RECORDS OF ENERGY CONSERVATION COMPARISION OF LAST TWO YEARS

Transcription

1 RECORDS OF ENERGY CONSERVATION COMPARISION OF LAST TWO YEARS Energy Consumption: There is a steady decline of specific energy conservation due to implementation of various energy conservation measures in last 2 years. The details are as given below: DESCRIPTION UNIT Annual Milk & Milk Production MT Total Electricity Consumption / Annum Specific Energy Consumption Total Thermal Energy Consumption / Annum Specific Energy Consumption Thermal Lakh Kwh Kwh / MT Million kcal Million Kcal / MT

2 Electrical (A) & Thermal (B) Energy Saving Achievements for Year :- ( A ) Electrical Points Year of Commi ssionin g of the projects Project Description Achievement of Annual Energy Savings in Investment incurred on Electricity Fuels Total Savings the project (Rs.Lakh) Rs.(Lakhs) 1. Getting Rebate in Power bill for Maintaining Unity Power Factor for the system 2. Installation of Soft Starter in place of Conventional starters upto 10 HP Motors in Plant Area - 25 No 3. Installation of Low speed 2 HP Agitator in place of 7.5 HP Agitator for Milk Silos - 4 No 4. Installation of Ammonia Based Milk Cold Storage in place of Freon Based at Main Gate area 5. Installation of VFD for Milk pouch filling Direct from Milk Silo in place of VMST - 2 Nos 6. To Reduce the Chilled Water Supply pressure from 3.5 Bar to 3.2 Bar for Supplying the chilled water in plant area 7. Energy Saving for Crate Washing & Crate Conveyor by Installation of High Speed Milk Pouch Packing Machine in place of Conventional Machine - 1 Line 8. Energy Saving for Pouch Machines by Installation of High Speed (Speed : 9600 Pouches / Hr) Milk Pouch Packing Machine in place of Conventional Machine ( Speed : 5400 Pouches / Hr ) - 5 Nos 9. Installation of 30 HP VFD in Place of Star Delta Starter for Air Blower of Aearation Tank at ETP 10. Installation of Energy Efficient Grundfoss Make 20 HP Energy Efficient Pump in place of 30 HP Pump at Boiler Feedwater 11. Installation of VFD on Air Blower Motor of Burner at Boiler 12. Installation of 120 Watt LED Lowbay Lighting Fixtures in place of 250 Watt for Plant Lighting - 35 No 13. Installation of VFD in place of Star Delta Starter on 40 HP motor for Alfa Laval Butter Churn 14. Installation of Energy Efficient Grundfoss make 7.5 HP Pump in place of 12.5 HP for Under Ground Tank Return pump 15. Installation of VFD in place of DOL Starter for Booster pump of Milk (Lakh KWh) F. Oil (KL) Gas (Lakh Nm 3 ) Total Fuel ( MTOE )

3 Pastuerizer - 2 No 16. Installation of Energy Efficient Grundfoss make 3 HP Pump in place of 5 HP for Chilled water circulation in pouch machines 17. Installation of 45 Watt LED Street Light Fixtures in place of 150 Watt for Campus Lighting - 30 No 18. Reduce the Running hour for Chilling Of Milk by Installation of Energy Efficient Chiller for GOA plant 19. Installation of 33 Watt LED Light Fixtures in place of 72 Watt for Office Lighting - 30 No Total Electrical ( A )

4 ( B ) Thermal Points Year of Commi ssionin g of the project s Project Description Achievement of Annual Energy Savings in Investment incurred on Electri Fuels Total the project city Savings Rs.(Lakhs) (Rs.Lakh) 1. To Reduce the Setpoint of Germfree Chemical from 59 Deg C to 45 Deg C for Process CIP system 2. Installation Plant Packaged Room System (PPRS) in place of Direct heating for Dahi Section 3. Installation Plant Packaged Room System (PPRS) in place of Direct heating for UHT Section 4. Installation of VFD for Milk pouch filling Direct from Milk Silo in place of VMST - 2 Nos 5. Energy Saving for Crate Washing & Crate Conveyor by Installation of High Speed Milk Pouch Packing Machine in place of Conventional Machine - 1 Line 6. Prevention of thermal losses by adopting LRB insulation in place of Glass wool for 1.5", 2" & 3" of Hot water lines 7. Installation of Economizer in Boiler for Recovery of heat & use for Feed water 8. Recovery of Flash steam of 10 TPH Boiler (Lakh KWh) F. Oil (KL) Gas (Lakh Nm 3 ) Total Fuel ( MTOE ) Total Thermal ( B ) Grand Total (Electrical + Thermal) (A ) + ( B )

5 Brief write up for the Electrical (A) & Thermal (B) Energy Achievement points for Year ( A ) Electrical Points 1. Getting Rebate in Power Bill for Maintaining Unity Power Factor for the System. By installing APFC we are now maintain Unity power factor in power bill. For maintaining that we got Lakh Rupees in the year as a rebate in power bill from M/s Torrent Power. 2. Installation of Soft Starter in place of Conventional starters up to 10 HP Motors. Replacement of 25 Nos Conventional Starters with Soft Starters for various pumps in plant MCC panel. Earlier pumps were taking 9.6 Amps at Full load now after installation of Soft starters, pumps are running at Average Amp of 8.1. So overall power consumption is gone down by 431 Units (Kwh) per Day. 3. Installation of Low Speed 2 HP Agitator in place of 7.5 HP Agitator for Milk Silos 4 Nos. Replaced 4 Nos of 7.5 HP Milk Agitators of Milk Silos with 2 HP Energy Efficient Agitators with special design of propellers. By doing this replacement there is no change in Agitation system of Milk. Earlier the Agitator was getting 10.5 Amp at Full load now after installation of Low speed agitator is getting 2.5 Amp. So overall power consumption is gone down by 414 Units (Kwh) per Day.

6 4. Installation of Ammonia based milk cold storage in place of Frion Based at Main gate area. Earlier our Milk cold storage was run on Frion based refrigeration system. Now we have converted our Frion based cold storage to Ammonia based system. So power consumption gone down by 370 Units (Kwh) per Day. 5. Installation of VFD for Milk pouch filling Direct from Milk Silo in place of VMST 2 Nos. Earlier we use to run the pouch machines by gravity of milk transfer from our VMST to pouch filling machines. At that time the milk was transferred from PMS (Pasteurized Milk Silo) to VMST (Vertical Milk Storage Tank) and VMST to pouch filling machines by gravity. Now we have installed VFD on milk transfer pump of PMS to Direct Milk pouch packing machines which is controlling the pump through the feedback of pressure transmitter. So the equal pressure maintain throughout the line along with getting good control on weight variation in milk pouches. Also bypassed all VMST so there is no need to run the agitator of all VMST & CIP of the VMST could be avoided which reflecting large amount of energy saving in terms of power. Therefore power consumption is gone down by 241 Units (Kwh) per Day. Advantages are listed below due to starting of direct filling of milk from PMST to Pouch machines:- (1) Earlier PMST transfer pump rating was 15 HP at present it is 7.5 HP. (2) 2 Nos of VMST are bypassed hence 2 nos of agitators operations are avoided having a rating of 2 HP. (3) CIP of both VMST are not required hence water, acid & caustic consumption goes down. Also stopped the operation of Forward & Return pump of CIP. (4) Accuracy of the Milk filling in pouches is increased & getting good control on weight variation in pouch machines. Pouch filling time is decreased due to continuous availability of milk from PMST (Avoided the changeover of VMST)

7 6. To Reduce the Chilled water supply pressure from 3.5 Bar to 3.2 Bar for supplying the Chilled water in plant area. Earlier we were supplying chilled water at the pressure of 3.5 Bar to our plant area for chilled water application. Now we have installed chilled water flow control valve and changed th process, we are able to reduced chilled water supply pressure from 3.5 Bar to 3.2 Bar without affecting process parameter. So overall power consumption is gone down by 172 Units (Kwh) per Day. 7. Energy Saving for Crate Washing & Crate conveyor by installation of High Speed Milk Conventional Machine 1 Line. As we have installed the new energy efficient high speed pouch packing machines, running hours of the crate washing & crate conveying systems gone down about 3 to 4 hours. It is reflecting to saving in energy (power). And hence the total power consumption is gone down by 144 Units (Kwh) per Day.

8 8. Energy Saving for Pouch Machines by Installation of High Speed (Speed : 9600 Pouches / Hr.) Milk Pouch Packing Machine in place of Conventional Machine (Speed : 5400 Pouches / Hr.) 5 Nos. Earlier in the pouch section we had conventional milk pouch packing machines having a speed of 5400 pouches per hour & the full load of the one machine was 20 Amp. Now we have installed energy efficient high speed milk pouch machines having load of 16 Amp for one machine. So the power consumption gone down by 115 Units (Kwh) per Day. 9. Installation of 30 HP VFD in place of Star Delta Starter for Blower of Aeration Tank at ETP. Earlier the motor of Air blower was running on star delta starter. Now we have installed the soft starter on the motor of Air Blower which is controlling the amp of air blower motor and a result we have saved around 115 Units (Kwh) per Day. 10. Installation of Energy Efficient Grundfoss make 20 HP Pump in place of 30 HP Pump at Boiler Feed Water. Earlier 30 HP Pump was being used to supply the feed water to the Boiler. Now we have installed Energy Efficient 20 HP Grundfoss make vertical pump to supply the feed water to the Boiler drum. We are able to save 108 Units (Kwh) per Day.

9 11. Installation of VFD on Air Blower motor of Burner at Boiler. Earlier Air blower motor was being run on Star Delta Starter. Now we have installed VFD on Air Blower Motor at Boiler. We are able to save 103 Units (Kwh) per Day. 12. Installation of LED Lowbay Lighting Fixtures in place of 250 Watt Conventional fixtures for plant lighting 35 Nos. Earlier 250 Watt Conventional fixtures were used for the lighting in the plant. Now we have installed Energy Efficient Lowbay LED lighting fixture having wattage of 120 in the plant area. So overall lighting power consumption is gone down by 91 Units (Kwh) per Day. 13. Installation of VFD in place of Star Delta Starter on 40 HP Motor for Alfa Laval Butter Churn Machine. Earlier Butter Churn motor was being run on Star Delta Starter. Now we have installed VFD on Motor of Butter Churn. Therefore we are able to save 72 Units (Kwh) per Day.

10 14. Installation of Energy Efficient Grundfoss make 7.5 HP Pump in place of 12.5 HP for Under Ground Tank Return Pump. Earlier 12.5 HP Pump was being used for Return pump of UGT. Now we have installed Energy Efficient 7.5 HP Grundfoss make vertical pump for UGT. Therefore we are able to save 60 Units (Kwh) per Day. 15. Installation of VFD in place of DOL starter for Booster Pump of Milk Pastuerizer 2 Nos. Earlier both Booster pumps were running at full frequency along with throttling of valves, now we have installed 2 Nos of VFD for Booster pumps of Pasteurizer. Now the pumps are taking 7.5 Amp in place of 10 Amp. So power consumption is gone down by 57 Units (Kwh) per Day. 16. Installation of Energy Efficient Grundfoss make 3 HP Pump in place of 5 HP for Chilled Water Circulation in Pouch Machines. Earlier 5 HP Pump was being used for chilled water circulation in pouch machines. Now we have installed Energy Efficient 3 HP Grundfoss make vertical pump for chilled water circulation. Therefore we are able to save 43 Units (Kwh) per Day.

11 17. Installation of 45 Watt LED Street light fixtures in place of 150 Watt for Campus lighting 30 Nos. Earlier 150 Watt Conventional fixtures were used for the lighting in campus area. Now we have installed Energy Efficient LED lighting fixtures having wattage of 45 in the campus area. Hence overall lighting power consumption is gone down by 43 Units (Kwh) per Day. 18. Reduce the Running hour for Chilling the Milk by Installation of energy Efficient Chiller for GOA plant. Earlier we were using Conventional chiller to fill the milk for GOA plant. Now we have replaced Energy Efficient GEA make PHE chiller for chilling the milk for GOA plant. Therefore we are able fill the tanker at 4 Deg C in less time. Overall power consumption gone down by 22 Units (Kwh) per Day. 19. Installation of 33 Watt LED light Fixtures in place of 72 Watt for Office lighting 30 Nos. Earlier 72 Watt Conventional fixtures were used for the lighting in offices. Now we have installed Energy Efficient LED lighting fixtures having wattage of 33 in the offices. So overall lighting power consumption is gone down by 9 Units (Kwh) per Day.

12 ( B ) Thermal Points 1. Reducing the Setpoint of Germfree Chemical from 59 Deg C to 45 Deg C for Process CIP System. Earlier in Central CIP system, Sterilization through Germfree chemical was being done at 59 deg. C. temperature leads to consumption of more steam & ultimately high Natural Gas consumption. Now after the setpoint of Germfree Chemical for sterilization is being done at 45 Deg. C. temperature leads to consume less Steam. This reflects in the saving of Thermal Energy & hence the total Natural Gas consumption is down by 352 Units (SCM) per Day. 2. Installation of Packaged Plant Room System (PPRS) to supply hot water in place of Direct heating for Dahi Section. Earlier Hot Water tank was installed with direct steam injection in it & due to design constraint, condensate could not be recovered. installation of Hot Water Generator System (PPRS Packaged Plant Room System PHE based system) steam condensate could be recovered & sent back to Boiler Feed Water Tank. This reflects in the saving of Thermal Energy & hence the total Natural Gas consumption is down by 248 Units (SCM) per Day.

13 3. Installation of Packaged Plant Room System (PPRS) to supply hot water in place of Direct heating for UHT Section. Earlier Hot Water tank was installed with direct steam injection in it & due to design constraint, condensate could not be recovered. installation of Hot Water Generator System (PPRS Packaged Plant Room System PHE based system) steam condensate could be recovered & sent back to Boiler Feed Water Tank. This reflects in the saving of Thermal Energy & hence the total Natural Gas consumption is down by 209 Units (SCM) per Day. 4. Installation of VFD for Milk Pouch filling Direct from Milk silo in place of VMST 2 Nos. Earlier we use to run the pouch machines by gravity of milk transfer from our VMST to pouch filling machines. At that time the milk was transferred from PMS (Pasteurized Milk Silo) to VMST (Vertical Milk Storage Tank) and VMST to pouch filling machines by gravity. Now we have installed VFD on milk transfer pump of PMS to Direct Milk pouch packing machines which is controlling the pump through the feedback of pressure transmitter. So the equal pressure is maintained throughout the line & also getting good control on weight variation in milk pouches. Also bypassed all VMST so there is no need to run the agitator of all VMST & CIP of the VMST could be avoided which reflecting large amount of energy is saving in terms of Thermal Energy (Natural Gas). Therefore Natural Gas consumption is gone down by 151 Units (SCM) per Day.

14 5. Energy Saving for Crate Washing & Crate Conveyor by installation of High Speed Milk Pouch packing machine in place of Conventional Machines 1 Line. As we have installed the new energy efficient high speed pouch packing machines, running hours of the crate washing & crate conveying systems gone down about 4 hours. It is reflecting in saving of energy (Steam - Thermal). And hence the total Natural Gas consumption is gone down by 90 Units (SCM) per Day. 6. Prevention of thermal losses by adopting LRB insulation in place of Glass wool for 1.5, 2, 2.5 & 3 hot water supply lines. Earlier Hot Water & Steam lines were insulated by using Glass Wool as insulation material leads to more surface temperature on insulated line compared to ambient temperature. Now we have replaced Glass Wool by LRB insulation material & found less surface temperature on insulated line. This reflects in the saving of Thermal Energy & hence the total Natural Gas consumption is down by 51 Units (SCM) per Day. Advantages are listed below due to Adoption of the LRB insulation in place of Glass wool:- (1) Surface Temperature of the Insulated lines reduced by 5 Deg C. as compared to Glass wool insulation leads to reduction of Fuel Consumption in Boiler. (2) Possibility of spreading Glass Wool Particles in the surrounding area of insulated lines is avoided which is not acceptable as per ISO requirement & also it is harm full to human body. Repairing of Insulation could be avoided due to adoption of LRB Insulation.

15 7. Installation of Economizer in Boiler for Recovery of heat & pre-heating of Feed water. Earlier there was no economizer and hence heat of flue gas was not utilized, now we have installed Energy Efficient Economizer in between boiler and chimney to utilize flue gas temperature to pre-heat the feed water of boiler. Hence we are able to save 45 Units (SCM) per day by installing Economizer in Boiler. 8. Recovery of Flash Steam of 10 TPH Boiler. Earlier there was no system for recovery of flash steam and hence heat of flash steam was not utilized, now we have installed Energy Efficient system in boiler to utilize flash steam to pre-heat the feed water of boiler. Hence we are able to save 43 Units (SCM) per day by installing Economizer in Boiler.

16 Energy Graphs Overall Power consumption Ratio (Kwh/MT of Milk & Milk Product) is down from in the year to in the year due to installation of Energy Efficient Equipments in the plant.

17 Overall Specific Thermal Energy Consumption (in Million Kcal / Milk Handling in Tons) is down from in the year to in year due to installation of Energy efficient equipments.

18 Summary of Annual Saving in Energy Conservation Section Investment, Rs. in Lakh Annual Saving, Rs. In Lakh Electrical Thermal TOTAL Energy Conservation Journey of Sumul Dairy, Surat SR NO. PERTICULAR RANK YEAR SNAP 1 National Energy Conservation 1 st 2006 Award from Ministry of Power (Govt. of India). 2 National Energy Conservation Award from Ministry of Power (Govt. of India). 2 nd National Energy Conservation Award from Ministry of Power (Govt. of India). 1 st National Energy Conservation Award from Ministry of Power (Govt. of India). 2 nd National Energy Conservation Award from Ministry of Power (Govt. of India). 1 st 2013