JK Tyre & Industries Ltd - Green Business Centre · JK Tyre –Business Overview Late Lala J...

© Confederation of Indian Industry

JK Tyre & Industries LtdChennai Tyre Plant

Team Members:S K Satpathy - Head EngineeringB Ramesh Kumar - Head EEIM Pandiarajan - Head Utilities

1

CII – NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT 2020


JK Tyre – Business Overview

Late Lala

Juggilal Singhania

Late Lala

Kamlapat Singhania

Established tyre business in 1977, JK Tyre is amongst the leading tyre manufacturer in India

Pioneer of radial technology in India and ranked No. 1 Truck/Bus Radial (TBR) manufacturer

with market share of ~30%

Presence across product verticals starting from 2 kg to 3.4 ton

Annual capacity of 32mn Tyres with 12 manufacturing plants globally

Among the Most energy efficient tyre companies in the world (9.81Gj/Ton)

1st Indian tyre company to have certified for ISO 50001 (Energy Management)

1st Indian tyre company to have verified Carbon Footprint as per IS-14064

2

Our plant : 8.70 Gj/Ton


JK Tyre – Chennai Tyre Plant Profile

Salient Features of Chennai Tyre Plant

Location Selection –Automobile Hub

Most technologically advanced plant

Equipment Selection for high Energy Efficiency

Environment friendly technology considered during Plant Inception itself

Zero Liquid Discharge Plant

Usage of Maximum Day lights

Highly optimized WIP material flow

Modular designs for seamless expansion

Young Workforce

Chennai Tyre Plant in Tamil Nadu is the 6th manufacturing plant of JK Tyre whichwent on stream on 05th February 2012 presently produces 45 Lakhs Passenger CarRadial (PCR) tyres and 12 Lakhs Truck / Bus Radial (TBR) tyres per annum.

Major Products – Chennai Tyre Plant

3


Manufacturing Process Flow

Raw Materials

Mixing & Calendering

Tyre Components Building & Inspection

Rubber Bales Rubber Chemicals

Textiles Steels

Banbury Mixer

Tyre Building

Tyre Curing

Visual Inspection

Uniformity ,X Ray ,

Balancing & QA Inspection

Finished Tyre

Tread & Sidewall Extruder

Inner Liner Calendering

Body Ply Cutter

Belt CutterCalendering

Bead Preparation

4


64%

36%

Electrical and Thermal Energy use

Thermal Electricl

1. Energy Consumption Overview

5

0

5000

10000

15000

20000 15192

9654

5538

Ab

solu

te E

ne

rgy

(To

e)

Plant Absolute Energy consumption FY 2019-20 (in Toe)



6

Plant Energy flow Diagram



7

820 782 811644

0

500

1000

2016-17 2017-18 2018-19 2019-20

Kw

h in

Lac

s

Absolute Electrical power consumption in Kwh (Lacs)

20312 18579 1920915192

05000

10000150002000025000

2016-17 2017-18 2018-19 2019-20

Toe

Overall Plant energy consumption in Toe

1322511819 12232

9654

0

5000

10000

15000

2016-17 2017-18 2018-19 2019-20

Toe

Absolute Thermal Energy Consumption in Toe

Plant Capacity utilisation

FY 16-17 – 85.1%FY 17-18 – 78.5% FY 18-19 – 88.2%FY 19-20 – 73.0%


2. Specific Energy in Last 3 Years

8

0.3

66

0.3

43

0.3

14

0.3

08

0.25

0.29

0.33

0.37

2016-17 2017-18 2018-19 2019-20

KG

/ K

G

Specific coal consumption (Kg / Kg of finished product)

0.9

45

0.9

41

0.8

88

0.8

78

0.7

0.8

0.9

1

2016-17 2017-18 2018-19 2019-20

KW

H /

KG

Specific Power Consumption (Kwh / Kg of finished product)

23432237

2103 2071

1800

2000

2200

2400

2016-17 2017-18 2018-19 2019-20

Kca

l / K

g

Specific Energy Consumption – Electrical & Thermal (Kcal/Kg of finished product) 11.6%

reduction


2. Specific Energy in Last 3 Years

9

Internal context

Tyre technology development trials

Scrap and reworks

Machine availability

Employee involvement

Effective Energy Management System

External context

Pandemic Situation (Covid-19)

Capacity utilization because of market changes

Climatic condition

OEM/Customer requirements/ No of SKU’s in market

Fuel price and availability in market

Factors influence SEC variation


3. Information on Competitors, National & Global benchmark

10

35563114

27342307 2381 2256 2071

0

1000

2000

3000

4000

VTPIII BTP LTP VTPII VTPI KTP CTP

Kca

l / K

G

JK Tyre plants, India

Plant Specific Energy Consumption

Chennai Tyre Plant is the most Energy Efficient plant among JK Tyre group, having seven plants located various parts in India1

Internal benchmarking



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3215 29862458 2228 2071

0

1000

2000

3000

4000

Pir

elli

Mic

he

lin

Han

koo

k

Bri

dge

sto

ne

JK C

TP

Kca

l / K

G

Plant Specific Energy Consumption

Chennai JK Tyre Plant is one of the most Energy Efficient plant . The information's are taken from respective plant sustainability report published in web.1

Global benchmarking



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Way forwards next 3 years

Short term Targets

• Energy reduction @ pumping system & Compressors

• Solar Thermal for ETP Evaporator

• Passenger Car Radial Tires 100% Nitrogen curing

Medium Term Targets

• Innovative project implementation at Ventilation fan system –45 Nos of fans

• Solar Thermal for boiler feed water Heating

Long term targets

• 30% Biomass fuel mix-up with coal @ boilers

• Increasing Renewable energy substitution from 70% (Solar – 15% / Wind Power 55%)

11.3% Overall Energy reduction from current level (From 2071Kcal/Kg of production to 1836 Kcal / Kg of production)

Energy Reduction

70% Renewable Energy substitution @ Electrical Energy 30% renewable energy substitution @ Thermal Energy

Renewable Energy


4. Energy Saving projects implemented in Last 3 Years

2018 - 19

2017 - 18

Projects implemented in Last 3 years - Summary

DESCRIPTION ZERO INVESTMENT WITH INVESTMENT TOTALProjects in (Nos) 4 8 12Total savings in (Million Kcal) 1689 8669 10358Total Savings in (Million Rs) 30.91Total Investment in (Million Rs) 10.98Payback in (Months) 4

2019 - 20





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TRIGGER POINT: Higher pressure setting @ PCR hydraulic system leads to excess power consumption

IDEA: Existing design of Common PCR hydraulic system has two sub system. 1. PCR Hydraulic Ejector system, operating Pressure 12+/-2 Kg/Cm2 2. PCR Hydraulic Press operation, operating Pressure 20+/-2 Kg/Cm2. Pipelines modification can be done so that systems will run independently with reduced pressure and there by energy can be saved.

RESULT: 7500 Units/Month saved, ROI – 18 Months

Significant Projects – EnP 1

2

1

3



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TRIGGER POINT: High Vent losses during Nitrogen unloading in the storage tank

which leads to 450 Kgs – 900 Kgs per unloading as per the Tank Capacity

IDEA: Existing design of Nitrogen pumping system modified to avoid the vent losses during Nitrogen unloading (High pressure pump used in place of low pressure pump)

RESULT: Unloading Hours reduced from 4 hrs to 45 Mins. Which results in 1500 Kwh saved/ Month & Nitrogen Saving: 43375 Kgs/Month and Cost savings : 3.2 lacs /Month


2

1

3



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TRIGGER POINT : Fixed Power Consumption which is 21.6 % of Overall plant power consumption

IDEA: High Power consuming Centrifugal Fan can be replaced with High Energy Efficient Axial Fan

RESULT: 14 Nos of units converted with investment of 1 Crore Rs., 48% of Energy Saving achieved (9 lacs units/annum), ROI of 21 months period. Another 2 Crore project (Phase II – FY 20-21) in Progress.

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2

3

© Confederation of Indian Industry17

1/3 of the power only consumed per

electrical panel


TRIGGER POINT : To Reduce Panel AC fixed power Consumption @ Electrical panels by introducing Alternate technology for panel cooling

IDEA: To introduce low power Peltier based panel cooler for Curing presses instead of high power conventional compressor type Panel AC. Concept developed in-house, and kaizen made in OEM design.

RESULT: Very reliable, less power, no maintenance, quiet/vibration free, no GHG refrigerant, economical and best suitable for panel cooling application. 300 kwh / Panel saving per month – 20 Nos completed

1


2

3



TRIGGER POINT : Presently we are 100% depending on coal for steam generation. As part of sustainability practice there is need to identify on alternative source of fuel

IDEA: Vegetation waste (GCV 3800-4000 Kcal/kg) can be used as alternative fuel in some proportion which can reduce the conventional fuel usage

RESULT: 500 Kg / day of waste been used in boiler as alternate fuel

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2

3


5. Innovative Projects implemented

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Innovation Details: Elimination of Traditional cooling water system and using the Existing Chilled water system in place of Cooling Water requirement by fine tuning the Temperature.

IDEA: Quintoplex extruder cooling water system can be merged with chilled water system with the increased temperature from 18 Deg C to 23 Deg C without any process change. By that pumping load for cooling water system and reduction in chiller load as well reduction in steam consumption of VAM chiller.

Cooling WaterSystem

@ 30 deg

Chilled WaterSystem

@ 18 deg

Conveyor for Cooling the Product to Ambient

Quintoplex Extruder Chilled Water

System@ 23 deg

Conveyor for Cooling the Product to Ambient

Zero Investment Savings - 384 unit /Day, Steam consumption – 5 MT/Day, Cost : 25.01 lacs / annum

Redesigning of Chilled Water Distribution System

Result:



Innovation Details: To reduce the Copper losses in the Transformer operation, shelter has been provided. Although Transformer is designed for Outdoor Application, shelter has been provided specifically to minimize the Energy loss in it which is unique among the industries. So we considered this project as innovative.

IDEA: To reduce the Fixed Energy consumption which is arising due to Transformer and Cable loss. While Analysis the Transformer loss for Last 2 years, Seasonal pattern of losses are understood which reveals the opportunity for improvement

Result:

3 Nos Completed. Power Saving of 45000 kWh/annum Cost Savings of 2.7 Lacs /Annum



IDEA: To improve the Energy Performance in Mixer Batch off Fan group by optimizing the Speed (Air Flow) of Fan The energy performance improvement done by ON/OFF method, increased the Spares and PM

maintenance cost. Then there is the need for low maintenance, same time less investment project

Total 40 Nos of fan

(10X4)



Innovation Details: The processed rubber sheet of 120 Deg temperature being cooled to atmospheric temperature in the 15 mtr cooling conveyor with the help of 40 Nos of small fans. These fans are running with DOL starters. Previously the energy saving achieved based on ON/OFF operation of the fan groups (4X10 nos). As this increase PM maintenance cost and Spares cost, VFD has been introduced to control the airflow based on temperature.

This project is unique because instead providing 40 Nos small size VFDs, we have provided only 4 Nos VFD (1 VFD controls 10 nos fans) by doing necessary design modification in the electrical circuit and providing appropriate rated choke.

Result: This is implemented at 1

no. mixer (F270 Mixer, Batch off unit)

Power savings of 23000 Units / annum

Cost savings of 1.4 lacs Rs/Annum


6. Utilisation of renewable energy sources

23

Non renewable

energy

Renewable energyTotal Energy

ON Site OFF Site

509.8 58.9 107.4 676.1

Renewable consumption FY 2019-20 (in TJ)

Non renewable

energy

Renewable energyTotal Energy

ON Site OFF Site

75.4% 8.7% 15.9% 100.0%

Renewable consumption FY 2019-20 (in %)

75%

16%9%

Non Renewable Renewable - Off site Renewable On-site


6. Utilisation of renewable energy sources

24

24

Total On-site Renewable Energy Generation 80 LacsKwh (12% of Total Electrical)

Total Off-site Renewable Energy Generation fromWind 300 lacs kwh (45% of Total Electrical)

15.2 MW Installation Capacity (Electrical)

6 MW Installation Capacity (Electrical) Thermal - Saw dust mix with Coal

Thermal -Dried Leaves ,Wooden waste with Coal

Total On-site Renewable Energy substitution in a yearFY 19-20 – 6116 million Kcal (15% of Total Thermal)


7. Utilisation of waste material as fuel

25

USAGE OF SPILLEAGE & WASTE COAL FINES :Palletizing of Coal Fines from Coal Handling

Plant & Coal Yard by using Palletizer Machine andPalletized Coal fines used in Boiler( 0.5 Ton / Day Coal Fine Palletized and used)ASH RECYCLING FOR UNBURNT REDUCTION

Bed Ashes are collected from the Boiler BankZone, Economizer & APH Hopers where Un burntcontent is high. Collected Ashes are recycled in theBoiler for further combustion.

PLANT VEGETATION WASTE USED AS FUEL FORBOILER:

Plant Vegetation Waste has been sent to Recycler and then Crushed into Wooden Dust. Then Wooden dust mixed with Coal in 20% ratio and used in Boiler


8. GHG Inventorisation

26

Carbon foot print of any entity is the measureof the Green House Gas (GHG) emitted due tothe activities of that entity.

• All Plant (decentralized level) GHG Inventorisation

• Rolling up the inventory to Corporate Level

Identification of GHG Sources and Sinks

Selection of Quantification Methodology

Selection and collection of GHG Activity Data

Selection of GHG Emission Factor

Calculation of GHG Emission and Removal

Emission Sources Scope of Emission

Diesel for internal material transport

Direct Emission (scope 1)

Diesel for generators

Boiler coal

HSD (High speed diesel)

Company vehicle‐Diesel

Company vehicle‐Petrol

LPG consumption ( GH)

Release of refrigerant

Use of Acetylene

Weight of CO2 released from fire extinguishers

Overall purchase of Electricity Energy Indirect Emission

(scope 2)

Material Logistics (Raw Material & FGTransportation)

Other Indirect Emission (Scope 3)

Business Travel

Employee Commute

Waste Disposal

Setting GHG Operational Boundaries Emission Sources:


8. GHG Emission Intensity and Verification

27

1.73

1.40 1.441.28

1.010.91 0.88

0.00

0.50

1.00

1.50

2.00

2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Inte

nsi

ty

EMISSION INTENSITY GRAPH (CO2E TON/TON OF TYRE

Base Year

49.1% reduction from the Base Year

2013-14


8. GHG Verification & Public Disclosure

28

1st Indian tyre company to have verified Carbon Footprint as per IS-14064

Public Disclosure through Sustainability Report & GHG Annual Report


8. GHG Target Setting

29

0.88

0.74 0.71 0.68 0.67

2019-20 2020-21 2021-22 2022-23 2023-24

Inte

nsi

ty

EMISSION INTENSITY G RAPH (CO2E TON/TON OF TYRE

Actual Short Term Long Term

Note : Target for next 3 years based on: Based on planned Energy & Renewable

projects. Mission statement on sustainable growth.

0.1020.095 0.090 0.086 0.082

2019-20 2020-21 2021-22 2022-23 2023-24

Inte

nsi

ty

E M I SSION I N T ENSITY G R A PH (C O 2 E T O N /TON O F T Y R E

Actual Short Term Long Term

Note : Target for next 3 years based on: Planned Scope 3 Projects on Transport

Route reduction, Employee Transport Optimizing etc.

Scope 1 & 2 Scope 3


9. Green Supply Chain

30

Annual Energy Conference is organized to share the Energy Projects, Improvements & Best practices within JK organization, Supplier and Vendors. Horizontal deployment done across the verticals based on the Applicability of the Projects.

SUPPLIER VISITS: TO SHARE THE GREEN PRACTICES


9. Information's on Benefits Achieved

31

276

258 256 253

237

200

220

240

260

280

2015-16 2016-17 2017-18 2018-19 2019-20

Kwh

/MT

Power

14 % reduction

Supplier 1 – Pondicherry

Supplier 2 –Chennai

0.0420.039

0.035 0.034 0.032

0

0.01

0.02

0.03

0.04

0.05

2015-16 2016-17 2017-18 2018-19 2019-20

Lts/

MT

Furnace Oil

23 % reduction

Supplier 3 – Alwar

Supplier 4 –Chennai (Recycler)

425.5 418.3

372.9 368.4356.6

300

350

400

450

2015-16 2016-17 2017-18 2018-19 2019-20

Kwh

/MT

Power

16.2 % reduction

0.75 0.760.71 0.67

0.61

0

0.2

0.4

0.6

0.8

2015-16 2016-17 2017-18 2018-19 2019-20

Kwh

/Kg

Power

18.7 % reduction


9. Green Supply Chain

32

S.No Material Green Procurement Guideline

1Energy Products

100% Procurement of BEE Star rated products (Motors, AC’s , LED etc)

High Energy Efficiency Motor

Requirement of energy efficiency gets reflected in all Purchase documents

Transport route optimization: Raw material supply truck used to carry our finished goods to various customers and depots.

We minimise the transit distance by selecting the vendor which is near to our plant.

Coins type stuffing to Lacing type stuffing for increasing load capacity and reduce trucks & fuel.

OTHER INITIATIVES:


10. Team work, Employee Involvement & Monitoring

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34

Advance EMS system connected with 1013 Energymeters (Monitor <1% consumption) and 256 NosBreakers

EMS plus breaker controlling system to controlenergy

System alerts the excess energy consumptionimmediately thro Auto SMS, and E-mail helps to takeappropriate actions immediately rather thanafterward investigation

System records Sag/swell and transients and allelectrical parameters at the sampling rate of 1024samples/cycle

Daily Review Meeting chaired by Plant Head

Monthly Energy Review meeting chaired byDirector Manufacturing

Monthly Business Review Meeting chaired by President – India Operations

EnMS Management Review Meeting chaired by Plant Head – Half Yearly

Power consumption Monitor & Control

Energy Review



35

Advance EMS system connected with 1013 Energymeters (Monitor <1% consumption) and 256 NosBreakers

EMS plus breaker controlling system to controlenergy

System alerts the excess energy consumptionimmediately thro Auto SMS, and E-mail helps to takeappropriate actions immediately rather thanafterward investigation

System records Sag/swell and transients and allelectrical parameters at the sampling rate of 1024samples/cycle

Daily Review Meeting chaired by Plant Head

Monthly Energy Review meeting chaired byDirector Manufacturing

Monthly Business Review Meeting chaired by President – India Operations

EnMS Management Review Meeting chaired by Plant Head – Half Yearly

Power consumption Monitor & Control

Energy Review



36

Energy Management cell



37

Energy Pledge of Chennai JK Tyre Plant

On National Energy Conservation Day I pledge my wholehearted commitment towards energy conservationin my daily lives that will reduce greenhouse gas emissions and help protect our climate and preserve theenvironment for years to come. I understand that energy consumption affects our natural environment andhuman health and well-being.I pledge that I will strive to:• Improving machine efficiency by reducing energy wastage and losses, through improved operation and

maintenance.• Encourage my workforces to avoid excessive and wasteful uses of energy to reduce energy

consumption.• I Promote people for less energy usage by eliminating the excessive and wasteful uses.

Energy Conservation day celebration @ Schools

ENERGY PROGRAM - SCHOOL ENERGY PROGRAM - SCHOOL National energy conservation day celebrated at two schools in order to promote energy conservation in the employees home and public



1. Class room training –All Employees were trained with Green Initiatives like plant Energy consumption & Energy efficiency methodology in planned intervals

2. Visual aids – Training has been taken with different visual aids for better understanding on Green Initiatives.

3. Displaying posters – On shop floor stickers/posters were pasted to create awareness in every individual.

4. Cross Functional Team /Kaizens – In shop floor, CFT Approach followed to understand the Energy consumption & process of their equipment/machine.

5. Motivation by Awards & Recognition – Awards & recognition has been given to employee upon their performance which can be indicated as KAIZEN’s etc.

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623

1483

21312451

2152

2015-16 2016-17 2017-18 2018-19 2019-20

Year wise - Kaizen Trend



39

Star Performers of the Quarter – Relevant to its Scope of Work (Includes EnergyPerformance)Monthly Best Performance AwardBest Kaizen AwardBest Suggestion AwardParticipation in Quality Circles Regional (CCQC) &National Level ( NCQC)Participation in Break Through Projects – JK organization Level CompetitionSelf Development Scheme for Higher EducationParticipation in Kaizen & CFT Competitions ( Regional Level)Encouraging to participate in National Conference to acquire knowledge on recenttechnologies so that same can be applied based on applicabilitySpot Awards for uncertainty identificationCore Training to the identified personal for skill enhancement

JK TYRE encourage the practice of continuously improving new ideas, suggestions andrecommendations pertaining to energy efficiency and recognizing and rewarding ideas,which add value to the company’s operations

Rewards and Recognition scheme


Training – ISO 50001 Internal Auditor

Training – Energy Use Awareness

Training – Capacity Building and Small Group Activities

Training – Green Co Training – Energy Use Awareness



11. Implementation of ISO 50001/Green Co/IGBC rating

ISO 50001 : 2011 Certified on July 2013

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12. Other Innovative Technologies implemented

Implementation of IIOT

Track and trace report Sample

Track and Trace reportCompleted from RMS toMixing area – Componentarea and Tyre building is inProgress

Centralized ItemManagement System isimplemented

Mistake proofing andinterlocking completed inRMS and Mixer

Activity Based Energymonitoring

Condition Based Monitoring Real time Data Exchange Improved Time to Market

IIOT features


12. Long Term Vision on EE

43

1.5

00

1.4

75

1.4

50

1.4

25

1.200

1.300

1.400

1.500

2020 -21 2021-22 2022-23 2023-24

KG

/ K

G

Specific Steam consumption (Kg / Kg of finished product)

0.7

90

0.7

75

0.7

65

0.7

50

0.700

0.800

2020 -21 2021-22 2022-23 2023-24

KW

H /

KG

Specific Power Consumption (Kwh / Kg of finished product)

19001867

18341790

1700

1800

1900

2000

2020 -21 2021-22 2022-23 2023-24

Kca

l / K

g

Overall SEC(Kcal/Kg of finished product)

Supports requirement to achieve target 9 Crore rupess budget allotment for

energy projects in next 3 years Strengthening the Team on Energy

Conservation by SGA & MFT concept Participating in National Conferences

to understand the New Technologies in Energy Front


12. Long Term Vision on EE

44

3D PrintingTools & Die manufacturing

Green Energy SubstitutionAdditional 1 Cr KwH Wind Energy

Increase Biomass substitution by 30%

Smart TyresIndividual identification of every tyre

Tyre LabellingPlant ready as and when

implementation of standards in India

Silica System with low

Hysteresis Loss

Special Alloy Steel Belts

Gen 4 Hi Performance Polyester, Hybrid Fabrics

RRc 7.8 N/kN

Mileage Index: 110

Traction Index :100

Noise: Stage 2 requirement

RRc of 7.0 N/kN

Mileage Index : 100

Traction Index :100

Noise:2dB(A) reduction(pass by Noise)

RRc of 6.0 N/1kN

Mileage Index :100

Traction Index:100

Noise: 3 dB(A) reduction (pass by Noise)

Specialized Green polymer with Hyper

Bonding Silica Tech

2020-20222018 - 20192018

Road Map for Rolling Resistance

Human Resource 4.0

JK GyanSagarA Group initiative for centralized

knowledge portal

eGuruOnline Learning

Management System


Awards and Accolades

Golden Peacock Energy Efficiency Award 2017

CEM Global award - Excellence in Energy Management 2019 – First company

received the award from India

CII – National Energy Leader Award 2019

BEE – National Energy Conservation Award 2014 & 2015

CII - Green Factory Certification 2016

CII - Green Co Certification 2019 -Platinum

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Thank you

46

Contact Details:B Ramesh Kumar – Head (EEI) Email ID : [email protected] No: 8754440031

JK Tyre & Industries Ltd - Green Business Centre · JK Tyre –Business Overview Late Lala J...

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