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Energy efficiency program

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USIPL offers customized EPC solutions for Energy Efficiency Programs, including design, manufacturing, supply, civil construction, erection, and commissioning. We have successfully completed over 40 energy-saving projects for prominent clients.

Why Energy Efficiency Matters

Energy efficiency is essential for the profitability and viability of sugar plants, especially those without co-generation capabilities. Governments worldwide are enforcing energy conservation legislation, making energy-efficient equipment and systems critical for compliance and long-term sustainability.

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Customized Solutions for Optimal Performance

USIPL provides tailor-made energy efficiency solutions to:

  • Reduce fuel consumption in existing sugar refineries

  • Lower steam consumption to 28% or below on sugarcane

  • Enhance power generation capabilities

  • Increase crushing capacity without modifying the boiler setup

  • Maintain process house power below 9 kW/TCH

  • Achieve high-efficiency, high-pressure boilers above 2.2 tons of steam per ton of bagasse

  • Target zero PRDS (Pressure Reducing De superheating Station) steam usage

Advanced Technologies and Key Equipment

Our energy efficiency initiatives include:

  • Vapour Line Juice Heating and Direct Contact Heating

  • Short Retention Time Clarifier (SRTC)

  • Superheated Wash Water Systems for centrifugals

  • Falling Film Evaporator and Optimization of Evaporator Stations

  • Continuous Vacuum Pan (CVP)

  • Mechanical Circulators in Batch Pans

  • Variable Frequency Drives (VFDs) on pumps and compressors to adapt to plant capacity

  • Planetary Gearboxes on essential equipment like clarifiers and crystallizers for increased efficiency

Ongoing Research & Development

USIPL is continually innovating to set new benchmarks in energy efficiency, including:

  • Achieving steam consumption below 26% on cane

  • Utilizing 4th vapour for pan boiling

  • Reducing captive power consumption further

  • Implementing zero-discharge effluent solutions

  • Recycling excess condensate for irrigation and potable water use

Our dedicated engineering and project management teams are fully equipped to meet the challenges of energy-efficient project execution, even in remote and challenging locations, ensuring sustainable and cost-effective solutions for the future.

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