ENERGY CONSERVAION IN

SUGAR INDUSTRY
By
Sumit Pal Bhati
Addl. Manager-Engg.

Bajaj Hindusthan Ltd.

Unit- Kinauni, Meerut

WHAT IS ENERGY CONSERVATION

IT DEALS WITH EFFICIENT USE OF
ENERGY IN A PARTICULAR APPLICATION
,REDUCING ENERGY LOSSES ,ENERGY
COST,REDUCING ENERGY/POWER BILL
AND TO EXPLORE VARIOUS ASPECT OF
RENEWAL ENERGY

WHY CONSERVE ENERGY

Reduce Cost of production

Improve competitiveness (Saleable
power/bagasse)
For future generation
Energy resources are finite
Environment benefits

AREAS OF HIGH POWER

CONSUMPTION

Cane preparation
Mills
Condensing and Cooling
Centrifugal

AREAS OF ENERGY CONSERVATION

Area

Existing plant &

process

Energy efficient
plant & process

Energy
production

Boiler/ Turbine
efficient operation

High pressure
boiler/ condensing
turbine

Energy
consumption

Use of VFD, Helical

gears, Anti friction
bearings
Use of flashes etc.

DC/AC thyristor
controlled motors,
continuous pan,
direct contact
heaters etc.

ENERGY CONSERVATION POTENTIOAL

IN SUGAR INDUSTRY

Indian sugar industry is highly energyintensive

Energy efficiency is well below that of other
industrialized countries
Energy conservation measures shall lead to
reduction in cost of production
Thus to make Indian sugar industry more
competitive globally
The total energy conservation potential is 25 %
of total energy consumption

POTENTIAL FOR REDUCTION IN STEAM

CONSUMPTION

Reduction in direct steam leakages.

Rectification of faulty steam traps.

Insulation of bare pipes, flanges and valves etc. to reduce surface

temperature to 55 0C.

Reduction in redundant steam pipelines.

Pressure control and syrup Brix control in the evaporator section.

Adequate changes in steam and juice piping to ensure juice heating from
different bodies of evaporator.

Application of continuous pans for A,B & C boiling.

Application of continuous crystallizers for A, B & C massecuites and

continuous centrifugals for B & C curing, high gravity/high capacity batch
centrifugals for A curing etc.

Improved instrumentation and control for pressure and temperature of

exhaust steam required for process.

Rationalization of operations of minimize fluctuations in steam demand.

MAJOR ENERGY EFFICIENCY

IMPROVEMENT AREAS IN SUGAR
INDUSTRY

CANE MILLING
STEAM GENERATION
POWER GENERATION
SUGAR PROCESSING
LIGHTING SYSTEM
CO-GENERATION

CANE MILLING

Use of Antifriction bearings at head and tail shafts of

cane carrier and mill transmission gears
Use of HT motors for cane cutter and fibrizer
Use of VFD at cane carriers ,rake carriers
Use of high efficiency planetary gear drive
Use of hydraulic motor and AC VFD for mill drive
Use of belt conveyor in place of chain and slat conveyor
Optimization of imbibition percent
Adoption of complete mill house automation
Proper planning to decrease stoppages/reduce crushing
situation due to shortage of cane

STEAM GENERATION

By adopting high efficiency boilers, steam generation to fuel ratio

can be increased
Reduction in specific steam consumption by adopting high pressure
and high temperature boilers
Recovery of heat from flue gas by using bagasse dryer
Use of VFD for ID and FD fans
Use of HP/LP heaters for boiler feed water to increase cycle
efficiency
Recovery of heat from blowdown
The amount of blowdown should be minimized
Add waste heat recovery unit to blowdown for flash steam
generation
Adoption of complete automation at boilers
Avoid incomplete combustion
Control on excess air supply

EFFICIENT BOILER OPERATION

1.
2.
3.
4.
5.
6.
7.

It may means to reduce the heat losses to

minimum so as to increase the efficiency of
boiler
HEAT LOSSES
Heat loss in flue gas
Heat loss due to moisture in bagasse
Heat loss due to Hydrogen present in bagasse
Heat loss due to blowdown
Heat loss due to radiation /convection
Heat loss due to bad combustion of Carbon
Losses in unburned solids

REDUCE STACK TEMPEERATURE

Stack temperature greater than

170deg. C indicates potential for
recovery of waste heat
Use of bagasse dryer
22deg.C reduction in flue gas
temperature increases boiler
efficiency by 1%

FEED WATER HEATING BY

ECONOMISER/HP HEATER

First heating of feed water in Deaerator

Second stage heating in HP heater
Third stage heating in economizer
6deg.C rise in feed water
temperature corresponds to 1%
saving in fuel consumption

DE-AERATION

In de-aeration dissolved gases such as

oxygen and carbon dioxide are expelled by
pre heating the feed water
These gases greatly increase corrosion.
When heated in boiler system, CO2 and
O2 released and combined with water to
form carbonic acid
Removal of these gases from feed water is
vital to boiler equipment longevity as well
as safety of operation

DEAERATION TYPES

Mechanical
Chemical

Mechanical
The pressure type de-aerator operate by allowing steam
into feed water and maintaining pressure of about 1.5
kg/cm2. The steam rises the temperature of water causing
release of gases that are then vented from system
Reduce the oxygen content to 0.005 ppm
Chemical
Use of chemical oxygen scavenger such as
sodium sulfite and hydrazine
It remove traces of oxygen

COMBUSTION AIR HEATING

The rise in combustion air

temperature by 20deg.C will improve
thermal efficiency by 1%

INCOMPLETE COMBUSTION

IT MAY BE DUE TO FOLLOWING

REASONS
Shortage of excess air
Excess of fuel supply
Poor distribution of fuel

CONTROL ON EXCESS AIR

The optimum excess air level varies

with furnace design, type of fuel and
process variables
Excess air % theoretical air should
not exceed to 35%
For every 1% reduction in excess
air ,0.6% rise in boiler efficiency

REDIATION AND CONVECTION

HEAT LOSS

The surfaces lose heat to the

surroundings depending on surface
area and the difference in
temperature between the surface
and surroundings
With modern design boiler this loss
may represent only 1.5% on GCV

BLOWDOWN HEAT LOSS

1.

2.
3.
4.

This loss varies between 1% to 6% and

depends on number of factors
Total dissolved solids (TDS) allowable in boiler
water
Quality of makeup water
Amount of uncontaminated condensate return
Boiler load variations
Correct checking and maintenance of feed
water and boiler water quality, maximising
condensate return and smoothing load swings
will minimise the loss

BLOWDOWN HEAT RECORVERY

Blowdown of boilers to reduce sludge and

solids contents allows heat to go down the
drain
The amount of blowdown should be
minimised by allowing a good water
treatment programme
Installation of a heat recovery unit (heat
exchanger) in the blowdown line allows
the waste heat to be used in preheating
make up and feed water

AUTOMATIC BLOWDOWN
CONTROL

Uncontrolled continuous blowdown is

very wasteful
Automatic blowdown control can be
installed that sense and respond to
boiler water conductivity and pH

REDUCTION OFSCALING AND

SOOT LOSSES

Soot build up on tubes acts as an insulator against heat

transfer. Any such deposits should be removed on a regular
basis. Elevated stack temperature may indicate excessive
soot build up. Also same results will occur due to scaling on
the water side
Stack temperature should be checked and recorded
regularly as an indicator of soot deposits.
Every millimeter thickness of soot coating increases the
stack temperature by about 55deg.C
3mm of soot thickness can cause an increase in fuel
consumption by 2.5%
A 1mm thick scale on water side could increase fuel
consumption by5 to 8%

SUGAR PROCESSING

Optimization of evaporator design to minimize exhaust

steam needs and maximize vapour bleeding
Optimization of syrup Brix
Step wise recovery of flash heat from the condensate of
evaporator, juice heaters and pans
Use of first condensate for wash water heating at
centrifugals
Recovery of waste heat from clarifier flash tank
Selective incorporation of direct contact heater
Use of continuous pans for massecuite boiling
Seed sugar melting by using syrup and very low
temperature vapour in place of exhaust steam and hot
water
Use of efficient heat exchanger
Elimination of direct live steam bleeding in process
Adoption of process automation and controls
Discouraging production of bold grain
Use of low temperature vapour for pan washing
Heating of air by hot condensate at sugar dryer /hopper
Recovery of heat from non condensable gases

USE OF PLANETARY GEAR DRIVE

Transmission efficiency is about 90%

Combined efficiency of conventional
worm and worm wheel with enclosed
worm gear box is hardly 40-50%

HELICAL GEAR DRIVE

The efficiency of helical gear drive is

approx. 96-97%
The efficiency of worm gear box is 7080%

ELECTRICAL SYSTEMS

Have good potential to energy

conservation

ELECTRICAL LOADS

Two types of Electrical loads in modern

distribution system
1. Resistive
2. Inductive
Resistive loads are incandescent
lighting, resistance heating and use of
resistance in circuit.
Inductive loads are AC Motors,
transformers, induction furnaces

INDUCTIVE LOADS
Inductive loads require two type of power:
1. Active (Working ) power to perform the
work (KW)
2. Reactive power to create and maintain
electro-magnetic fields (KVAR)
The vector sum of active and reactive
power make up the total (apparent) power
(KVA)

POWER FACTOR

Power Factor ( COS ) = KW

KVA
Use of capacitors to improve P.F.
Improving Power Factor reactive
power can be reduced
That reduces the load on transformer

TO DETEMINE THE RATING OF

CAPACITOR

Power Factor improvement

From 0.72 to 0.95
Cos 1 = 0.72
Cos 2 = 0.95

Tan1 = 0.963
Tan2 = 0.329

KVAR required = P (Tan 1- Tan2)

= P (0.963 0.329)
Where P = Average active power (KW)

REDUCED POWER LOSS

As current flows through conductors,

the conductors heat.
Conductors loss can account to 2.5%
of total load
Capacitor can reduce power losses
by 1 to 2% of the total load

% Loss Reduction = 100x [1- (Original PF)2]

(Original PF)2

TRANSFORMERS

Transformers consist of two or more coils

that are electrically insulated but
magnetically linked.
Primary coil is connected to power source
and secondary coil connects to loads
The turns ratio is the ratio between the
number of turns on the secondary to the
turns on primary
Primary ampere turns are equal to
secondary ampere turns

TRANSFORMERS TYPES

Power transformers
Used in transmission network of higher
voltages for step-up and step-down
transformer application
(400KV,200KV,132KV,66KV,33KV)
Distribution transformers
Used for lower voltage distribution
network as a means to end user
connectivity(11KV,440V,230V)

TRANSFORMERS LOSS

Load loss (copper loss)=P1

No load loss (iron loss)=P2

The total transformer loss, P at any

load level can be calculated as
P = P1x (% load )2+ P2

TRANSFORMER LOSS FOR

DISTRIBUTION TRANSFORMER
KVA Rating

Voltage Rating No load loss

W

160
200
250
315
500
630
1000
1600
2000

11000/433

425
570
620
800
1100
1200
1800
2400
3000

Load loss
W

3000
3300
3700
4600
6500
7500
11000
15500
20000

TRANSFORMER LOSS FOR

DISTRIBUTION TRANSFORMER
KVA Rating

Voltage Rating

No load loss
W

630

33000/433 1450

Load loss
W

7500

1000

2200

11500

1600

3000

16000

2000

3300

21000

WAYS TO MINIMIZE DISTRIBUTION LOSSES

Relocating transformers and

substation near to load centres,
reducing LT network
Power factor improvement by
incorporating capacitors at load end
Optimum loading of transformer in
the system
Minimizing the losses due to weak
links in distribution network

ELECTRICAL MOTORS
Motors convert electrical energy into
mechanical energy by the interaction
between the magnetic fields set up in the
stator and currents in rotor windings
All motor types have four operating
components
1. Stator (Stationary windings )
2. Rotor (Rotating windings )
3. Rotor shaft with bearings
4. Frame

MOTOR SPEED

Synchronous Speed (RPM ) =

120 x Frequency (Hz)
Poles
Slip (%)= Synchronous speed-Full load speedx100
Synchronous speed

MOTOR EFFICIENCY
Efficiency = Input Losses x100
Input
= 746 x HP output x 100
Watts input

TO MAINTAIN VOLTAGE LEVELS

Motors are designed to operate within

10% of rated voltage, large variations
significantly reduce efficiency, power factor
and service life
When motor operates at less than 95% of
design voltage, motor loses 2 to 4 units of
efficiency and service temperature
increases up to 20o F, greatly reducing
insulation life
Running a motor above its design voltage
also reduces power factor and efficiency

MINIMIZE REWIND LOSSES

Rewinding can reduce efficiency and reliability

Rewind-versus- replace decision is quite complicated and
depends on variables as
1. Rewind cost, expected rewind loss
2. Purchase price of new motor/ energy efficient motor
3. Motor size and original efficiency

Majority of the users would wish to rewind the motor

During a motor failure, high temperature may occur. These
temperatures can, in many cases, effect the electrical
characteristics of the stator core steel and results in
increased iron losses and lower motor efficiency

MOTOR LOSSES

Core loss = 18% (22%) of total loss at

full load
Stator and rotor resistance (I2R) loss =
approx. 42%(56%) of total loss at full load
Friction and windage loss =
approx.30%(11%) of total loss at full load
Stray load loss = approx 10%(11%) of
total loss at full load

ENERGY EFFICIENT MOTORS

DESIGN FEATURES

1. Use of thinner gauge lower loss core steel reduces eddy

current loss. Longer core adds more steel to the design
which reduces losses due to lower operating flux density.
2. Use of more copper and larger conductors increases cross
sectional area of stator winding. This lowers resistance of
the windings and reduces losses due to current flow.
3. Use of larger rotor conductor bars increases cross section.
Lowering conductors resistance and losses due to current
flow.
4. Use of low loss fan design reduces losses due to air
movement.
5. Use of optimize design and strict quality control production
minimized stray load losses.

OPTIMIZE TRANSMISSION
EFFICIENCY

Transmission equipments like shafts,

belts, chains and gears should be
properly installed and maintained
When possible, use flat belts in place
of V-belts
Helical gears are more efficient than
worm gear
It is better to have direct drive like
planetary gears and hydraulic motors

LIGHTING SYSTEM

Make maximum use of natural light

(Use of translucent sheets / more windows and
opening )
Switch off when not required
Modify lighting layout to meet the need
Provide lighting transformer to operate at reduced
voltage
Install energy efficient lamps, luminaries and controls
Use of gas discharge lamps in place of incandescent
lamps
Use of Compact Fluorescent Lamps (CFL)
Use of Metal Halide lamps in place of
Mercury/Sodium lamps

CO-GENERATION

Sequential production of process

heat and electricity to export with
same fuel is termed as co-generation
In sugar industry the co-generation
is of TOPPING CYCLE
TOPPING CYCLE
The steam generated is fed to the
turbo generator and extracted at
desired pressure for process work

BENEFIT OF CO-GENERATION

The fuel, bagasse is renewable source of energy

The sugar industry generates additional power
with the bagasse which is used for generation of
steam to meet process requirements
Results in reduced emission levels and global
warming and is therefore environment friendly
Ensure fuel security
Co-generation project leads to reduction in
transmission losses considerably and thus helps
in stabilizing the grid voltage because of their
proximity to the load centres

ENERGY EFFICIENCY
IMPROVEMENT
Energy efficiency improvement and energy conservation is of great
importance for making the co-generation project viable and
sustainable in the long run

STEPS
1.The system up-gradation in the entire sugar manufacturing
process
2. Implementing energy conservation measures in respect of steam.
3. Implementing energy conservation measures in respect of
electricity
4. To reduce captive consumption
5. To save additional quantity of bagasse/electricity

TURBINE COFIGURATIONS FOR

CO-GENERATION

Pure back pressure turbine

Single extraction back pressure
turbine
Double extraction back pressure
turbine
Pure condensing turbine
Single extraction condensing turbine
Double extraction condensing turbine

Specific steam consumption in

condensing turbine
Steam temperature at the
turbine inlet, C

Steam pressure at the

turbine inlet, Kg/cm2
40

62

83

100

440

4.25

4.00

3.90

3.86

460

4.03

3.82

3.80

3.76

470

3.98

3.79

3.70

3.60

480

3.94

3.75

3.68

3.57

490

3.90

3.72

3.60

3.50

510

3.80

3.65

3.55

3.35

RENEWABLE ENERGY
Renewable can create a significant impact
in electric power generation. Indian
Renewable energy programme is the largest
and most extensive among the developing
country. Ministry of Non conventional
energy the nodal Ministry of the Govt. is
entrusted with responsibility of policy
making, planning, information and coordination of various aspects of renewable
energy. As per their draft policy set up for
the goal is to be achieved till 2012 an
addition of 10% share i.e. 12000 MW
through renewable.

RENEWABLE ENERGY
SOURCES

Co-generation from bagasse

Supplementary fuel such as cane
trashes, wood chips, rice husk and
other bio-mass material
Hydro-power
Wind power
Sea tides
Pelamis wave power

ENERGY MANAGEMENT
OBJECTIVE
The judicious and efficient production
and use of energy to maximize profit
with least contribution to global
warming

Principles of Energy Management

Produce and procure energy at lowest

possible price
Manage energy use at highest energy
efficiency
Reusing and recycling energy
Select low investment technology to meet
present requirement and environment
condition
Make use of wastes generated within the
plant

ENERGY MANAGEMENT SKILLS

Managerial Skills
1. Awareness, motivating employees
2. Changing structures and
procedures
3. Monitoring energy consuption and
target setting
Technical Skills
Well equipped with processes, energy
utilization technologies

Energy Management Strategies

Strategic Corporate Approach

Appointment of Energy Manager
Set up an energy monitoring and reporting
system
Conduct Energy Audit
Formalise an Energy Policy Statement
Prepare and undertake implementation
plan
Implement staff awareness and training
programme
Annual review