NAVA BHARAT VENTURES LIMITED

Investor Presentation19th NATIONAL AWARD FOR

EXCELLENCE IN ENERGY MANAGEMENT - 2018

Contents

Company Profile

Process Profile

Trend setting projects

Reduction in SEC & Global benchmarking

Encon projects

Involvement of employees

Environmental concern

Awards and accolades

Company profile

Corporate

with a

conscience

Company profile

*Zambia, South Africa, Tanzania and Zimbabwe

Aerial view of present

“Integrated Sugar Complex”

Integrated sugar complex

122 years old

▪ 1897 - Established as Gur Refinery

▪ 1902 - Commencement of Distillery

▪ 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

▪ 2005 - Co Generation power plant – 3300 TCD

▪ 2006 - ISO 9001 certified – 3500 TCD

▪ 2007 - ISO 14001 certified

▪ 2008 - One of the very few to register with UNFCCC in the sector

▪ 2011 - OHSAS 18001 certified – 4000 TCD

▪ 2012 - Ethanol plant

▪ 2013 - Spent wash evaporation plant

▪ 2014 - Multi fuel, 8 TPH Boiler for Distillery

▪ 2017 - Integration of Spent wash evaporation system with existing 20 KLPD Distillery

Sugar division profile

Process profile

Integrated sugar complex Process flow chart

MILLING

RAW JUICEBAGASSE

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

Mono Vertical Crystallizer 1982 - 83

Microwave probe for batch pan brix control 2003 - 04

AC VF Drives for Sugar Cane Mills 2004 - 06

Vapor Absorption Heat Pump (VAHP) for AC needs 2005-06

Quintuple 3rd effect vapour for Pan boiling and 2005 - 06

Clear Juice in place of condensate for pans, cfgl & sugar melter 2006 - 07

Integrated spent wash evaporation 2007 - 08

Sulphur free sugar without extra energy - Innovative award by CII 2007 - 08

Whole cane milling 2008 - 09

Bagacillo floatation cell 2009 - 10

Mechanical circulators for ‘A’ continuous pan 2010 - 11

Vibro screens for Raw juice - Innovative award by CII 2011 - 12

Four Massecuite boiling 2013 - 14

Increased juice drainage area for all the Mills - innovative award by CII 2015 - 16

Reduction in SEC &

global benchmarking

Reduction in SEC 2017-18

Reduction in SEC 2017-18

Addition of 5th Mill

Comparison with global benchmarks 2017-18

Parameters Global Norms

National

benchmark as

submitted to

CII

NBV – SD

Achievement

Specific Thermal

Energy Consumption

40-41%

As per ISSCT

proceedings

2005

32.81 %

M/s. EID Parry

Nellikuppam

32.16 %

Specific Electrical

Energy consumption

For sugar plant

operations alone

27-28 kWh/ton

of cane

As per NFCSF

21.35 kWh/ton

of cane

M/s. Madras

Sugars

24.40 kWh

Comparison with neighboring factories 2017-18

Description

Nearest Competitor-1

Nearest Competitor-2

NBV - Sugar Division, Samalkot

Thermal Energy (Steam% Cane) 35.76 32.4 32.16

Electrical Energy (KWH/TC) 27.46 25.8 24.40

The above comparison is for the crushing season 2017-18

Encon projects

Encon Project – 1

Improvement in capacity utilization

Previous Practice :

Higher specific thermal & electrical energy consumption due to low

average crush rate & capacity utilization.

Present Practice :

With the implementation of best preventive maintenance practices, down

time reduced from 8.25% to 6.58% thereby increased plant capacity

utilization from 75 to 82%. This resulted in reduction of specific thermal &

electrical energy consumption.

Result : Power - 1,11,500 kWh and Bagasse - 670 MT saved per season.

Investment in Rs.

Lakhs

Annual savings in

Rs.Lakhs

Payback

Months

- 15.0 -

Encon Project – 2

Utilization of Pressure difference

Previous practice :

Pumping (20 HP) of clarified syrup from runoff tank to evaporator 5th

body.

Present Practice :

Utilized the pressure difference according to vacuum in 5th body of the

evaporator. For this increased the line size from 4” to 6” and level

control valve was provided to transfer the clarified syrup.

Result : Power saving of 50000 kWh per season.

Investment in Rs.

Lakhs

Annual savings in Rs.

Lakhs

Payback

Months

1.0 2.0 6

Investment in Rs.

Lakhs

Annual savings in

Rs.Lakhs

Payback

Months

1.5 2.6 7

Previous practice :

B continuous centrifugal machine massecuite feed control was done

manually.

Present Practice :

Installed IRIS feed control valve to B continuous centrifugal machine

and massecuite feeding done in auto mode. This helped to optimize

the machine capacity there by reduction in running hours of the

machine.

Result : Power saving of 63000 kWh/ season

Encon Project – 3

Installation of IRIS control valve

IRIS Control Valve with panel

Investment in Rs.

Lakhs

Annual savings in

Rs.Lakhs

Payback Months

5 2.0 30

Previous practice :

Conventional worm reduction gear box for C massecuite mono vertical

crystallizer.

Present Practice :

Replaced the conventional gear box with planetary drive to reduce the

power consumption and maintenance cost.

Result : Power saving of 22000 kWh / Season

Encon Project – 4

Installation of Planetary drive

Investment in Rs.

Lakhs

Annual savings in

Rs.Lakhs

Payback Months

3.3 2.0 20

Previous practice :

SV & Metal halide lamps were installed in the plant & Colony

Present Practice :

96 Nos. of SV lamps and Metal halide lamps were replaced with LED.

Result : Power saving of 48000 kWh / year

Encon Project – 5

Installation of LED lights

Other encon projects

SN Project Name

Year

Power saved

in million kWh

Bagasse saved in

Tons

Annual Saving

s in million

Rs

Investment in million

RsPayback in

Months

1 Reduction in steam & power consumption per tonne of cane with increase in average crushing rate by reducing plant downtime.

2017-18 1.11 670 1.5 0 Immediate

2 Avoided the operation of clarified syrup transfer pump from syrup clarification by providing 6” pipe line to transfer the syrup by means of vacuum by using the pressure difference in the system.

2017-18 0.0504 - 0.206 0.1 6

3 Installation of high precision massecuite feed control valve for NK1503 B continuous centrifugal machine for effective capacity utilization and to reduce power consumption

2017-18 0.0633 - 0.26 0.15 7

Encon projects implemented during last three years.

Other encon projects…. Contd.

SN Project Name

Year

Power saved

in million kWh

Bagasse saved in

Tons

Annual Savings in million Rs

Investment in million

RsPayback in

Months

4 Installation of planetary drive in place of conventional worm reduction gear for C massecuite Mono Vertical Crystallizer to reduce the power consumption.

2017-18 0.022 - 0.2 0.5 30

5 Replacement of SV lights with LED lights to reduce the power consumption.

2017-18 0.048 - 0.2 0.336 20

6 Plugging of Evaporator condenser nozzles to reduce the water consumption for energy saving

2016-17 0.05 - 0.2 0 Immediate

7 Replacement of 10 Nos. of old motors with energy efficient motors

2016-17 0.01 - 0.04 0.2 24

SN Project Name YearPower saved

in million kWh

Bagasse saved in

Tons

Annual Savings in million Rs

Investment in million

RsPayback in

Months

8 Replacement of 20 Nos. of SVLights with LED lights at plant& colony street lighting

2016-17 0.0026 - 0.015 0.053 43

9 Replacement of 4 Nos. ofwelding transformers withrectifiers

2016-17 0.071 - 0.284 0.27 11

10 Installation of lotus top rollerin place of conventional rollerfor 5th Mill along withincreased juice drainage areafor all the mills

2015-16 - 2500 15.4 0.15 Immediate

11 Reduction in power plantauxiliary consumption by0.24% with the reduction inBagasse Moisture .

2015-16 0.085 - 0.36 - Immediate

Other encon projects…contd.

Other encon projects…contd.

SN Project NameYear

Power saved in million kWh

Bagasse saved in

Tons

Annual Savings in million Rs

Investment in million

RsPayback in

Months

12 Diversion of processcondensate to polishingpond stream to reduce theeffluent load on sugar ETP.

2015-16 0.023 - 0.1 0.01 1

13 Utilization of clear juice in place of hot water at 'A' continuous pan to reduce the steam consumption.

2015-16 - 170 0.27 0.03 1

Total savings from past three

years 1.53 3340 19.03 1.8

Involvement of employees

ENERGY CONSERVATION CELL

Vice PresidentAs Advisor

General Manager - Plant(Certified Energy Manager)

H.O.DMech.

H.O.D

E & I

H.O.D

Process

Shop Floor Engineers and Process Technologists

Team Leaders

Source of ideas and implementation team

Involvement of employees

H.O.D

Dist.

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

Involvement of employees…contd.

S.noENCON idea Year of

implementationSource of

ideaAnnual savings

1 Installation of high precisionmassecuite feed control valve forNK1503 B continuous centrifugalmachine

2017-18 C&I technician

2.6 Lakhs

2 Avoided the operation of clarifiedsyrup transfer pump from syrupclarification

2017-18 Process supervisor

2 Lakhs

3 Installation of planetary drive in placeof conventional worm reduction

2017-18 Mechanical fitter

2 lakhs

4 Replacement of SV lights with LEDlights

2017-18 Electricaldept.

2 Lakhs

Projects implemented

▪ Utilization of smart sensors for motors operating in remote area

▪ ERM software for online centralized monitoring of all electrical parameters

to reduce the losses and improve the power factor

▪ PC based thermal image to identify the thermal losses and to prevent

electrical breakdowns

▪ Extensive use of energy meters and flow meters

▪ Flow meter for instrumentation air and air audit by external agencies

▪ Dynamic balancing of all rotating equipments by external agencies

▪ Internal and external energy audits at regular intervals

▪ Display of section wise target Vs actual energy consumption parameters at

appropriate areas

▪ Daily report to the top management

Monitoring & reporting

Photograph of the motor with Smart Sensor

Environmental concern

Environmental Project -1Installation of Lateral Agitators for fermenters 2017

Installed 6 Nos. of lateral agitators for

fermenters at distillery to increase the Alcohol

yield and to reduce the effluent generation.

Effluent generation (before) - 30 M3 / day

Effluent generation (after) - 15 M3 / day

Environmental Project – 2

Stripper column for MEE condensate 2016

Installed stripper column to reuse the

MEE condensate for Distillery cooling

tower makeup and to minimize the

usage of ground water consumption

MEE Condensate reused - 60 M3/day

Environmental Project - 3Spent wash evaporation plant 2013

Installed 170 M3 / day capacity Spent wash evaporation plant in 2013 for further

concentration of reject from RO plant

Input quantity - 120 M3 / day

Condensate - 60 M3 / day

Reject - 60 M3 / day

used for organic manure

Other environmental projects

▪ Reduced the lubricants consumption from 25.65 ml to 24.57 ml per

ton of cane during 2017-18 season.

▪ Online opacity and treated effluent monitoring system

▪ On foot rally on the eve of “World Environment Day”

▪ Effluent quantity reduction at distillery by installing higher capacity

▪ PHE’s and using dry yeast in place of bakers yeast

▪ Awareness meeting by top management on Environment protection

▪ Plantation of saplings in and around the plant

Plantation of Saplings on World Environment Day

1. ETP sludge Converted into bio manure and issued to farmers

▪ 660 MT of sludge in 2017-18

▪ 350 & 400 MT of sludge in 2016-17 & 2015-16

2. Promoted boiler ash for brick manufacturing

▪ 4800 MT of ash in 2017-18

▪ 3300 & 3575 MT of ash in 2016-17 & 2015-16

3. Press mud and distillery spent wash are used for producing organic

manure, which minimizes the chemical fertilizer consumption

▪ 8500 MT of organic manure in 2017-18

▪ 10000 & 9000 MT of organic manure in 2016-17 & 2015-16

4. Utilization of Bio gas as fuel to boiler

▪ 807000 NM3 of bio gas in 2017-18

▪ 1365000 & 1358000 NM3 of bio gas in 2016-17 & 2015-16

Utilization of waste

IMS – Non conformities summary 2016 - 18

SNName of the Standard

Number of Non Conformities

2016 2017 2018

1 ISO 9001 : 2015 1 Nil 2

2 ISO 14001 : 2015 Nil Nil 5

3 OHSAS 18001 : 2007 2 2 2

SN ENCON idea Year Benefit

Appx.Annual

savings in Rs. Lakhs

1 Replacement of 300 CFM reciprocating aircompressor with 380 CFM screw type.

2018 - 19Power saving and

reduced O&M cost1.6

2 Installation of VFD for air blower at Sulphurstation

2018-19Power saving and

reduced O&M cost2.8

3 Installation of LED lamps in place of SV lamps in sugar processing section

2018-19Power saving

5.3

4 Replacement of 10 Nos. of old motors with energy efficient motors

2018-19Power saving

0.41

5Installation of Plate type condenser for A CVP 2019-20

Ground Waterconservation

----

Future Encon & Enviro Projects

Awards & Accolades

Awards & Accolades from past four years

Best Technical efficiency gold award by SISSTA 2017

Best Co-generation silver award by SISSTA 2017

Best overall performance of Sugar Mill Award by Bharatiya Sugar 2017

Excellent energy efficient unit award by CII 2016

Most Innovative project award by CII 2016

Energy efficient unit award by CII 2015

Dr. Bhansi dhar gold medal award by STAI 2014

Excellent energy efficient unit award by CII from 2007 to 2012 ,2014 & 2016

Thank you