Nava Bharat Ventures Ltd Samalkot

7/27/2019 Nava Bharat Ventures Ltd Samalkot

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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



Corporatewith a

conscience

Company profile

Zambia, South Africa, Tanzania and Zimbabwe

Laos



The state-of-the-art technology

“Integrated Sugar Complex”

Integrated sugar complex

114 years old



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

2002 - One of the few to implement 5S – 2500 TCD

2003 – Extra Neutral Alcohol (ENA) plant commissioning - Branded Sugar

2005 - Co Generation power plant – 3300 TCD

2006 - ISO 9001 certified – 3500 TCD

2007 - ISO 14001 certified

2008 – One of very few to register with UNFCCC in the sector

2011 - OHSAS 18001 certified – 4000 TCD 2012 –Ethanol plant commissioning

Sugar division profile



Process

profile



Integrated sugar complex Process flow chart

MILLING

RAW JUICEBAGASSE

CLARIFICATION

CO-GEN

POWER PLANT

EVAPORATION

PAN BOILING

CENTRIFUGALS

MOLASSES

FILTER CAKE

ORGANICMANURE

ENA

RECTIFIED

SPIRIT

CANE

ETHANOL

SUGAR

SPENT WASH







Mono Vertical Crystallizer 1982 ‐ 83

Microwave probe for batch pan brix control 2003 ‐ 04

AC

VF

Drives

for

Sugar

Cane

Mills 2004 ‐

06Quintuple 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 ‐

07Integrated spent wash evaporation 2007 ‐ 08

Manufacturing Sulphur free sugar without extra energy 2007 ‐ 08

Whole

cane

milling 2008 ‐

09Bagacillo floatation cell 2009 ‐ 10

Recirculation of condensate for VAHP 2010 ‐11

Mechanical

circulators

for

‘A’

continuous

pan 2010 ‐

11Installation

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 consumptionlevels.



Reduction in SEC &

global benchmarking



Reduction in SEC



Reduction in SEC



Comparison with global benchmarks

Parameters Global Norms

Global

benchmark

as

per CII

NBV – SD

Achievement

Specific Thermal

Energy Consumption

40‐41%

As

per

ISSCT

proceedings 2005

38.00

%

32.25

%

Specific Electrical

Energy consumption

For sugar plant

operations alone

27‐

28

kWh/ton

of

cane

As per NFCSF

30

kWh 24.31 kWh



Comparison with neighboring factories

Description

Sri Renuka

Sugars

Havalgaa

Parrys Sugar

Industries

Ltd.

Sankili

KCP Sugar

&Industries,

Vuyyuru

NBVL, Sugar

Division,

Samalkot

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



Innovative ProjectVibro screens for Raw juice 2011-12

General Practice :

Bagacillo (Fine fiber particles) carries along with raw juice to the proces

causes high lime and sulphur consumption and thereby high scaling in hea

exchangers

Innovation :

Installed 5 No.s of 60” Vibro screens with 50 mesh at the outlet of the Rotar

juice screen to remove the Bagacillo. This resulted in reduction of lime ansulphur consumption thereby steam saving due to reduced scaling in hea

exchangers

Result :1500 MT of Bagasse

Investment in Rs. Lakhs Annual savings in Rs.

Lakhs

Payback Months

30 15.82 22

Innovative Project



Innovative ProjectVibro screens for Raw juice contd.. 2011-12

Encon Project 1



Encon Project – 1Usage of Light filtrate at Mills 2011-12

Previous practice :

Both Heavy and Light filtrate juices from vacuum filters were mixed and sent t

Filtrate clarifier for further clarification

Present Practice :

Light filtrate was diverted to mill maceration tank to reduce the maceratiowater consumption and thereby reduced steam consumption at evaporators.

Result :

Bagasse of 1500 MT

Investment in Rs. Lakhs Annual savings in Rs.Lakhs Payback Month

2.5 15.9 1.88

E P j t 2



Investment in Rs. Lakhs Annual savings in Rs.Lakhs Payback Months

8.0 4.9 20

Previous practice :

Exhaust fans

Present Practice :

Turbo ventilators are installed for Boilinghouse shed.

Result :

Avoided the usage of exhaust fans.

Encon Project – 2Turbo ventilators 2011-12

E P j t 3



Investment in Rs. Lakhs Annual savings in Rs. Lakhs Payback Months

22.6 2.2 120

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.

Encon Project – 3Safe lights 2011-12

E P j t 4



Encon Project - 4Welding 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



SN Project Name Year Power

saved in

m kWh

Bagasse

saved in

Tons

Annual Savings

in m

Rs

Investment

in m

Rs

Payback i

Months1 No‐8 Condensate juice

heater in Parallel with

PHE for Raw juice heating

2010‐11 ‐ 482 0.518 ‐ Immediat

2 Replacing dyno

drive

with

VFD for C CVP massecuite

and magma pumps 2010‐11 0.026 ‐ 0.068 0.309 55

3 Replacement of Boiler

feed water

pumps

with

a

single higher capacity

energy efficient pump

2010‐11 0.210 ‐ 0.548 2.77 61

4 VFD for

Cooling

tower

fan 2010

‐11 0.050

‐ 0.992 0.218 20

Other encon projects

Few of other encon projects implemented from last three years.



SN Project Name Year Power

saved in

m kWh

Bagasse

saved in

Tons

Annual

Savings in m

Rs

Investment in

m Rs

Payback i

Months

5 Planetary

gear

box

and rope coupling

for new 40”X80” mill

2010‐11 0.380 ‐ 0.992 3.340 40

6 Planetary gear box

for Rake elevator

and Bagasse

elevator

2010‐11 0.053 ‐ 0.138 0.420 36

7 Installation of Turbo

ventilators for Mill

house shed

2010‐11 0.034 ‐ 0.089 0.350 47

8 Installation of

Light

piping system for

Mill house shed2010‐11 0.034 ‐ 0.089 1.010 137

9 Molasses lubrication

for

C ‐

massecuite 2009‐10 0.046

‐ 0.127 0.020 2

Other encon projects…contd.








ENERGY CONSERVATION CELL

Vice President

As Advisor

General Manager ‐ Plant

(Certif ied Energy Manager)

H.O.D

Mech.

H.O.D

E & I

H.O.D

Process

Shop Floor Engineers and Process Technologists

Team Leaders

Source of ideas and implementation team


H.O.D

Dist.

Involvement of employees…contd.




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

5 Using common

pump

for

both

“B” & “C” seed. 2009

‐10 Chemist 18800

kWh

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

8 “C” light Molasses pump

ON/OFF control wrt tank level.

2009‐10 Fitter 12500 kWh

9 Reducing pulley size of final

Molasses pump

to

avoid

running of second pump.2009

‐10 Fitter 9200

kWh

10 Replacing 21 nos. of 40 W

bulbs with 1W LED lights at

Cont. pans.

2009‐10

Elect.

Supervisor 1850 kWh

p y

Few of the projects implemented



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

Monitoring & reporting

I l t ti th d l



Conceivingencon ideas

Feasibility study & finalization of projects by

encon cell in weekly meetings

Project design and planning

Project implementation

Gap analysis and review for furtherimprovement

Implementation methodology

Employees

Internalaudits

Externalaudits



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



jCSTR 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

Estimated Total CO2 reduction

(Tons)

Investment made

( Rs. Million)

20000 25

CER Project - 2



9 MW condensing cum extraction turbine 2005‐06

Low capacity back pressure turbines

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

Oth i t l j t 2011 12



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

Utili ti f t 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.

Utilization of waste 2011-12

IMS C ti & P ti ti



IMS – Corrective & Preventive actions

Nature of non conformance:

No evidence of ensuring calibration of equipment used for monitoring ambien

air quality standards

Correction:

The calibration report of the AAQ monitoring equipment has been reviewedand found to be in order .

Corrective action taken:

Procedure for testing of the samples at external agency QC/PR/08 has beenestablished.

IMS C ti & P ti ti



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 tesreport

Corrective action taken:

The board has been modified to contain the columns for displaying theenvironmental 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 controlrooms.

F t P j t



SN ENCON idea

Year of

implementation

Appx.

Investment

In Rs. Lakhs

Appx. Annual

savings

1 Waste heat recovery fromboiler flue gas with bagasse

dryer

2013‐14 500 5130 MT Bagass

2 Replacement of conventional

gears for all mills with highefficient planetary gears

2013‐14 350

1370000 kWh

3 E‐Melt for sulphur melting 2012‐13 10 1230 MT Bagass

4 Rotary juice screen wash waterfor Mill maceration

2012‐13 3 1140 MT Bagass

5 PHE for Raw juice heating with

4th

vapor

2012‐13 20 590 MT Bagasse

Future Projects



Awards & Accolades

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 2008 & 2011

Certificate of merit for Best 5S practices by CII 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)

Awards & Accolades



Thank you



Thank you

Documents

Nava Bharat Ventures Ltd Samalkot