
Reduction in SEC
Comparison with global benchmarks
Parameters
Global Norms
Specific Thermal Energy Consumption
40‐41%
Specific Electrical Energy consumption For sugar plant operations alone
Global NBV – SD benchmark as Achievement per CII
As per ISSCT proceedings 2005
38.00 %
32.25 %
27‐28 kWh/ton of cane
30 kWh
24.31 kWh
As per NFCSF
Comparison with neighboring factories
Description
Sri Renuka Sugars Havalgaa
Parrys Sugar Industries Ltd.
KCP Sugar &Industries, Vuyyuru
NBVL, Sugar Division, Samalkot
Sankili Thermal Energy (Steam% Cane)
42.00
36.63
34.88
32.25
Electrical Energy (KWH/TC)
26.00
25.55
25.34
24.31
Total energy consumption (Mcal/TC)
258.21
227.67
217.66
202.01
Innovative & Encon projects
Innovative Project Vibro screens for Raw juice
2011-12
General Practice : Bagacillo (Fine fiber particles) carries along with raw juice to the process causes high lime and sulphur consumption and thereby high scaling in heat exchangers Innovation : Installed 5 No.s of 60” Vibro screens with 50 mesh at the outlet of the Rotary juice screen to remove the Bagacillo. This resulted in reduction of lime and sulphur consumption thereby steam saving due to reduced scaling in heat exchangers Result : 1500 MT of Bagasse Investment in Rs. Lakhs
Annual savings in Rs. Lakhs
Payback Months
30
15 82
22
Innovative Project Vibro screens for Raw juice
contd..
2011-12
Encon Project – 1 Usage of Light filtrate at Mills
2011-12
Previous practice : Both Heavy and Light filtrate juices from vacuum filters were mixed and sent to Filtrate clarifier for further clarification Present Practice : Light filtrate was diverted to mill maceration tank to reduce the maceration water consumption and thereby reduced steam consumption at evaporators. Result : Bagasse of 1500 MT Investment in Rs. Lakhs 2.5
Annual savings in Rs.Lakhs Payback Months 15.9
1.88
Encon Project – 2 Turbo ventilators
2011-12
Previous practice : Exhaust fans Present Practice : Turbo ventilators are installed for Boiling house shed. Result : Avoided the usage of exhaust fans. Investment in Rs. Lakhs Annual savings in Rs.Lakhs Payback Months 8.0
4.9
20
Encon Project – 3 Safe lights
2011-12
Previous practice : Electrical lighting Present Practice : Installed safe lights for Boiling house shed to make use of sun light. Result : Avoided the usage of electric lights during daytime. Investment in Rs. Lakhs Annual savings in Rs. Lakhs Payback Months 22.6
2.2
120
Encon Project - 4 Welding rectifiers
2011-12
Previous practice : Welding Transformers Present Practice : 7 Nos. of welding transformers were replaced with rectifiers Result : Power saving of 125000 Kwh.
Investment in Rs. Lakhs
Annual savings in Rs. Lakhs
Payback Months
4.50
6.0
9
Other encon projects Few of other encon projects implemented from last three years. SN
1
2
3
4
Project Name
No‐8 Condensate juice heater in Parallel with PHE for Raw juice heating
Year
Power saved in m kWh
Annual Savings in m Rs
Investment in m Rs
482
0.518
‐
‐
2010‐11
0.026
‐
0.068
0.309
55
2010‐11
0.210
‐
0.548
2.77
61
VFD for Cooling tower fan 2010‐11
0.050
‐
0.992
0.218
20
Replacement of Boiler feed water pumps with a single higher capacity energy efficient pump
Payback in Months
2010‐11
Replacing dyno drive with VFD for C CVP massecuite and magma pumps
Bagasse saved in Tons
Immediate
Other encon projects… contd. SN Project Name
5
6
7
8
9
Year
Power saved in m kWh
Bagasse saved in Tons
Annual Savings in m Rs
Investment in m Rs
Payback in Months
Planetary gear box and rope coupling for new 40”X80” mill
2010‐11
0.380
‐
0.992
3.340
40
Planetary gear box for Rake elevator and Bagasse elevator
2010‐11
0.053
‐
0.138
0.420
36
Installation of Turbo ventilators for Mill house shed
2010‐11
0.034
‐
0.089
0.350
47
Installation of Light piping system for Mill house shed
2010‐11
0.034
‐
0.089
1.010
137
Molasses lubrication for C ‐ massecuite
2009‐10
0.046
‐
0.127
0.020
2
Other encon projects… contd. SN Project Name 10
11
12
13
14
Year
Power saved in m kWh
Bagasse saved in Tons
Annual Savings in m Rs
Investmen t in m Rs
Payback in Months
Pan cutover line washing with first vapor instead of MP steam
2009‐10
‐
26
0.030
0.030
12
Modification of liquor feed line for Pan No. 1,2 &4
2009‐10
‐
259
0.306
0.225
9
PHE for raw juice heating with hot condensate
2009‐10
0.010
240
0.313
2.469
95
Replacing boiler feed water pumps with energy efficient pumps
2009‐10
0.034
‐
0.094
0.175
22
2009‐10
0.046
‐
0.127
0.409
39
1.163
2491
5.73
15
31
VFD for boiler SA fans
Total savings in the last three years
Involvement of employees
Involvement of employees ENERGY CONSERVATION CELL Vice President As Advisor General Manager ‐ Plant (Certified Energy Manager) Team Leaders H.O.D Mech.
H.O.D E&I
H.O.D Process
H.O.D Dist.
Source of ideas and implementation team Shop Floor Engineers and Process Technologists
Involvement of employees… contd. Few of the projects implemented Sno.
ENCON idea
Year of implementation
Source of idea
Annual savings
1
Diversion of Light filtrate to mills to reduce the maceration water there by steam saving
2011‐12
Chemist
1500 MT Bagasse
2
Stoppage of one sugar melter by improving the capacity utilization of the other.
2010‐11
Chemist
29000 kWh
3
Using low capacity DM water pump for continuous operation.
2010‐11
Engineers
3800 kWh
4
Replacing existing SV lamps with LED lamps provided with dimming option for colony street lightning
2010‐11
Elec. Supervisor
1650 kWh
2009‐10
Chemist
18800 kWh
5
Using common pump for both “B” & “C” seed.
Involvement of employees… contd. Few of the projects implemented Sno.
ENCON idea
Year of implementation
Source of idea
Annual savings
6
Using syrup instead of hot water for dry seed preparation.
2009‐10
Chemist
70 Tons Bagasse
7
CJ pump impeller resizing as per present requirement.
2009‐10
Engineer & Chemist
9500 kWh
2009‐10
Fitter
12500 kWh
2009‐10
Fitter
9200 kWh
2009‐10
Elect. Supervisor
1850 kWh
8
“C” light Molasses pump ON/OFF control wrt tank level.
9
Reducing pulley size of final Molasses pump to avoid running of second pump.
10
Replacing 21 nos. of 40 W bulbs with 1W LED lights at Cont. pans.
Monitoring & reporting
Thermal imager
PLC based data logging for daily energy monitoring and reporting
35 energy meters were installed at all important stations
52 flow meters for all process fluids including steam
Non contact type ultrasonic flow meter for instantaneous monitoring
Dynamic balancing of all rotating equipment by external agencies
Internal and external energy audits at regular interval
Displaying daily energy consumption figures in the plant
Daily report to the top management
Monitoring & reporting Using thermal Imager • To identify and avoid radiation losses from heat exchangers, chillers, refractory, insulation etc. • For condition monitoring of rotating and electrical equipments to minimize breakdowns
Implementation methodology Employees
Internal audits
Conceiving encon ideas
External audits
Feasibility study & finalization of projects by encon cell in weekly meetings Project design and planning
Project implementation Gap analysis and review for further improvement
Environmental concern
Environmental Project RO Plant
2011-12
Installed 300 cu.m/ day capacity Reverse Osmosis plant for distillery spent wash treatment. Input quantity
- 300 cu.m / day
Permeate
- 180 cu.m / day used for agricultural fields
Reject
- 120 cu.m / day used for preparation of organic Manure
CER Project – 1 CSTR Bio-Digester
2009-10
A CSTR Bio-Digester has been installed to recover biogas and is being used as fuel to distillery boiler. 300 – 350 m3/hr of biogas can be recovered. Project is yet to be registered with UNFCCC
were replaced with 9 MW condensing cum extraction turbine. The project was registered with UNFCCC
CERs sold 65,000
CERs accumulated 22000
Total CO2 reduction (Tons)
Total Annual Avg.Savings ( Rs. Million)
Investment made (Rs. Million)
Payback (Months)
32000
13.71
187.27
164
Other environmental projects
2011-12
On foot rally on the eve of “World Environment Day” Awareness meeting by top management on Environment protection Plantation of saplings in and around the plant
Utilization of waste
2011-12
1. ETP sludge Converted into bio manure and issued to farmers at free of cost.
1200 MT of sludge in 2011-12
1500 & 900 MT of sludge in 2010-11 & 2009-10
2. Promoted boiler ash for brick manufacturing
3355 MT of ash in 2011-12
3500 & 2300 MT of ash in 2010-11 & 2009-10
3. Press mud and distillery spent wash are used for producing organic manure,
which minimizes the chemical fertilizer consumption
7200 MT of organic manure in 2011-12
3000 & 3200 MT of organic manure in 2010-11 & 2009-10.
IMS – Corrective & Preventive actions Nature of non conformance: No evidence of ensuring calibration of equipment used for monitoring ambient air quality standards Correction: The calibration report of the AAQ monitoring equipment has been reviewed and found to be in order . Corrective action taken: Procedure for testing of the samples at external agency QC/PR/08 has been established.
IMS – Corrective & Preventive actions Nature of non conformance: No evidence of periodically updating results of applicable legal requirements related to air emission (i.e. display of particulate matter parameters) Correction: The status of the particulate matter has been now displayed based on the test report Corrective action taken: The board has been modified to contain the columns for displaying the environmental performance related to particulate matter
Best practices replicated from others
Regular monitoring of compressed air flow with the help of flow meter
Automation of CT fan with respect to water temperature
Installation of screw compressor for Ethanol plant
Condensate recovery system
Energy conservation information in “Manchi” news letter by NBV – SD
Harmonics audit
Best practices replicated by others
Installation of VFD for sugar cane mills
Utilization of 3rd vapors for pan boiling - resulted in reduction of 4% process steam consumption.
Installation of PHE for raw juice heating with condensate
VAHP to replace conventional air conditioners for total plant control rooms.
Future Projects Year of implementation
Appx. Investment In Rs. Lakhs
Appx. Annual savings
5130 MT Bagasse
SN
ENCON idea
1
Waste heat recovery from boiler flue gas with bagasse dryer
2013‐14
500
Replacement of conventional gears for all mills with high efficient planetary gears
2013‐14
350
1370000 kWh
3
E‐Melt for sulphur melting
2012‐13
10
1230 MT Bagasse
4
Rotary juice screen wash water for Mill maceration
2012‐13
3
1140 MT Bagasse
5
PHE for Raw juice heating with 4th vapor
2012‐13
20
590 MT Bagasse
2
Awards & Accolades
Awards & Accolades
5S Excellence award
2007
Innovative project award by CII
2008
Certificate of merit in energy conservation in sugar sector by BEE
2010
Best technical efficiency award by SISSTA
2010
Most Innovative Environmental project award by CII
2010
Best performing co‐gen factory in Andhra Pradesh by SISSTA Certificate of merit for Best 5S practices by CII
2008 & 2011 2011
Excellent energy efficient unit award by CII from past five consecutive years
Awards & Accolades
Shri. J.P. Mukherji Gold Medal Award as “Best Engineer of the year 2011” by
The Sugar Technologists’ Association of India (STAI)
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