When water is the only hope

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When it is a matter of survival

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When rivers become dry

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When chemicals are becoming costly day by day

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When energy is the hot issue

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When we experience these things daily
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 Training on
Resource Conservation

Habib Sugar Mills Limited

Program for Industrial Sustainable Development-Sugar

A Joint Project of CPI and Royal Netherlands Embassy

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 What Is Conservation?

 Conservation is exactly what we do when we

remain with some thing which is about to be
finished. We conserve our money when it
become scarce at the end of the month.

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Resources for Sugar Industry!
Resources used by sugar industry to produce
refined sugar are,
water
steam
electricity
chemicals
bagasse
All are God gifts which needs protection.

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Why Conservation Is Important for
you (as worker) ?
 Our religious duty to save natural resources
 Show that you are responsible, reactive and human.
 Because you love neat and clean places to work.
 When resources are conserved, the company get benefit,
so does you.
 Do you want that your generation face scarce resources.

If all our natural resources died, where would we be? We

cannot live without them. So conserving them is a
necessity

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Resource Conservation
in
Sugar Industries

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 Now, think of energy
Forms of Energy at sugar Industry are

 Bagasse Production Electricity

 Steam
 Electricity steam

Bagasse

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 Energy losses due to electricity

 Use of lights/bulbs during day time

 Use of machine with out production

 Under capacity machine utilization

 Compressed air use, as cleaning

 Over sized and old pumps

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 Energy losses due to steam
 Leakages

 Direct heating
 Un-insulation of hot pipes

 Faulty steam traps

 Large blow downs

 Condensate drain

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 Workers can play an important role in
energy conservation

 Identify the location where insulation is

damaged or missing
 Identify the steam traps which are not
working properly
 Identify the locations where steam leakages
are found
 Switch off the lights on those locations
where not necessary
 Stop machines which are unnecessary running

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 Now think of chemicals

 Chemicals are silent killers

 Chemicals handling is the most
ignored issue.
 Chemical cost some times go up
to 20 % of product cost

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 Chemicals related problems within
Sugar Industry
 The Sugar mill uses number of different chemicals,
acids , base, Polymers and oils & greases during the
processing
 Chemicals are generally not measured accurately
enough and only their estimated quantities are added
in the process vessels
 Leakages and spillages are quite often during
transferring chemicals and dispensing from large
containers to smaller one which results loss of
chemicals
 Generally secondary containment is not provided to
collect leaks and spills which ultimately contaminate
soil and water & loss of chemicals

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 Chemical Conservation
 During manual mixing, only measured
quantities of chemicals should be used as
per recipe. Proper balancing is required.
 In automatic dosing system, calibration
should be checked.
 Use specific measuring transferring vessels
 To control spillage and leakages of the
chemicals, proper containment for the
collection of spillage and leakage should be
provided
 Process control parameters should be
followed to avoid extra chemical usage.

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 Chemical Conservation

 Purity and properties of chemicals be closely

checked. If the quantity requirement is high
than normal the chemical may be B- Grade.
 Chemicals can be reused. (as Oil & Greases)
 Use suction pump for Ethyl Alcohol.
 Unsealed drums of new arrived lot be
identified.
 Drums should always be capped specially of
powdered/liquid .

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 Now Think of Water
 Industry bear a huge cost of water ,as major
quantity of water is generally procured

 Average water consumption to process 1 TCD

is 1-2 m3

 Only Good practices can reduce the hydraulic

load up to 20% or more

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Wastage of Fresh Water within Sugar Industry
 Water hoses are used
to wash chemical
drums, process
vessels, machines and
floors

 Workers leave these

water hoses on the
floor without closing
water inlets

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Wastage of Water within Sugar Industry

 Pump Leakages
 Excessive blow down

 Drain of surplus condensate

 Drain of washing liquor

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 Need of water conservation
 Excess use of water is not only the direct loss
of natural resource but also it results into
excess use of chemicals in the process vessels
and energy loss.

 Generally workers & even management, are

not much aware about the consequences of
excessive use of water in different processes

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 How To Conserve Water?

There are many effective and simple ways to

conserve water as we need water to live, it is
important to conserve as much water as we
can. But Water monitoring is necessary.

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 Water Monitoring
 Lack of water monitoring is one of the
real cause of water wastage and
unnecessary usage.

saying “ when you will measure some

thing it will improve”

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 What is water monitoring

 How much water is consumed

per day?
 Where it is consumed?
 What are fluctuations each
day?
 Why it is so much consumed?

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 About water monitoring
 Water optimization can not be implemented without
water monitoring
 Without monitoring you can not believe what can you
save and can not direct the saving activities.
 Goals and benchmarks are necessary for any effort
to succeed.
 You don’t know how much and where you are wasting
water.
 Water flow meters should be installed at water
inlets and at all the major water utility machines and
areas

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 Water Conservation Measures
 Identify & repair leaks & faulty
valves
 turning off the running water
taps & hoses when not using it
 All the water hoses used in the
production area to be fitted with
water shut off nozzles
 Drum washing by wiping out the
print paste first
 Filling the baths of machines to
the required level
 Avoid frequent cleaning of
machines
 Use wipers to take out solids
rather than water pressure 28
 Conservation is the tool

For

Our Safe & Healthy Future!

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