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Cost reduction in sugar production: A case study
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Saturday, 09 December, 2006, 08 : 00 AM [IST]
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U K Ghute, A J Shinde, R D Kadam
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lised the crushing capacity above 150% since last 5 seasons. The capacity utilisation is the most important factor for reducing the cost of sugar production in sugar industry. The capacity of plant is measured in terms of tonnes of cane crushed per day.
Following are the measures which have reduced our cost of sugar production.
1. Capacity utilisation
2. Hours lost % hours available
3. Steam consumption
4. Power saving
5. Additional equipments in boiling house
6. Store inventory
7. Manspower
1. CAPACITY UTILISATION
The higher capacity utilisation reduces the consumption of oil, lubricants, steam consumption, chemicals, power & ultimately increases bagasse saving per ton of cane crushed. We have crushed up to 2810 MT of cane for a day during season 2002-03.Following main factors involved to achieve the maximum capacity utilisation.
a) Preparative index:
To improve milling efficiency "PI" plays major role. Higher the "PI" higher the primary mill extraction, higher mill extraction. However, there shall be balance between "PI" and Power consumption. We have achieved up to 87 "PI" by using heavy duty swing type fibrizer.
b) Auto cane feed system:
The system ensures confirmed cane feeding (of the first mill by taking the load sensing from fibriser, first mill and height of Donnelly chute without kick load. We have achieved uniform crushing rate, the variation in crushing rate is+- 50 tonnes per day only. We arc able to change the feed rate at any time.
c) Rotary juice screen:
We have installed rotary juice screen of SS wedge bar with 0.5 mm slot width for separation of Cush Cush particle and fine bagacillo to avoid recirculation of juice and unnecessary load on mill. The clarification of juice is improved, the load on clarifier reduced and chemical consumption is also reduced to some extent.
2. HOURS LOST - % HOURS AVAILABLE:
Continuous working is desirable for efficient working of plant. Generally mill stoppages occur due to
1. Cane shortage
2. Mechanical & electrical stoppages
3. General periodical cleaning
Our management had already planned to supply the sufficient cane for crushing in time. Shortage of cane reduces the capacity utilisation and increase the production cost. To reduce the breakdown maintenance we have a condition monitoring. During off-season we check the condition of machinery spares and replace it if necessary. During season also we check the condition of running machinery and take appropriate action by preplanning to avoid sudden major breakdown of ions time.
3. STEAM CONSUMPTION
We have adopted maximum vapour bleeding system in boiling house which have saved steam and ultimately increased the bagasse saving. The vapour bleeding system is as shown in drawing No 1
4. POWER SAVING
We have installed harmonic filter in power department to avoid variation in power factor. We have achieved power factor up to 0.90 to 0.91. The bus bar temperature is reduced and current drawn is less.Ultimately KW and crushing capacity of the plant is increased. To reduce the power consumption we have discarded all juice heater condensale pumps except pre-heater and condensate is taken into the evaporator condensate receiver as shown in drawing No. 2.Previously, We were taking clarifier mud into the mud tank by gravity and then it was lifted in mud mixer by a mud pump. We have taken the compartmenl wise mud directly into the mud mixture by gravity flow and saved the pump and power for the same.
Instead of separate light and heavy filtrate pump receiver, we have taken light and heavy filtrate into a common receiver and whole filtrate is lifted by only one pump and another pump is used as a stand by.
a) Juice and water flow meter
Use of mass flow meter for juice and water eliminates one stage of pumping and juice is directly pumped to sulphitation through juice heater.Use of mass flow meter for juice & water stabilises the fix percentage of water to cane at a varying crushing rate. The constant rate of flow for mix juice helps to maintain the clarity, constant pH and temperature of juice. With this we have achieved better quality of juice and reduced the quantity of lime and sulphur. Last year our consumption of sulphur and lime percent cane is 0.05 & 0.145 respectively.
b Water management
We have a well planned water management system from last four years. We are able to run the plant without in take of fresh water. Recycling of once taken water is done for process throughout the season.This resulted in a saving of crore liters of water and cost due to it. Load of ETP and cost for processing the effluent water is also reduced. We have minimized the wastage of water by plugging the water taps for hand washing and floor washing.
We have collected all air vent condensate of pan. 1st body of evaporator & preheater in a hot water imbibition tank for mill imbibition. We have taken all compressor cooling water, desuper heater drain water, super heater water wash drain, vacuum pump cooling water to the mini spray. Excess hot water from over head tank is taken to the mini spray for cooling.All these cooled water is sent to the Ground Service water Reservoir for reuse.
5. ADDITIONAL EQUIPMENTS IN BOILING HOUSE
We have installed one semikestner of 2000 sq. mtrs. heating surface area and a 60 MT capacity low head calandria W saucer type pan during last crushing season for up gradation of higher capacity utilization.
Our semikestner commissioned on dt. 27 December, 2005. Up to which we have crushed 105280 MT of cane on Quadruple. We have taken on line the new SK as one body of quintuple set & crushed continuously 2500 to 2600 MT of cane per day. We have avoided the general periodical cleaning and saved the cleaning chemicals and reduced down time. This also helped to minimize the steam consumption and ultimately increased bagasse saving.After installation of new 60 MT pan from 21 January, 2006 for A boiling. We have produced up to 50% M30 sugar.
6. STORE INVENTORY
We have developed technique of yearly rate contract of machinery spares, chemicals, stationery, cleaning equipments and all types of consumable items. We intimate the party to supply the material whenever required which reduces the store inventory cost and avoids blockage of unnecessary capital.
7. MANPOWER
As the saying goes "man behind the machine is extremely important". To develop worker relations we conduct (he seminars on "Human Research Development"We have appointed only 50% staff as compared Lo staffing pattern recommended for 1250 TCD. We have installed computer online system for cane weighing, cane harvesting, cane plantation, billing. Inventory management, Finance and cost accounting etc.
Source: The Deccan Sugar Technologists' Association (India), Pune
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