Flow of Presentation - CIIGBCgreenbusinesscentre.com/energyaward2017presentations/General/ITC...Flow...
Transcript of Flow of Presentation - CIIGBCgreenbusinesscentre.com/energyaward2017presentations/General/ITC...Flow...
Flow of Presentation
Specific Energy Consumption –Benchmarking
01Thermal & Electrical Interventions
03Waste To Energy: Innovative Approach
Biogas Plant: 19m3/day.
05Sustainable Society
Biogas and Solid waste Management
07
Energy Conservation-Technology Map.
02Renewable Energy
1 MW Rooftop Solar Power .
04Employee
Engagement
TPM
06
Electrical Supervisor
Branch Engineer
Energy Manager
I/C Electrical
MFG Executive
HR Executive
Utility Supervisor
Commercial Executive
ESP Member
Central Management Committee
The Energy Management Committee consists of Management, non-Management and Service Providers who actively takes part in the meeting
Energy Management organization Chart
TECHNOLOGY
Feasibility
Viability
BUSINESS
Usability, Desirability
HUMAN VALUES
DESIGN &
INTERACTIVITY
ORGANIZATION
BEHAVIOR
MANUFACTURING
Design
Innovation
Energy Management
Divisional and International benchmarks!!
Energy Audits-Expert
Internal Brain Storming
& Learning
Awareness Building
Bench Marking
Innovations
Approach
4.743
4.617
2015-16 2016-17
GJ/MNC
4.625.4
5.82
8.04
9.82
MGR SER PUN BLR BAT
GJ/MNC
GJ/MNC 16-17
Energy/MNC
Thermal Energy (FO & LPG)
LPG
Electrical Energy
EnCon Projects/Practices: Technology Map
5
• Hot Condensate Recovery system including SOPTs
• Process heat recovery• Feed water heating through
Solar Heater• Economizers• Air-fuel ratio optimization to
1.5-2.5%• Steam Trap monitoring
Steam generated (Tobacco Processing)
• Substitution of LPG with Biogasgenerated from Tobacco Waste
LPG / Biogasconsumption
• LED lighting for shop floor
• LED street lights for compound lighting
• Light Pipe
Lighting
• Screw compressors for better efficiency
• Aluminum line to supply compressed air line with minimal pressure drops
• Auto-cut off valves
Compressed Air
• Chilled condensate recycling system
• AHU Cooling coils replacement
• Auto Tube Cleaning System
• VRV system
HVAC
• Interlocks for to prevent idle losses on compressed air and DRF lines
• VFD installed on DRFs for optimal consumption
• Compressed air leakage audits by production teams on shop floor
Motors/Rotating parts on Shop floor (Cigarette manufacturing)
Solar 1 MWpBiogas: 19 m3/day
05
04
03
02
01
Condensate water recovery for feed water heating
Process heat recovery for feed water heating .
Economizer for Boiler No. 1
Optimized Air-Fuel ratio (1.5-2.5%)
Strengthening maintenance & Minimizing Breakdowns
Thermal Energy – Supply Side
12.4
13.3
FY 15-16 FY 16-17
Evaporation Ratio
Waste Heat Recovery UnitWater in temp. = 35 *CWater out temp. = 69 *C
Thermal Energy – Demand Side
Reducing Consumption: SOPTs for Comas and KLD driers
Optimizing Consumption:PRV for Admoist
Minimize losses:Arresting leakage, focus on increasing condensate recovery
Reducing Losses:Monitoring steam traps & Plug leakages
Steam Hours:Reduction in steam hours, increase in steam-hour throughput
836
822
760
FY 14-15 FY 15-16 FY 16-17Steam/TOT
530
242200
2014-15 2015-16 FY 16-17HVAC Steam (Tons)
Revamp of HVAC system to increase humidification through air washers
7.5 % reduction
Waste to Energy – Innovative Approach
First tobacco sand (process waste) to biogas conversion plant installed
Composite Pit
Tobacco dust in feeding tank
Digest the dust using anaerobic digester
Send the effluent to ETP for treatment
Output
Anaerobic
Digester
Collection of bio gas
17.67
15.6813.99
LPG (Tons)
LPG Consumption Trend
14-15 15-16 16-17
Output
Catalyst : pH>7 • Achieved by less tobacco mixed with large amount of water (1kg :20L)• Neutralizing tobacco’s acidic nature
Electrical Performance – Units/MNC
744732
680
2015-16 2016-17 2017-18 …
Units/MNC
Auto Cut off Valves Incorporated to reduce compressed air wastage.
Saved 15 units/hr of idle consumption
HVAC revamp to save 6 units/mnc of consumption
Compressed Air Unit Audited to continuous leakages, to save 20
units/mnc
Auto tube Cleaning system for HVAC
DRF drive frequency optimized by running two drive
Key Efforts
10
732
797
938959
MGR SRE PUN BLR
Units/MNC
Automatic Tube Cleaning System
Energy savings with ATCS
Periodic cleaning each 6 months
ATCS – Continuous Automatic Cleaning
Periodic cleaningEvery 1*F increase in Condenser approach increases power consumption by 1.5%
Potential Savings of 43.4 Mwh
MGF UF RO
TDS : 2500PPMPH:7.2
From W.W.T.P To CoolingTower
TDS : <200 PPMPH:6.6
Renewable Energy: SolarFocus on continuous replacement of conventional energy with renewable energy
Commissioned 1.063 MW of Rooftop Solar Plant in Sep’15
11
10%
14%
24%
3%
10%14%
2014-15 2015-16 2016-17
% Renewable Energy Share
Electrical Energy substitution Total energy substituted
Online Panel level Monitoring system – Breakdown diagnosis
and resolution
Water based cleaning of Solar panels – Higher efficiency/PR
Sustainability
326
806
1075
2014-15 2015-16 2016-17
GHG Reduction (in Tonnes)
Pressurized Recycled water pipeline across factory for
cleaning
3.8
9.38
12.35
2014-15 2015-16 2016-17
Units Generated in Lacs
13
Daily area wise Energy consumptions are monitored and circulated to top level executives.
Energy consumptions reviewed, analyzed & corrective actions planned in
- Daily production meetings
- Weekly Energy Management cell meeting
- Monthly Performance review by HODs & Factory Head.
Designated Energy Manager and Encon Members facilitates the reviews
- Implementation status of suggestions from Encon Task Force (workmen ) are
reviewed in monthly performance reviews.
- Energy consumption trends, Encon project status and new project proposals are
reviewed in Monthly Operational Group Meetings.
Encon Task Forces: Employee Engagement-TPM
0
1000
2000
3000
4000
5000
1 4 7 10 13 16 19 22 25 28 31
Generation
STEAM/HR in kg/hr EVR
0
200
400
600
800
1000
1200
1400
0
2000
4000
6000
1 5 9 13 17 21 25 29 33
Consumption
THROUGHPUT (w.r.t Steam hrs)
STEAM/TOT
TPM-Key Initiative and Results
• Identified Pressure Drop avenues ( Rerouting/
modification/Automation of demand for reducing
idle run) and corrected through selective
replacement of bag filters in SMD & PMD
• Reduction of DRF fan frequency post reduction
of PD
• New VFD installation at lamina & central DRF
• Identification, Selection and
correction of Existing Power
Factor correction to replace
defective Capacitors
• Design Change of APFC for
better control at Centralized
Panel is in progress
Power Factor improved to 0.99
DRF
DRF fan frequency reduced to 38HZ from 45Hz
PMD consumption reduced 24KW/TOT to 17Kw/TOT
Power Factor improvement
• Identification, elimination, Re-routing of
compressed air lines which reduces 300m
pipelines at SMD and leakage associated
• Identified leakages and defective spares
replaced
• Segregation of Cleaning and Process line to
reduce pressure set point for cleaning
• Implemented maintenance schedule for
components to reduce defects/leakages
Compressor
SMD compressor Set point reduced to 5.9 bar from 6.2
PMD compressor set point reduced to 5.8 Bar from 6.2
132
119
Pre Post
Compressor Unit/MNC
34
19
Pre Post
DRF Unit/MNC
0.97
0.99
Pre Post
Power Factor
15
Employee Engagement• Training Session • Celebration of Key Events • Events Extensive Communication
Organise Quiz contest, Skit competition, Slogan & Suggestion Contest conducted along with recognition
Participated by Employee’s and
ESP’s.
Biogas Plants installed in nearby villages and households are getting benefit38 plants of 2m3/day capacity each
Sustainable Society
16
Household Garbage
Recyclables
Non-Recyclables+
Kitchen Waste
Green waste
BiodegradableSolid Waste
RecyclableSolid Waste
Non-DegradableSolid Waste
Solid to recycling units
Dumping(Landfills)
Organic Composite
Solid waste Management at Munger
Sustainable Society
Seco
nd
ary
Segr
egat
ionP
rimary Segregatio
n
18
ITC Triple Bottom Line
The only Company in the world of its size to be carbon, water and solid waste recycling positive
Carbon Positive organisationRenewable Energy Share
Zero Liquid Discharge 100% Solid Waste Recycling
19
1.Energy ManagementUnits/MNC-680 (2017-18)Units/MNC-590(2017-21).
2.Renewable Energy5Mw Offsite Solar plant-2020
3.Water ManagementKL/MNC-2017-18:4.24Kl/MNC-2017-21: 3.86
4.Waste Management
Upgradation of Bio gas to 100m3 -2018
8.Environ friendly MaterialsExploring Environment friendly Materials-
Biodegradable plastics, filters , led free pain etc.
7.Greening the supply chainStandarisation of vendor selection
criteria based on green parameters and provide support
6.Regulatory FrameworkScan regulatory framework
continuously and frame suitable strategies
5.Green RecognitionsIGBC platinum Certification renewal-2017
Exploring and applying various national and international Green award.
Greenovation– Roadmap of Green Journey 2017-20
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Greenovation