ITC Limited, Bangalore - CIIGBC Award... · National Award for Excellence in Energy Management-2010...

National Award for Excellence in Energy Management-2010

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Company Profile

ITC Limited

The Only company in the world to be Carbon, Water and Waste Recycling Positive

ITC Limited – Bangalore Cigarette Factory:

Established in 1912. Green Field Factory started production in 1999.

Production Capacity: 170 million Cigarettes/day

Producing 27 different domestic brands and 57 different Export brands.

Accreditation

Golden Award for occupational safety – 5 years in row.

British safety council 5 star award – 4 years in row.

Greentech Environmental Excellence Award – 3 years in a row.

Golden Peacock Occupational health and safety award – 2008.

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Primary Manufacturing

DivisionLeaf Tobacco

Processed Cut tobacco

Secondary Manufacturing

DivisionPacked Cigarettes

Leaf Waste Leaf Waste + WMS Waste

Machineries, Lighting,Compressed Air, Steam, Fans,

Cold storage conditioning

Machineries, Lighting,Compressed Air, Fans, Air

Handling units

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Overview of Energy Consumption

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Conservation Methodology

Cannot improve on what is not measured

Instantaneous power monitoring and storage through 80 energy

meters across factory from a single system.

Instantaneous boiler parameters, efficiency , 02 % monitoring, losses

can also be monitored from a single system.

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Cannot act on what is not monitored

Daily reporting and analysis:

Generator: Specific fuel consumption, Auxiliary consumption.

Boiler: Evaporation ratio, Efficiency.

Power consumption of each compressor, chillers, water pumps

Specific electricity consumption of individual areas.

Specific Thermal consumption.

Water consumption at various locations - Source wise.

Periodical reporting and analysis:

Compressor FAD.

Chiller IKW/TR.

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Carbon Positive, Water positive

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Energy Conservation – Lighting System

Design:

Roof which allows sunlight during day time(9 AM – 5 PM).

Saves around 9 Lakhs unit/year

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Engineering intervention:

Energy Saver transformer in all the lighting circuit which

saves 3 Lakhs units per year.

Output to Lighting system: 375 VInput: 415 V

Savings: 20 %

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ü Lux level based lighting control in

the shop floor.

ü Timer based i.e., need based

lighting in Leaf godown, Canteen,

change room, yard Lighting

ü Savings: 1.8 Lakhs unit per year

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Energy Conservation – Boilers

Design:

Installation of Boiler with state of art Effimax system with online O2 monitoring

and correction which improves the EVR by 10%.

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Energy Conservation – Boilers Chimney

Economizer

Boiler

Economizer raises the feed water temperature by 20 deg

Flue gas

240 deg

200 deg

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Flue gas

400 degSteam

To atmosphere @ 200 degSteam generated from WHRB is

used for low pressure applications

and heating boiler feed water

WHRB

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Steam

WHRB

Boiler Feed

Water Tank

Water to Boiler @ 90 deg

Condensate from process @ 95 deg

Saves around 1000 KL of fuel/year

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Energy Conservation – HVAC

Design:

Replacement of air cooled chiller

with water cooled chiller.

Savings: 7 Lakhs units/year.

Administrative control:

Performance guarantee from the

vendor for IKW/TR.

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Evaporative cooling system for air cooled chiller with ambiator pads

Savings:1 Lakhs units/year

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Old FRB fans are replaced with Fans with energy efficient (Light weight optimal

blade angle design) fan.

Savings:5 Lakhs units/year

Description Unit Old Fan

New Fan

Rated Motor Power KW 37 30

Measured Flow m3/hr 90216 97426

Measure Static Pressure

mmwg

18.1 20.9

Measured input Power KW 26.7 20

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Energy Conservation – Services

Air receiver

5 single stage Comp – each 300 cfm Machineries

To Cleaning

Inefficient compressor

All 100 % loading continuously.

Higher pressure (6.3 bar) for cleaning air as well.

Compressed air supplied to machines that are stopped.

Open house for cleaning.

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Air receiver

2 dual stage Comp – each 750 cfm

Machineries

Solenoid Valve for individual M/C

Multi step controller 0%, 50%,100%

Air GunPressure reduction to 3bar

Savings:5.5 Lakhs units/year

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Replacement of fans with energy

efficient fans in DRF system.

Replacement of motors with optimally

sized energy efficient motors.

Savings:11.7 Lakhs units/year

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Wind Energy

Installed 10 windmills, each of 2.1

MW totalling to 21 MW.

Wind turbine generators will

prevent 42000 tons-eq. of CO2 from

entering into atmosphere.

Entire electrical energy consumed

by the Bangalore factory will be

renewable green energy.

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Wind Energy

The generated energy will cater to the

entire demands of all ITC establishments

in Karnataka

The 21 MW windfarm will provide relief

to the energy-deficient Southern Grid of

India, contributing almost 5 crore units of electricity annually – enough to

sustain 10,000 households of the region

The windfarm, commissioned on 28th June 2010, has already generated

1.25 crore units of electricity

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Solar Energy

Installation of solar heating system

Installation of solar bore wells

Installation of solar street lights

Savings: 64000 units/year

Installation of solar water heater

Savings:4 KL of HSD per year.

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Energy Management Organization structure

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Energy Management

Energy indices are reviewed daily by Branch Manager.

Energy conservation projects are part of objectives for

engineers.

Energy management projects are reviewed and monitored

through Energy cell headed by Branch Engineer.

Periodical audits by competent organizations such as

CII, Forbes marshal ,TERI, Ion Exchange, M/S UVK

Associates.

Ideas from various levels of staffs are implemented and

imitated through I3I in a structured manner..

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Water Management

8000 KL storage Rain water pond

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Environment Management

State of art Cold plasma

system to abate odour

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Waste Management – Towards Excellence

Projects related to waste reduction have been taken up using six sigma methodology.

Waste reduced by 25%

More than 2 crores financial benefits had been achieved.

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International Benchmark*: 9.1 GJ/Mnc.

*Source: BAT 2009 sustainability Report

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On account of intake of electricity from

Electricity Board

On account of steam generation

On account of transport of raw

materials/finished goods

Free CO2 Release by GALT Process

On account of carbon

sequestration due to trees

On account of LPG used in canteen &

GALT

On account of power

produced by wind mills

Total Emission: 23155 Tons.

Total offset due to windmill: 17385 Tons.

Total no of trees and shrubs in the factory:20000.

Balance CO2 to be offset: 5770 Tons

Towards carbon positive

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Options towards carbon positive

Options tCO2 reduction

5 MW Solar plant 7425

3 MW Wind Farm 6000

2 MW Mini Hydel plant 8000

Afforestation – 400 acres 6400

Biomass fired boiler 700

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Towards water positive

Building of additional rainwater ponds and using the same.

Water shed development projects.

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ITC Limited, Bangalore - CIIGBC Award... · National Award for Excellence in Energy Management-2010...

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Transcript of ITC Limited, Bangalore - CIIGBC Award... · National Award for Excellence in Energy Management-2010...