A Novel Energy Management System
In Sugar Industry at Co-generation Plant
M V Kiran1 A Suresh2
EIE DEPARTMENT EIE DEPARTMENT
VNRVJIET, INDIA VNRVJIET, INDIA
venkatkiran1989@gmail.com suresh.aldhandi@gmail.com
Abstract— In this paper, the energy management at sugar
industry is presented with manipulating and controlling at
different sections in the plant. A case study on a sugar plant
directs an innovative application of saving power and cost by
using vapor absorption chillier is discussed. The
implementation of Vapour Absoption Chiller (VAC) can be
done by manipulation in co-generation and sugar processing.
This manipulation is achieved by implement of proportional
integral derivative(PID) controller in cascade loop at co-
generation and design manipulations at sugar processing. The
tuning of these modified sections is carried out by Ziegler-
Nichols (Z-N) method. Since every industry tries to minimize
its power consumption, it is one of method to reduce power and
manage energy in industry.
Keywords— Energy management, VAC, Co-generation,
Cascade loop, Z-N Tuning.
I. INTRODUCTION
Mainly power generation plants are non-renewal and
renewal energy sources. In Non renewal energy sources, to
generate electricity coal, gas or liquid based diesel and some
uranium chemical reaction materials are widely popular [1].
The main drawback is the availability of these sources. This
is the reason nowadays most of the countries are running to
develop the electricity by using renewal energy sources such
as solar, wind and bio-mass. Initially capital cost to
implement renewal energy power plants is high cost and
generating power in watts also less. These drawbacks of
power generation plants are overcome by generating
electricity in sugar plant. Here in this paper discussed real
world problems of generating power in sugar plant and
energy management at different areas. How process control
variable such as pressure, temperature, flow are monitoring
in the plant is presented with real time values. As sugar
plant has capability of producing sugar as well as power and
syrup [2]. It is an excellent absorber of natural sources in
producing required demand. So a plant consumes more
power for fulfilling their demands. As we aware of power
it’s so valuable. To reduce consumption of power several
techniques are implemented before and now another
impressive technique is presented by the application of
vapor absorption chillier [3].
978-1-4799-3975-6/14/$31.00 ©2014 IEEE
K Sudha Rani3
EIE DEPARTMENT
VNRVJIET, INDIA
sudhasarah@gmail.com
A. Study on Sugar Industry
In parry’s sugar industry they produce sugar, power and
syrup by the use of sophisticated technology in the field.
The production of sugar is a commercial aspect in which it’s
purely depends on its processing technique and the use of
steam energy in an appropriate manner. Here this plant can
be referred as co generation [4]. Hence by the application of
vapor absorption chillier this plant can be referred as tri
generation. The combined process of generating power
steam and cooling can be referred as tri-generation. This can
be implemented by any steam or hot air producing industry
because the essential input is hot air or steam for this
VAC[5] operation. In which by this VAC the output is
cooling water or ac which makes the plant to save cost on
refrigeration and ac. For this achievement, energy
management has to be done in cogeneration plant and sugar
plant.
B. Energy Management in Sugar Industry
Energy management is the collective term for all the
systematic practices for minimize and control both the
quantity and cost of energy used in providing a service [6].
Efficient energy management systems lead to reduced energy
consumption which in turn results in reduced climate change
impacts. Energy efficiency improvement means decreasing
the use of energy per unit of activity. There are two
indicators that can be used to evaluate change in energy
efficiency, the energy intensity and specific energy
consumption. Energy intensity is the energy consumption per
unit of value added for the sector. Specific energy
consumption (SEC) is the amount of energy per unit of
human activity measured in physical terms, starting from the
primary energy carriers. In the present analysis emphasis is
given to specific energy consumption as an indicator of
energy efficiency. To implement energy management in the
sugar industry an alteration of steam usage should be taken
which must serve the sugar process and it should fulfill our
demand. For this two different modifications has been taken
in the sugar industry and co generation.
C. Cogeneration Process
Any plant which generates combined heat and power for
process is referred as co- generation.
 2014 IEEE International Conference on Computational Intelligence and Computing Research
Fig. 1. Block diagram of co-generation plant
In this considered plant the operation held by two boilers
in which with respective capacity. In the fig 1 FT is flow
transmitter. As these boilers output is steam for power
generating and sugar processing. Hence the first work of
steam at turbine to generate power after that steam is
divided into two extractions namely 1st and 2nd extractions at
the turbine outlet. In which by these extractions the sugar
process is done. But problems occur with 2nd extraction
because due to insufficient steam temperature which badly
effects sugar processing. As a result of insufficient steam
there is an occurrence of delay in sugar processing, quality
differs and juice consumption is more. To overcome these
problems turbo feed pump which is 3MW capacity is
considered, as its operation is to generate power to the
motors to carry water from dearator to boiler with help of
pump lines. This turbine runs with the inlet of steam and
exhausts steam after work done. So by considering this
turbo feed pump exhaust steam and 2nd extraction steam,
there are better improvements in clubbing these two steams
outlets and monitoring.
D. Experimental Modifications
The experimental modifications are done at 1) at turbine
outlet in co generation and 2) at pans in sugar industry. The
implemented diagram of energy management at turbine
outlet is shown in fig.2. At co-generation the two
extractions of the turbine i.e., high pressure loop (HP) and
low pressure loop (LP). Since problems associated with 2nd
extraction i.e., LP loop is considered for manipulation to
recover problems associated with it.
So for effective plant processing turbo feed pump outlet
and turbine LP outlet is made to mix in a steam bottle. In
this steam bottle temperature, pressure and flow increases
and in counter these must be controlled. Here temperature is
the crucial parameter to control because it should maintain a
required temperature for processing of sugar. Hence a
cascade loop is implemented for the control of temperature
over here.
ENERGY MANAGEMENT AT TURBINE OUTLET
Fig. 2. Block diagram of energy management at turbine outlet.
As LP line contains steam is passed through a de super
heater and enters into steam bottle where here in this bottle
another inlet is turbo feed pump steam. Thus this bottle is a
mixture of two different parameter valued steam which
results in the increase of each parameter. For this an cascade
loop operated at the steam bottle outlet and de super heater
outlet. Whenever temperature rises in the steam bottle outlet
the de super heater gets on and sprays water into the steam
to reduce temperature in accordance to the requirement. By
this steam outlet of required temperature (125 C) is
achieved and projected towards processing section in sugar
industry. The achieved steam is given juice storage tank for
boiling and there obtained vapor is used in pans section for
sugar processing. Here energy management can be
implemented by considering juice tank vapor and pans
section vapor which are exhausted into atmosphere after
work done. This exhausted vapor is considered and driven
towards vapor absorption chillier for achieving a desired
goal of reducing the cost of refrigeration and ac.
Here an inlet of 125 C vapor is given as input for pans
in sugar processing section in which each pan is operated at
different temperature for processing of sugar in sugar
industry and a simulation of simple transfer function is
shown in fig 5 for understanding the system.
 2014 IEEE International Conference on Computational Intelligence and Computing Research

Estimations: power saved for air conditioning by VAC:

Parameters and savings

A.c Power
consu
capacity Duration Power saved Cost saved
med by
in tons in hours
ac(unit
In units in rupees
s)

2.0 4100 1500 6150 1.6 Cores

1.5 4100 900 2.2 Cores
3690
1 4100 700 1.7 Cores
870

Table 2.2 VAC savings in air conditioning

In the above table the calculation of power and cost

Fig. 3. Schematic diagram of energy management pans.
shown by considering local cost/power unit value in air
As shown in above figure the pans are in series where
conditioning.
ones output is input to other by this temperature in the juice
tubes doesn’t get drop in more centigrade by this vapor can
be saved and if necessary there is an inlet for vapor to III. SIMULATION RESULTS
maintain temperature in the pans. By this here the vapor is
saved and the exhaust from pans also made to use for inlet In this plant real time data values are considered.
of VAC. The total operation can be carried out by any Mathematically represented transfer functions in simple first
sophisticated technology. Ex: distributed control system. order and time delay at different areas by considering
assumptions because the plant transfer function is non linear
E. Vapor Absorption Chiller which is difficult to produce actual transfer function. PID
Vapor absorption chiller is an innovative technology in values are calculated by adopting Ziegler-Nichols frequency
which it takes any hot source as input for giving an outlet of tuning approach method.
cooling water or ac. Hence due to its effective functioning The energy management at turbine outlet transfer
properties any steam generating industry can use it for better 1 -s
saving. This VAC uses dilute lithium bromide solution for functions G(s) = e
s +1 (1)
its operation. By using VAC any co generation can be
referred as tri generation. 1 -2s
G1(s) = 2 e
II. EXPERIMENTAL RESULTS s + 3s + 2 (2)
Power save by use of VAC in Kilowatt and cost is PI values of these transfer functions are summarized in table
tabulated in below table 2.1 in this table coefficient of
performance of refrigerators is 4.0 and the cost and power Transfer
Kp Ti
savings are listed in accordance to study of VAC function
Estimations: power saved for refrigeration by VAC [7]:
Parameters and savings G(s) 0.36 0.10
Tons
/hour Duration in Btu/ Power Cost
hrs ton saved(units) saved(rupees)
G1(s) 0.5 0.10

100 4100
12000
2574 18019.33
Table 3.1 Obtained PI values of energy management in Z-N
12000 tuning method.
200 4100 5148 36038.66
12000
300 4100 7722 54057.99
12000
400 4100 10296 72077.32
12000
500 4100 12870 90096.65
12000
600 4100 15445 108115.9

Table 2.1 VAC savings in refrigeration.

(*cop = coefficient of performance = 4.0
Btu = British thermal unit)
In the above table the calculation of savings by using
VAC is shown for refrigeration by considering local
cost/unit value.
 2014 IEEE International Conference on Computational Intelligence and Computing Research

The above output response shows the different

temperature of different pans which are for sugar processing
as energy management employed over here the pans attain
temperature by on/off control. i.e., when there is a drop in
temperature an inlet is allowed for attaining required
temperature.

IV Conclusion

“Energy is neither created nor destroyed”. Since energy can

be convert to one from to another. if the energy converted in
Fig. 4. Output response of turbine outlet accordance to our requirements than it gives fruitful results,
here the steam energy made to utilize where it’s necessary
The output response of turbine outlet is shown in above and the saved steam energy is driven to VAC and
figure, here the interacting junction has a rise in temperature simultaneously plant considered waste heat also is directed
and it is unstable. As here cascade loop is implemented with to inlet of VAC for power and cost savings. This made an
PID tuning the output response of final element reaches set achievement of no loss of heat energy and gain in chilling
point. areas.
Transfer functions of energy managements at pans is
considered as ACKNOWLEDGMENT
1 -s
G1(s) = e My sincere thanks to Professor Mr.S.Rajaratnam for his
s +1
support and motivation to write this paper and my heart full
1 −2s thanks to Mrs. K Sudha rani (Associate professor) for her
G2(s) = e
s+2 esteemed guidance and technical support. I thank to my
friend A Suresh in sharing his knowledge with me. My
1 -s sincere thanks to Mr. S Haribabu, Head of Instrumentation,
G3(s) = e (3)
s+3 parrys sugar industry to share his practical experience and
PI values of these transfer functions are summarized in my sincere thanks to professor Mr. Ketan (IIT Hyderabad)
table. 3.2 and my sincere thanks to my family members one and all.

Transfer
Kp Ti REFERENCES
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Fig. 5. Output response of pans in sugar processing.