NAVA BHARAT VENTURES LI MI TED

Investor Presentation
13
th
NATIONAL AWARD FOR
EXCELLENCE IN ENERGY MANAGEMENT - 2012
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
Corporate
with 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
Processprofile
Integrated sugar complex Process flow chart
MILLING
RAW JUICE
BAGASSE
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
MonoVerticalCrystallizer 1982 83
Microwaveprobeforbatchpanbrixcontrol 2003 04
ACVFDrivesforSugarCaneMills 2004 06
Quintuple3rdeffectvapourforPanboiling 2005 06
VapourAbsorptionHeatPump 2005 06
ClearJuiceinplaceofcondensateforpans,cfg &sugarmelter 2006 07
Integratedspentwashevaporation 2007 08
ManufacturingSulphurfreesugarwithoutextraenergy 2007 08
Wholecanemilling 2008 09
Bagacillofloatationcell 2009 10
RecirculationofcondensateforVAHP 201011
MechanicalcirculatorsforAcontinuouspan 201011
InstallationofVibroscreensforRawjuice 2011 12
Energy conservation 201112
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 years energy consumption
levels.
ReductioninSEC&
globalbenchmarking
Reduction in SEC
Reduction in SEC
Comparison with global benchmarks
Parameters GlobalNorms
Global
benchmarkas
perCII
NBV SD
Achievement
SpecificThermal
EnergyConsumption
4041%
AsperISSCT
proceedings2005
38.00% 32.25%
SpecificElectrical
Energyconsumption
Forsugarplant
operationsalone
2728kWh/tonof
cane
AsperNFCSF
30kWh
24.31kWh
Comparison with neighboring factories
Description
SriRenuka
Sugars
Havalgaa
ParrysSugar
Industries
Ltd.
Sankili
KCPSugar
&Industries,
Vuyyuru
NBVL,Sugar
Division,
Samalkot
ThermalEnergy
(Steam%Cane)
42.00 36.63 34.88 32.25
ElectricalEnergy
(KWH/TC)
26.00 25.55 25.34 24.31
Totalenergy
consumption
(Mcal/TC)
258.21 227.67 217.66 202.01
Innovative&Enconprojects
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 Annual savings in Rs.Lakhs Payback Months
2.5 15.9 1.88
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 Boiling
house shed.
Result :
Avoided the usage of exhaust fans.
Encon Project 2
Turbo ventilators 2011-12
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 3
Safe lights 2011-12
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
SN
ProjectName Year
Power
savedin
mkWh
Bagasse
savedin
Tons
AnnualSavings
inmRs
Investment
inmRs
Paybackin
Months
1 No8Condensatejuice
heaterinParallelwith
PHEforRawjuiceheating
201011 482 0.518 Immediate
2 Replacingdynodrivewith
VFDforCCVPmassecuite
andmagmapumps
201011 0.026 0.068 0.309 55
3 ReplacementofBoiler
feedwaterpumpswitha
singlehighercapacity
energyefficientpump
201011 0.210 0.548 2.77 61
4 VFDforCoolingtowerfan 201011 0.050 0.992 0.218 20
Other encon projects
Few of other encon projects implemented from last three years.
SN
ProjectName
Year
Power
savedin
mkWh
Bagasse
savedin
Tons
Annual
Savingsinm
Rs
Investmentin
mRs
Paybackin
Months
5 Planetarygearbox
andropecoupling
fornew40X80mill
201011 0.380 0.992 3.340 40
6 Planetarygearbox
forRakeelevator
andBagasseelevator
201011 0.053 0.138 0.420 36
7 InstallationofTurbo
ventilatorsforMill
houseshed
201011 0.034 0.089 0.350 47
8 InstallationofLight
pipingsystemfor
Millhouseshed
201011 0.034 0.089 1.010 137
9 Molasseslubrication
forC massecuite
200910 0.046 0.127 0.020 2
Other encon projectscontd.
SN
ProjectName
Year
Power
savedin
mkWh
Bagasse
savedin
Tons
Annual
Savings
inmRs
Investmen
tinmRs
Paybackin
Months
10 Pancutoverline
washingwithfirstvapor
insteadofMPsteam
200910 26 0.030 0.030 12
11 Modificationofliquor
feedlineforPanNo.1,2
&4
200910 259 0.306 0.225 9
12 PHEforrawjuice
heatingwithhot
condensate
200910 0.010 240 0.313 2.469 95
13 Replacingboilerfeed
waterpumpswith
energyefficientpumps
200910 0.034 0.094 0.175 22
14 VFDforboilerSAfans 200910 0.046 0.127 0.409 39
Total savings in the last
three years
1.163 2491 5.73 15 31
Other encon projectscontd.
Involvementofemployees
ENERGY CONSERVATION CELL
VicePresident
AsAdvisor
GeneralManager Plant
(Certified Energy Manager)
H.O.D
Mech.
H.O.D
E & I
H.O.D
Process
Shop Floor Engineers and Process Technologists
TeamLeaders
Source of ideas and implementation team
Involvement of employees
H.O.D
Dist.
Involvement of employeescontd.
Sno. ENCONidea Year of
implementation
Sourceof
idea
Annualsavings
1 Diversion ofLightfiltratetomills
toreducethemacerationwater
therebysteamsaving
201112 Chemist 1500MTBagasse
2 Stoppageofonesugarmelter
byimprovingthecapacity
utilizationoftheother.
201011 Chemist 29000kWh
3 UsinglowcapacityDMwater
pumpforcontinuous operation.
201011 Engineers 3800kWh
4 ReplacingexistingSVlampswith
LEDlampsprovidedwith
dimmingoptionforcolony
streetlightning
201011 Elec.
Supervisor
1650kWh
5 Usingcommonpumpforboth
B&Cseed.
200910 Chemist 18800kWh
Few of the projects implemented
Sno. ENCONidea Year of
implementation
Sourceof
idea
Annualsavings
6 Usingsyrupinsteadofhot
waterfordryseedpreparation.
200910 Chemist 70Tons
Bagasse
7 CJpumpimpellerresizingas
perpresentrequirement. 200910
Engineer&
Chemist 9500kWh
8 ClightMolassespump
ON/OFFcontrolwrttanklevel.
200910 Fitter 12500kWh
9 Reducingpulleysizeoffinal
Molassespumptoavoid
runningofsecondpump.
200910 Fitter 9200kWh
10 Replacing21nos.of40W
bulbswith1WLEDlightsat
Cont.pans.
200910
Elect.
Supervisor 1850kWh
Involvement of employeescontd.
Few of the projects implemented
Thermalimager
PLCbaseddataloggingfordailyenergymonitoringandreporting
35energymeterswereinstalledatallimportantstations
52flowmetersforallprocessfluidsincludingsteam
Noncontacttypeultrasonicflowmeterforinstantaneousmonitoring
Dynamicbalancingofallrotatingequipmentbyexternalagencies
Internalandexternalenergyauditsatregularinterval
Displayingdailyenergyconsumptionfiguresintheplant
Dailyreporttothetopmanagement
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
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
Environmentalconcern
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
Estimated Total CO2 reduction
(Tons)
Investment made
( Rs. Million)
20000 25
CER Project - 2
9MWcondensingcumextractionturbine200506
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
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
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 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 3
rd
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.
SN ENCONidea
Year of
implementation
Appx.
Investment
In Rs.Lakhs
Appx. Annual
savings
1 Waste heat recovery from
boiler flue gas with bagasse
dryer
201314 500 5130MT Bagasse
2 Replacement of conventional
gears for all mills with high
efficient planetary gears
201314 350 1370000 kWh
3
EMelt forsulphurmelting 201213 10 1230MT Bagasse
4 Rotary juice screen wash water
for Mill maceration
201213 3 1140MT Bagasse
5 PHE for Raw juice heating with
4
th
vapor
201213 20 590MTBagasse
Future Projects
Awards&Accolades
Awards & Accolades
5SExcellenceaward 2007
InnovativeprojectawardbyCII 2008
Certificateofmeritinenergyconservationinsugar sectorbyBEE 2010
Besttechnicalefficiency awardbySISSTA 2010
MostInnovativeEnvironmentalprojectawardbyCII 2010
Best performingcogenfactoryinAndhraPradeshbySISSTA 2008&2011
CertificateofmeritforBest5S practicesbyCII 2011
Excellent energy efficient unit award by CII from past five consecutive years
Shri.J.P.MukherjiGoldMedalAwardasBestEngineeroftheyear2011by
TheSugarTechnologistsAssociationofIndia(STAI)
Awards & Accolades
Thankyou
Thankyou