NAVA BHARAT VENTURES LIMITED
Investor Presentation19th NATIONAL AWARD FOR
EXCELLENCE IN ENERGY MANAGEMENT - 2018
Contents
Company Profile
Process Profile
Trend setting projects
Reduction in SEC & Global benchmarking
Encon projects
Involvement of employees
Environmental concern
Awards and accolades
Company profile
Corporate
with a
conscience
Company profile
*Zambia, South Africa, Tanzania and Zimbabwe
Aerial view of present
“Integrated Sugar Complex”
Integrated sugar complex
122 years old
▪ 1897 - Established as Gur Refinery
▪ 1902 - Commencement of Distillery
▪ 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
▪ 2005 - Co Generation power plant – 3300 TCD
▪ 2006 - ISO 9001 certified – 3500 TCD
▪ 2007 - ISO 14001 certified
▪ 2008 - One of the very few to register with UNFCCC in the sector
▪ 2011 - OHSAS 18001 certified – 4000 TCD
▪ 2012 - Ethanol plant
▪ 2013 - Spent wash evaporation plant
▪ 2014 - Multi fuel, 8 TPH Boiler for Distillery
▪ 2017 - Integration of Spent wash evaporation system with existing 20 KLPD Distillery
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
ORGANIC
MANURE
ENA
RECTIFIED
SPIRIT
CANE
ETHANOL
SUGAR
SPENT WASH
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
Vapor Absorption Heat Pump (VAHP) for AC needs 2005-06
Quintuple 3rd effect vapour for Pan boiling and 2005 - 06
Clear Juice in place of condensate for pans, cfgl & sugar melter 2006 - 07
Integrated spent wash evaporation 2007 - 08
Sulphur free sugar without extra energy - Innovative award by CII 2007 - 08
Whole cane milling 2008 - 09
Bagacillo floatation cell 2009 - 10
Mechanical circulators for ‘A’ continuous pan 2010 - 11
Vibro screens for Raw juice - Innovative award by CII 2011 - 12
Four Massecuite boiling 2013 - 14
Increased juice drainage area for all the Mills - innovative award by CII 2015 - 16
Reduction in SEC &
global benchmarking
Reduction in SEC 2017-18
Reduction in SEC 2017-18
Addition of 5th Mill
Comparison with global benchmarks 2017-18
Parameters Global Norms
National
benchmark as
submitted to
CII
NBV – SD
Achievement
Specific Thermal
Energy Consumption
40-41%
As per ISSCT
proceedings
2005
32.81 %
M/s. EID Parry
Nellikuppam
32.16 %
Specific Electrical
Energy consumption
For sugar plant
operations alone
27-28 kWh/ton
of cane
As per NFCSF
21.35 kWh/ton
of cane
M/s. Madras
Sugars
24.40 kWh
Comparison with neighboring factories 2017-18
Description
Nearest Competitor-1
Nearest Competitor-2
NBV - Sugar Division, Samalkot
Thermal Energy (Steam% Cane) 35.76 32.4 32.16
Electrical Energy (KWH/TC) 27.46 25.8 24.40
The above comparison is for the crushing season 2017-18
Encon projects
Encon Project – 1
Improvement in capacity utilization
Previous Practice :
Higher specific thermal & electrical energy consumption due to low
average crush rate & capacity utilization.
Present Practice :
With the implementation of best preventive maintenance practices, down
time reduced from 8.25% to 6.58% thereby increased plant capacity
utilization from 75 to 82%. This resulted in reduction of specific thermal &
electrical energy consumption.
Result : Power - 1,11,500 kWh and Bagasse - 670 MT saved per season.
Investment in Rs.
Lakhs
Annual savings in
Rs.Lakhs
Payback
Months
- 15.0 -
Encon Project – 2
Utilization of Pressure difference
Previous practice :
Pumping (20 HP) of clarified syrup from runoff tank to evaporator 5th
body.
Present Practice :
Utilized the pressure difference according to vacuum in 5th body of the
evaporator. For this increased the line size from 4” to 6” and level
control valve was provided to transfer the clarified syrup.
Result : Power saving of 50000 kWh per season.
Investment in Rs.
Lakhs
Annual savings in Rs.
Lakhs
Payback
Months
1.0 2.0 6
Investment in Rs.
Lakhs
Annual savings in
Rs.Lakhs
Payback
Months
1.5 2.6 7
Previous practice :
B continuous centrifugal machine massecuite feed control was done
manually.
Present Practice :
Installed IRIS feed control valve to B continuous centrifugal machine
and massecuite feeding done in auto mode. This helped to optimize
the machine capacity there by reduction in running hours of the
machine.
Result : Power saving of 63000 kWh/ season
Encon Project – 3
Installation of IRIS control valve
IRIS Control Valve with panel
Investment in Rs.
Lakhs
Annual savings in
Rs.Lakhs
Payback Months
5 2.0 30
Previous practice :
Conventional worm reduction gear box for C massecuite mono vertical
crystallizer.
Present Practice :
Replaced the conventional gear box with planetary drive to reduce the
power consumption and maintenance cost.
Result : Power saving of 22000 kWh / Season
Encon Project – 4
Installation of Planetary drive
Investment in Rs.
Lakhs
Annual savings in
Rs.Lakhs
Payback Months
3.3 2.0 20
Previous practice :
SV & Metal halide lamps were installed in the plant & Colony
Present Practice :
96 Nos. of SV lamps and Metal halide lamps were replaced with LED.
Result : Power saving of 48000 kWh / year
Encon Project – 5
Installation of LED lights
Other encon projects
SN Project Name
Year
Power saved
in million kWh
Bagasse saved in
Tons
Annual Saving
s in million
Rs
Investment in million
RsPayback in
Months
1 Reduction in steam & power consumption per tonne of cane with increase in average crushing rate by reducing plant downtime.
2017-18 1.11 670 1.5 0 Immediate
2 Avoided the operation of clarified syrup transfer pump from syrup clarification by providing 6” pipe line to transfer the syrup by means of vacuum by using the pressure difference in the system.
2017-18 0.0504 - 0.206 0.1 6
3 Installation of high precision massecuite feed control valve for NK1503 B continuous centrifugal machine for effective capacity utilization and to reduce power consumption
2017-18 0.0633 - 0.26 0.15 7
Encon projects implemented during last three years.
Other encon projects…. Contd.
SN Project Name
Year
Power saved
in million kWh
Bagasse saved in
Tons
Annual Savings in million Rs
Investment in million
RsPayback in
Months
4 Installation of planetary drive in place of conventional worm reduction gear for C massecuite Mono Vertical Crystallizer to reduce the power consumption.
2017-18 0.022 - 0.2 0.5 30
5 Replacement of SV lights with LED lights to reduce the power consumption.
2017-18 0.048 - 0.2 0.336 20
6 Plugging of Evaporator condenser nozzles to reduce the water consumption for energy saving
2016-17 0.05 - 0.2 0 Immediate
7 Replacement of 10 Nos. of old motors with energy efficient motors
2016-17 0.01 - 0.04 0.2 24
SN Project Name YearPower saved
in million kWh
Bagasse saved in
Tons
Annual Savings in million Rs
Investment in million
RsPayback in
Months
8 Replacement of 20 Nos. of SVLights with LED lights at plant& colony street lighting
2016-17 0.0026 - 0.015 0.053 43
9 Replacement of 4 Nos. ofwelding transformers withrectifiers
2016-17 0.071 - 0.284 0.27 11
10 Installation of lotus top rollerin place of conventional rollerfor 5th Mill along withincreased juice drainage areafor all the mills
2015-16 - 2500 15.4 0.15 Immediate
11 Reduction in power plantauxiliary consumption by0.24% with the reduction inBagasse Moisture .
2015-16 0.085 - 0.36 - Immediate
Other encon projects…contd.
Other encon projects…contd.
SN Project NameYear
Power saved in million kWh
Bagasse saved in
Tons
Annual Savings in million Rs
Investment in million
RsPayback in
Months
12 Diversion of processcondensate to polishingpond stream to reduce theeffluent load on sugar ETP.
2015-16 0.023 - 0.1 0.01 1
13 Utilization of clear juice in place of hot water at 'A' continuous pan to reduce the steam consumption.
2015-16 - 170 0.27 0.03 1
Total savings from past three
years 1.53 3340 19.03 1.8
Involvement of employees
ENERGY CONSERVATION CELL
Vice PresidentAs Advisor
General Manager - Plant(Certified Energy Manager)
H.O.DMech.
H.O.D
E & I
H.O.D
Process
Shop Floor Engineers and Process Technologists
Team Leaders
Source of ideas and implementation team
Involvement of employees
H.O.D
Dist.
Conceiving
encon ideas
Feasibility study & finalization of projects by
encon cell in weekly meetings
Project design and planning
Project implementation
Gap analysis and review for further
improvement
Implementation methodology
Employees
Internal
audits
External
audits
Involvement of employees…contd.
S.noENCON idea Year of
implementationSource of
ideaAnnual savings
1 Installation of high precisionmassecuite feed control valve forNK1503 B continuous centrifugalmachine
2017-18 C&I technician
2.6 Lakhs
2 Avoided the operation of clarifiedsyrup transfer pump from syrupclarification
2017-18 Process supervisor
2 Lakhs
3 Installation of planetary drive in placeof conventional worm reduction
2017-18 Mechanical fitter
2 lakhs
4 Replacement of SV lights with LEDlights
2017-18 Electricaldept.
2 Lakhs
Projects implemented
▪ Utilization of smart sensors for motors operating in remote area
▪ ERM software for online centralized monitoring of all electrical parameters
to reduce the losses and improve the power factor
▪ PC based thermal image to identify the thermal losses and to prevent
electrical breakdowns
▪ Extensive use of energy meters and flow meters
▪ Flow meter for instrumentation air and air audit by external agencies
▪ Dynamic balancing of all rotating equipments by external agencies
▪ Internal and external energy audits at regular intervals
▪ Display of section wise target Vs actual energy consumption parameters at
appropriate areas
▪ Daily report to the top management
Monitoring & reporting
Photograph of the motor with Smart Sensor
Environmental concern
Environmental Project -1Installation of Lateral Agitators for fermenters 2017
Installed 6 Nos. of lateral agitators for
fermenters at distillery to increase the Alcohol
yield and to reduce the effluent generation.
Effluent generation (before) - 30 M3 / day
Effluent generation (after) - 15 M3 / day
Environmental Project – 2
Stripper column for MEE condensate 2016
Installed stripper column to reuse the
MEE condensate for Distillery cooling
tower makeup and to minimize the
usage of ground water consumption
MEE Condensate reused - 60 M3/day
Environmental Project - 3Spent wash evaporation plant 2013
Installed 170 M3 / day capacity Spent wash evaporation plant in 2013 for further
concentration of reject from RO plant
Input quantity - 120 M3 / day
Condensate - 60 M3 / day
Reject - 60 M3 / day
used for organic manure
Other environmental projects
▪ Reduced the lubricants consumption from 25.65 ml to 24.57 ml per
ton of cane during 2017-18 season.
▪ Online opacity and treated effluent monitoring system
▪ On foot rally on the eve of “World Environment Day”
▪ Effluent quantity reduction at distillery by installing higher capacity
▪ PHE’s and using dry yeast in place of bakers yeast
▪ Awareness meeting by top management on Environment protection
▪ Plantation of saplings in and around the plant
Plantation of Saplings on World Environment Day
1. ETP sludge Converted into bio manure and issued to farmers
▪ 660 MT of sludge in 2017-18
▪ 350 & 400 MT of sludge in 2016-17 & 2015-16
2. Promoted boiler ash for brick manufacturing
▪ 4800 MT of ash in 2017-18
▪ 3300 & 3575 MT of ash in 2016-17 & 2015-16
3. Press mud and distillery spent wash are used for producing organic
manure, which minimizes the chemical fertilizer consumption
▪ 8500 MT of organic manure in 2017-18
▪ 10000 & 9000 MT of organic manure in 2016-17 & 2015-16
4. Utilization of Bio gas as fuel to boiler
▪ 807000 NM3 of bio gas in 2017-18
▪ 1365000 & 1358000 NM3 of bio gas in 2016-17 & 2015-16
Utilization of waste
IMS – Non conformities summary 2016 - 18
SNName of the Standard
Number of Non Conformities
2016 2017 2018
1 ISO 9001 : 2015 1 Nil 2
2 ISO 14001 : 2015 Nil Nil 5
3 OHSAS 18001 : 2007 2 2 2
SN ENCON idea Year Benefit
Appx.Annual
savings in Rs. Lakhs
1 Replacement of 300 CFM reciprocating aircompressor with 380 CFM screw type.
2018 - 19Power saving and
reduced O&M cost1.6
2 Installation of VFD for air blower at Sulphurstation
2018-19Power saving and
reduced O&M cost2.8
3 Installation of LED lamps in place of SV lamps in sugar processing section
2018-19Power saving
5.3
4 Replacement of 10 Nos. of old motors with energy efficient motors
2018-19Power saving
0.41
5Installation of Plate type condenser for A CVP 2019-20
Ground Waterconservation
----
Future Encon & Enviro Projects
Awards & Accolades
Awards & Accolades from past four years
Best Technical efficiency gold award by SISSTA 2017
Best Co-generation silver award by SISSTA 2017
Best overall performance of Sugar Mill Award by Bharatiya Sugar 2017
Excellent energy efficient unit award by CII 2016
Most Innovative project award by CII 2016
Energy efficient unit award by CII 2015
Dr. Bhansi dhar gold medal award by STAI 2014
Excellent energy efficient unit award by CII from 2007 to 2012 ,2014 & 2016
Thank you