|
S NO.
|
DESCRIPTION
|
UNIT
|
|
|
A
|
TARGET ( % OF CANE)
|
%
|
45
|
|
B
|
ACTUAL ( % OF CANE)
|
%
|
50
|
|
C
|
SAVING (B-A)
|
%
|
5
|
|
D
|
STEAM TO BAGASSE RATIO
|
RATIO
|
2.1:1
|
|
E
|
BAGASSE SAVING BY REDUCING STEAM CONSUMPTIO.
|
TON/HR
|
1.8
|
|
F
|
TOTAL CANE CRUSHING (ESTIMATED)
|
LAC. MT
|
5.775
|
|
G
|
STEAM CONSUMPTION @ 50% ON CANE CRUSHING
|
LAC. MT
|
2.8875
|
|
H
|
BAGASSE CONSUMPTION FOR (G)
|
LAC. MT
|
1.375
|
|
I
|
STEAM CONSUMPTION @ 45% ON CANE CRUSHING
|
LAC. MT
|
2.59875
|
|
J
|
BAGASSE CONSUMPTION FOR (I)
|
LAC. MT
|
1.2375
|
|
K
|
BAGASSE SAVING (H-J)
|
MT
|
13750
|
|
L
|
AVERAGE PRICE REALISATION OF BAGASSE.
|
RS. /MT
|
500
|
|
M
|
TOTAL SAVING BY REDUCING STEAM CONSUMPTION (K X L)
|
RS. /LAC
|
68.75
|
STEPS TO BE TAKEN
TO ACHIVE STEAM CONSUMPTION 45% ON CANE: -
|
STEPS |
PERCENT REDUCTION
OF STEAM |
| a) Regular, uniform cane
crushing & use of smikestner as lst body evaporator.
|
2.58%
|
|
b)
To maintain 1.2 Kg./Cm2, 120 Deg. C low steam pressure by regular
power export and maintaining exhaust pressure at 1.2 Kg./Cm2.
|
1.25%
|
|
C)
Replacement of drain valves, on steam line, faulty steam traps,
proper re-insulation wherever required.
|
0.25%
|
|
d) Installation of auto imbibition control
for optimum water imbibition.
|
0.25%
|
|
e) Avoid boiler safety
valve blow on power export tripping by automatically regulating PRDS
control valve.
|
0.75%
|
|
f) Reuse of boiler
continuous blow down steam in deareator.
|
0.5%
|
Case (e) and (f) are not
recorded in flow meter, but results in wastage.
| COST
REDUCTION IN PLANT ELECTRICITY CONSUMPTION & EXPORT MORE POWER TO EARN
ADDITIONAL MONEY:
|
|
|
|
|
|
Target
|
29 KWH/Ton Cane Crushing
|
|
Actual in Last Season
|
34 KWH/Ton
|
|
Saving 5 KWH/Ton
|
28.875 Lac KWH
|
|
For 5.775 Lac. Ton crushing,
saving will be.
|
|
|
Money realization by
exporting
|
Rs. 2887500 X 2.47
|
|
Additional energy.
|
Rs. 7132125.00
|
STEPS
TO BE TAKEN TO ACHIEVE THIS REDUCTION ARE AS FOLLOWS;
|
STEPS
|
REDUCTION IN CONSUMPTION
|
|
A)
Regular and uniform cane crushing for optimum utilisation of
equipment.
|
3
KWH/TON OF CANE
|
|
B)
Continuous use of turbo feed pump instead of electrical feed pump,
average 160 KW available to export to grid. Steam passed through PRDS will
be utilised for this pump.
|
1 KWH/TON
|
By
Continuous monitoring of each section wise following steps should be taken to
reduce load in some extent:-
| STEPS
|
POWER SAVING
|
|
i)
Turbo-Alternator set generation voltage reduced from 6.6 KV to 6.4- 6.5
KV& to match with grid voltage,
OLTC is used
|
50 KW
|
|
ii)
Impeller of I.D. fan changed by backward curve instead of combination
forward curve.
|
30 KW
|
|
iii)
Impeller size of imbibition pumps, weighed juice pumps, DM plant, make up
pumps, clear juice pumps are reduced to avoid valve throtling loss.
|
|
|
iv)
Lightly loaded pumps of spray
water,condensate
& tubewells connection are being changed from delta to star
connections and its current are being monitored.
|
|
|
v)
Day time lighting avoided strictly, street light switch on & off
timers installed. Timing for colony tubwells fixed.
|
10
KW
|
|
vi)
Optimise cooling tower fan operation by required heat sensing.
Saving
of Electrical load from ( i ) to
(vi)
|
15
KW
1 KWH/TON of cane
|
Besides
above, our other proposal to make Sugar plant
energy efficient, which requires investment as
per list showing annual saving and investement.
PROPOSAL FOR ENERGY SAVING FOR COST REDUCTION WITH
INVESTMENT
|
S. no.
|
Energy
saving proposals
|
Annual
saving in Rs.lacs
|
Investment
in Rs .lac
|
Payback
inmonth
|
Payback
in season
|
|
1
|
Install
variable fluid
|
23.00
|
16.00
|
5
|
0.42
|
|
2
|
Install
variable frequency drive for boiler F.D.Fan
|
8.00
|
13.00
|
20
|
1.67
|
|
3
|
Install
variable frequency drive for boiler C.R.Fan
|
2.22
|
4.00
|
22
|
1.83
|
|
4
|
Convert MP
steam heating to LP B team heating in sugar dryer
|
3.11
|
1.50
|
6
|
.50
|
|
5
|
Install
VFD for weighed juice pump
|
1.39
|
4.00
|
35
|
2.92
|
|
6
|
Reduce RPM
of sulphur burner compressor by 30% in stage
|
1.29
|
0.30
|
3
|
0.25
|
|
7
|
Replace
HPMV lamps with HPSV lamps in identified areas
|
0.27
|
0.42
|
19
|
1.58
|
|
|
|
39.28
|
39.2
|
|
|
| COST REDUCTION
STEP TAKEN BY N PAYING TARIFF FOR SEB IMPORT
SUPPLY DURING OFF-
SEASON
|
|
|
Present
SEB contracted load for own consumption :-
|
500
KVA
|
|
Tariff
|
Rs.
3.90 Per Unit + As. 150 Per KVA demand charge or As. 2.50 Lac as MCG.
|
|
At
the end of crushing season KWH banked by Sugar plant from exported energy
to SEB grid for adjustment in SEB consumed energy by paying 12.50% energy
as banking charges.
|
4.57
Lac. KWH
|
|
Banked
unit cost after adjustment of 12.50% (comparing realization).
|
Rs.
2.82
|
COST
SAVING BY BANKING OF ENERGY OVER ACTUAL TARIFF OF UPSEB
|
ENERGY
ADJUSTED THROUGH BANKED
|
UPSEB
TARIFF AT @RS. 3.90/UNIT
|
UNIT
BANKED
|
COST
OF UNIT IF REALISED
|
COST
REDUCTION OR SAVING
|
|
400000
unit
|
Rs.
1560,000.00
|
457142
unit
|
1129140.74
|
Rs.
430859.26
|
On
optimising and controlling the electricity consumption in plant maintenance
street light, colony & tubewells. Demand reduction of 100 KVA observed &
now we are in process to reduce contracted load to 400 KVA from 500 KVA.
Rs.6.0
Lac. annual saving estimated by reduced MCG charges.
|
