By Zenith Energy Services (P) Limited Hyderabad

1. Presentation on Vellore Rice-mills Cluster Vellore, Tamilnadu State By Zenith Energy Services (P) Limited Hyderabad

2. Schedule of Implementation Zenith Energy Services Pvt. Ltd. started Energy use and Technology Audits in the Surat Cluster during the third week of October 2009. The Rice Mills are located at 1. Arni2. Arcot3. Vellore

3. No. of units Covered for Energy use and Technology Audit • Total No. of units in Vellore Cluster are 200(actual) • No. of units to be covered in the Cluster are 30 units • The Energy use and Technology audit studies has been initiated during November 2009

4. Products Manufactured • Boiled rice • Steam rice • Raw rice Capacity Raw Mills : 2TPH to 3 TPH Dryer : 10 tons to 24 tons per batch

5. Process Flow Diagram Contd.

7. Main Energy Forms used • Electricity • Fuels • Wood • GN Husk • Biomass fuels

8. Major Energy Consuming ProcessEquipments • Dryer • Cooking • Elevators • Paddy screeners • Hullers • Whiteners • Paddy graders • Sorters

9. Major Energy Consuming Equipments Utilities • Boiler • Hot air generator • Air compressors • Blowers

10. Energy Scenario • Energy cost: 3 to 5% of the total processing cost of paddy. • CMD: The connected load is varying from 120 to 250 KVA • Steam demand: About 1 – 1.5 TPD for hot gases dryers and 1.5 to 2.0 TPH for steam dryers depending on the production capacity of the plant. • Electricity Consumption: The average electricity consumption for a single plant is ranges from 1.50 to 3.00 lakh units per annum • Fuel Consumption: (Wood, GN Husk and other biomass materials) varies from 400 to 800 tons per annum. • Energy Bill: The annual energy bill is varies from Rs.20 to 40 lakhs per unit depending on the size of the plant.

11. Major Findings - Boilers • Local make boilers having efficiency of 20 to 25%. Factors for Low Efficiency: • Low heating surface area • High flue gas losses, temperature of flue gases is above 300 oC • High radiation heat losses from ash port and surface radiation losses • Un-burnt carbon • No control on fuel feeding • Frequent on and off of the boiler

12. Major Findings Dryer • Local make furnaces for hot air generation • Low heat transfer area and efficiency • High flue gas and surface radiation losses • Heat losses from ash and fuel feeding grates • MS heat exchangers

13. Major Findings • Local make elevators, paddy cleaners, graders, blowers and whiteners due to low investment leading high power consumption and low productivity

17. Finned tube Heat Exchanger used for Dryers

20. Possible Areas of EC and EEEnergy Conservation • Replacing the old boilers with new efficient design boilers - improved design • Improved design of the dryer for hot air generation • Replace inefficient and local make blowers with new efficient blowers • Replace elevators, paddy cleaners, rice graders etc

21. Wood Fired Hot Air Generator THERM TECH WAH is the highly efficient hot air generator. WAH  model hot air generator is designed to provide unmatched performance with high efficiency and maintenance free operation • FEATURES: • Heavy duty construction • Thermal efficiency 80 ± 2 % • Easy to clean • Three pass design • Noiseless operation

22. Solid Fuel Fired Shell Type Flue Tube Steam Boilers

23. Issues and concerns for Implementation • Involves high investment for technology change of various equipments • Doesn’t have clarity on the savings achievable for the industry owners • Lack of interest in implementation due to high investment and confidence Financial Issues

24. Technical Issues • Lack of awareness on technologies available in the market • Rely on local equipment suppliers and service providers

25. Other Issues • Interested in implementation of successful technologies of the cluster or successful technologies in neighbor industries

26. Thank You