ENERGY MANAGEMENT IN A SUGAR INDUSTRY A CASE STUDY: UTTAM SUGAR MILLS LIMITED, LIBBERHERI

Abstract

Energy has played an important role in world wide progress and industrialization. The rapid increase in population and desire for a higher standard of living has led to very sharp increase in the consumption of conventional energy resources. Deregulation of the energy market has created new opportunities for the development of new energy management methods based on energy assets and energy efficiency. Energy needs to be managed well to increase the business profitability and competitiveness. Thus setting up and running an effective energy management programme is of paramount importance. Potential for enhancing efficiency exists, in both operational and technological aspects. Much emphasis is placed on technological actions such as equipment retrofit and upgrades. Thus the need of the hour is to identify the equipments, operations involving high energy cost and to understand the energy behaviour. Energy management in the form of implementing new energy efficient technologies, materials and manufacturing processes helps the companies in improving their productivity and product or service quality. In this report a sugar processing plant having a capacity of 5500 TCD has been analyzed. The thermal analysis has been carried out for two boilers each of capacity 45 TPH and the third boiler of 50 TPH. Efficiencies of all the boilers obtained by direct method are in the range of 65% to 73% whereas by indirect method are in the range of 54% to 61%. The flue gas analysis has been done using flue gas analyzer (IMR2800P) and the combustion efficiency obtained is 92%. Heat loss calculation from the surface of the pipes and pans has been done and the equivalent saving of the bagasse, are indicated. Retrofitting techniques have been recommended for the lighting systems and economizer. The conventional FTLs are proposed to be replaced by energy efficient CFLs. Potential energy saving of 20-30% has been observed by retrofittings of lamps. Variable frequency drives are recommended for ID, FD fans, motors and pumps. The economic analysis of the sugar plant includes retrofittings techniques of different thermal and electrical components indicating payback periods.