NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT - 2020

ITC Limited , Saharanpur (U.P)

OVERVIEW OF ITC

ENERGY MANAGEMENT SYSTEM AND

PERFORMANCE

INNOVATIVE AND ENERGY CONSERVATI

ON PROJECTS

GREENOVATION JOURNEY

TOWARDS RENEWABLE

EMPLOYEE ENGAGEMENT

GREEN SUPPLY

CHAIN and FUEL

SUBSITUTION

INDUSTRY 4.0 &

ENCON-BEYOND

BOUNDARIES

PRESENTATION OVERVIEW

Environment

Water Positive : 18 years in a row

Carbon Positive : 15 consecutive years

Solid waste recycling positive : 13 consecutive years

Soil & moisture conservation over over 1 million acres

43% renewable energy

ITC’s bio-diversity program now covers 37,089 hectares

Economic

Market Capitalization Over $ 44 billion

Turnover: Nearly $ 8 billion

Powered by the vitality of world-class brands

Social

Over 6 million sustainable livelihoods for rural people

Primary Education Initiative: Benefitting 690,882 children

Empowering 6 million farmers

Approx. 135 million person-days of employment generated through afforestation programme

YEAR OF ESTABLISHMENT: 1926

PRODUCT: CIGARETTES & CUT TOBACCO

CAPACITY OF PRODUCTION: 35 BNC, 3 SHIFT OPERATION

MANPOWER: 750 EMPLOYEES & 225 ESPS

SEC: BENCHMARK IN SPECIFIC ENERGY CONSUMPTION

RENEWABLE ENERGY PORTFOLIO:29%

WATER: BENCHMARK IN SPECIFIC CONSUMPTION

ITC Saharanpur (Insight)

OVERVIEW OF ITC

ITC Saharanpur (Triple Bottom approach)

Top Management

Management

Employee

•Audit

•Review and vision setting

•I3I & I4I

•Ignite

•Sankalp

•UNIISTie

r 1

Tie

r 2

Tie

r 3

Execution team

Staff & workmen ESP’s

Management team

Asst. Manager operation (SMD)

Asst. Manager operation (PMD)

Utility Engineer (Mech)

Utility Engineer (Elec)

Asst. Commercial Manager

Asst.HR Manager

Branch Manager (Strategic Management)

Commercial Manager

HR Manager EHS Manager Production Manager Branch Engineer

Peer level Audit Peer Audit Divisional Audit Corporate Audit Third party Audit Steam and Air Audit

ENERGY MANAGEMENT SYSTEM AND PERFORMANCE

Idea sharing platform Organization structure Audit and Review

Electrical Thermal

ENERGY MANAGEMENT SYSTEM AND PERFORMANCE ENERGY MONITORING SYSTEM

Receipt

Generation

Consumption

On receipt Fuel quality monitoring

Normalization as per ASTM (In line with oil company)

Daily Steam consumption monitoring

Daily boiler performance monitoring-EVR

Monthly Steam trap monitoring

Condensate recovery monitoring and analysis

Daily monitoring of Grid utilization

Real time monitoring of power factor for all major load

Daily performance monitoring of DG and Solar plant

Real time monitoring of power consumption of major equipment by energy management system

Online monitoring of electrical loading of all sources by energy management system

Industry 4.0 solution for monitoring health of energy intensive equipment.

ENERGY MANAGEMENT SYSTEM AND PERFORMANCE Energy Reporting and Review Management

Unit Daily

(Dept. Management

team)

Weekly

(Deptt. HOD)

Monthly (Strategic Management

team)

DivisionQuarterly

Sustainability Reporting

(Divisional EHS)

Yearly Unit Review

(Divisional strategic

Management)

Yearly Divisional EHS Audit

CorporateYearly

Sustainability Review and

reporting

Yearly Corporate EHS Audit

Third party Audit by AEM

(Three year once)

ENERGY MANAGEMENT SYSTEM AND PERFORMANCE ENERGY PERFORMANCE

RE-SIZING OF CDRF FAN AUTO TUBE CLEANING SYSTEM SUBSTITUTIVE COOLING

KEY PROJECTS

3.16 3.26 3.18

2.272.01 1.90

5.435.27

5.08

2017-18 2018-19 2019-20

Energy GJ/mnc

Electrical Thermal Energy Overall

Electrical, 3.18, 63%

Thermal, 1.90, 37%

2019-20Electrical

Thermal

7.36

5.525.27

5.08

BLR Pune MMGR SRE

Energy GJ/mnc- National Benchmarking

9.82

5.08

4

5

6

7

8

9

10

BAT ITC Saharanpur

Energy GJ/mnc- International Benchmarking

Excellence in Water Management

4468941262

3767135787

3.04 2.722.44

2.39

0

5000

10000

15000

20000

25000

30000

35000

40000

45000

50000

0

0.5

1

1.5

2

2.5

3

3.5

2017-18 2018-19 2019-20 2020-21 plan

GW withdrawal (KL) KL/Mnc

Reduce

•Reduction in Domestic consumption

•Reduction in irrigation demand

•Segregation of DRY and Wet zone in Canteen

Recycle

•5% improvement in TTW RO recovery

•4% reduction in ETP inlet water with 9% reduction in GW withdrawal

Reuse

•ETP water for AHU filter and solar panel cleaning

•ETP water for PMD and SMD toilet cleaning

•WTP RO reject water for canteen dish wash (Total reuse-738 KL)

Sensomatric Taps-30 nos. location High Pressure Low Flow cleaning m/cDeep overhauling of ETP plant

40%

38%

42%

45%

2017-18 2018-19 2019-20 2020-21 plan

TTW performance (Recovery%)

LONG TERM DE-RISKING INITIATIVES

Overhead fire hydrant system

Vacuum switchControlled

Valve

Machine Speed setpoint

Valve Control

Feedback

Current System: • Selected CDRF fan runs on the preselected

frequency/speed irrespective to the

Proposed System:• To control the speed of CRDF fan in

accordance to the machined running status by installing a electrically controlled valve and pressure switch

Benefit:• Reduction of speed of the fan will result in

energy conservation• Always maintain the required suction in line• Reduction in probability of fan failure hence

advanced the life of the fan• Energy saving potential 8400

RE-SIZING OF CRDF FANINNOVATIVE AND ENCON PROJECTS

Cyclone isolation

25% reduction in fan capacity

Elimination of 100mm pressure drop

Change the machine limited to three fan

10Unit/mnc reduction in CDRF demand

New FanShutoff valve

Cyclone Isolation

• Isolation of Cyclone fan to reduce the pressure drop in the suction line

• Provision for monitoring pressure drop of suction line

Fan Change

• First principle calculation of suction requirement

• Re-design the machine mix to optimize of suction

Fan Speed Control

• Shutoff valve for suction line interlocked with machine

• Valve shutoff if machine does not run for 30 min

• Demand based speed change of CDRF fan

INNOVATIVE AND ENCON PROJECTS RE-SIZING OF CRDF FAN

42

3837

34

2019-20-Q1 2019-20-Q2 2019-20-Q3 2019-20-Q4

CDRF Energy Trend-Uni/mnc

INNOVATIVE AND ENCON PROJECTS AUTO TUBE CLEANING SYSTEM

Benefits:• Results in up to 3% energy saving in hvac chillers• Increases cooling capacity of hvac chillers• Improves condenser tube life• Improves compressor life• Avoids costly shutdown and downtime• Eliminates offline cleaning completely• Avoids harmful chemicals that are used for descaling

Salient Features:

• Ensures 100% clean tubes• Fully automatic, Zero ball loss system, no balls

can escape to cooling tower• Single System for Multiple Chillers even if the

Chiller capacity is different• Automatically operates a cleaning cycle on the

running chiller• Completes the cleaning cycle even if the chiller

is stopped during the cycle• No water wastage from the system

IEX Opportunity

NO Wind Energy from

PSPD

Higher Bilateral ISOA

Cost

Higher energy cost in UP

Non availability of seller for 1MW power

Innovation- Energy Cost Reduction

First Time Ever Purchases Of Through IEX In UP

Key Challenges

Key Activities

PPA with MPLRegistration UPSLDC for exchange

IEX Registration

Current Energy Charges: Rs. 7.31/unit

IEX Avg charges

Rs. 2.91/unit

OA Charges Rs. 1.65/Unit

Savings potential of

Rs. 15.6 Lakhs/Month

Realized saving Rs.26.33 lacs for two month

• Lack of precedence for IEX open access in UP

• Lack of knowledge in State Load dispatch center

• Infrastructural inabilities of IEX application

• Loss of Revenue to SLDC and state Utility

• Understanding CERC Guidelines

• Presentations on existing petitions & regulations

• Focused coordination between MPL & SLDC

• Required Infrastructure changes in SLDC Portal

Key Enabler for monthly approval of

ISOA>> Rs. 50L saving /annum

Addition of New cooling technology

Cost of project: 2L

Impact on unit/MNC 6

Unit/mnc

Annual Savings: 4.6L

Savings of 315 Unit/day

Innovative way of substituting chiller with freely available ambient energy during peak winter by just using a water-to water heat exchanger

INNOVATIVE AND ENCON PROJECTS Innovative project #1 Substitutive cooling in sUPS

1284

970

Before After

KWH consumption

Project Layout and benefit analysis

Replicability

• Across all region with low DBT

Scalability

• Across all panel with compressor cooling system

Return (Cost Benefit analysis)

• Simple pay back in 4 years

ENCON PROJECT IMPLEMENTED- 2017-18

No Title of Project Year

Annual

Electrical

Saving (kWh)

Annual

Electrical

Cost Saving

(Rs million)

Annual Thermal SavingAnnual

Thermal

Cost Saving

(Rs million)

Total

Annual

Savings (Rs

million)

Investment

Made (Rs

million)

Payback

(Months)Comments

QuantityUnit of

Measurement

1Segregation of Process &

Humidifier air line2017-2018 7250 0.054 0 0 0.055 0.1 22

2Occupancy sensor multiple

areas2017-2018 13500 0.1 0 0 0.1 0.1 12

3 Solar street light 2017-2018 1971 0.01 0 0 0.01 0.25 206

4 Light pipe installation in DRF 2017-2018 10800 0.08 0 0 0.08 0.3 45

5 LED tube light in offices 2017-2018 16200 0.12 0 0 0.12 0.125 12

6

Replacement of 4 TPH Boiler

with 8TPH boiler with

economizer

2017-2018 0 0 28 Ton 1.18 1.18 25 255

Saving of 28

ton

LDO/annum

7

Natural lighting utilization by

using polycarbonate sheet in

shop floor roofs

2017-2018 174000 1.28 0 0 1.28 0.6 7

8

Replacement of Conventional

Air handling unit with energy

efficient electrically commuted

motor

2017-2018 353150 2.6 0 0 2.6 0.93 45

9

Interstate wheeling of 1MW

power through open access

mechanism

2017-2018 6768000 27 0 0 27 0 0

Total 7344871 31.244 1.18 32.425 27.405 604

ENCON PROJECT IMPLEMENTED- 2018-19

No Title of Project Year

Annual

Electrical

Saving (kWh)

Annual

Electrical Cost

Saving (Rs

million)

Annual Thermal Saving

Annual

Thermal Cost

Saving (Rs

million)

Total Annual

Savings (Rs

million)

Investment Made

(Rs million)

Payback

(Months)Quantity

Unit of

Measurement

1HSD to LSHS

conversion of Boiler fuel2018-2019 0 0 0 20 20 2.5 1.50

2 Innovative cooling of SUPS 2018-2019 124896 0.874 0 0 0.874 0.4 5.49

3 VFD for Boiler FD fan 2018-2019 12600 0.09 0 0 0.09 0.3 40.00

4 Optimization of Flavour fan capacity 2018-2019 23418 0.164 0 0 0.164 0.4 29.27

5Pulley optimization of Canteen hood

fan2018-2019 15612 0.109 0 0 0.109 0.003 0.33

6 VFD for chiller condenser pump 2018-2019 8784 0.061 0 Ton 0 0.061 0.15 29.51

7 Replacement of air curtain 2018-2019 45000 0.242 0 0 0.242 0.8 39.67

8 Air receiver for FSP machines 2018-2019 165420 1.158 0 0 1.158 0.075 0.78

9VFD in RO

and Chiller plant2018-2019 4800 0.034 0 0 0.034 0.1 35.29

10

Replacement of Conventional Air

handling unit with energy efficient

electrically commuted motor

2018-2019 121296 0.849 0 0 0.849 5.1 72.08

Total 521826 30.381 20 23.581 9.828 255.09

Title of Project Year

Annual Electrical Saving,

kWh

Annual Electrical Cost Saving, Rs Million

Annual Thermal Saving,

Million kcal

Annual Thermal Saving,

Rs Million

Total Annual Savings, Million

Rs

Investment Made (Rs million)

Payback months

Energy efficient fan for CDRF 2019-20 100800 0.737 0.737 3.0 48

Isolation of cyclone CDRF 2019-20 14500 0.106 0.106 0.1 6

Automated Tube Brushing for maximizing

chiller efficiency2019-20 51785 0.379 0.379 2.0 63

Energy efficient EC for condenser of SUPS

air conditioner 2019-20 15768 0.115 0.115 0.3 31

upgradation of cold storage with energy

efficient 2019-20 83071 0.607 0.607 4.6 91

Energy saver in air conditioner 2019-20 21600 0.158 0.158 0.2 15

Canteen hood fan size optimization 2019-20 19200 0.140 0.140 0.1 4

Energy efficient Panel AC 2019-20 90000 0.658 0.658 4.9 89

Interlocking of air curtain with doors 2019-20 52560 0.384 0.384 0.1 3

High speed MAC valve in DRF 2019-20 14280 0.104 0.104 0.3 29

Total 463565 3.39 0.00 0.00 3.39 15.39 54.5

ENCON PROJECT IMPLEMENTED- 2019-20

S. No. Title of Project YearEstimated

Annual Electrical Savings, kWh

Estimated Annual

Thermal Savings, Million

kcal

Investment(Rs in Million)

1 Off site Solar plant - 9MWp 2020-21 665.7

2 Isolation of cyclone in PMD DRF 2020-21 19200 0.4

3 replacement of process pump with energy efficient 2020-21 36000 1.5

4 Smart utility-reduction of compressed air demand 2020-21 280000 9.5

5 Demand based Shutoff valve for compressed air 2020-21 42000 0.31

6 Demand based shutoff valve for pneumatic suction 2020-21 30000 0.12

7 High speed MAC valve in DRF 2020-21 85680 2.5

8 Enhancement in efficiency of Motors 2020-21 10800 1.6

9 HVLS fan in identified area 2020-21 8064 0.08

10 Monitoring the effectiveness of DRF Bag cleaning 2020-21 28800 0.24

11 Energy efficient Panel AC 2020-21 54000 2.38

12 Energy Efficient motor 2020-21 14850 1.3

Total 609394 685.70

ENCON PROJECT PLANNED-2020-21

HRC COMPRESSOR TURBO VENTILATOR

ENERGY EFFICIENT BURNERLED LIGHT

WHEELING OF POWER-ISOA

WASTE HEAT RECOVERY

INNOVATIVE AND ENCON PROJECTS Major Encon Projects

35.85

9.83

15.39

61.07

32.50

23.58

3.39

59.47

2017-18 2018-19 2019-20 Total

ENCON Project Investment vs annual saving

Investment (Rs million)

Annual saving (Rs million)

.

..

62% RE

7% RE

0% RE

2016-17

2018-19

2019-21

Offsite Solar Power

Wind Power

Roof top Solar Power

Electrical

Solar Thermal

Energy efficient Boiler

BIOMASS BOILER8% RE

RE-100

2018-19

2019-21

Thermal

Greenovation RENEWABLE JOURNEY

Continual Improvement in renewable foot-print

0.5% RE

2015-16

27MW Grid Connected Off-site Solar Project for ITC Saharanpur , ITC Mughal and ICML

32

7

4

4

44

Existing After Off-site Solar

Renewable Share

Inter-stateWheelingRooftopSolar

36%

55%

27 MWPhase 1: 9MW,

Phase 2: 18 MW

65.79 CrProject Cost

122L units

Annual Generation

5.95 CrAnnual Savings

14.3% IRR 98 AcreLand Area

Open Access – Transmission & Wheeling of Power using STU

network

Local DiscomSolar Power Plant

Stepping Up of power

Evacuation System – Feeding power to SItapur substation

Power scheduling by

SLDC

ITC Saharanpur

Right of Way (RoW)

Greenovation (Journey) Offsite –solar project

Plant Location Project Execution

Reduction in scope 3 emission by:• Truck optimization by

shipping multiple SKU in common truck

• Localize vendor for recyclable waste to local recyclers

Reduction in scope 1&2 emission by:• Introduction of high efficient

boiler• Improving grid utilization by

rigorous maintenance• Reduction in Specific Energy

consumption by ENCON project

Plan for kgCo2 reduction• Offsite solar plant to enhance

renewable footprint by 100% • Minimal OCM Dispatch • Channelizing better supply chain

management with optimal transportation

Greenovation (Journey) GHG Emission (YOY)

12274

11357

7957

2017-18 2018-19 2019-20

GHG emission Scpoe-1&2 ( Ton CO2)

641359

493523 487851

2017-18 2018-19 2019-20

GHG Emission Scpoe-3

44.50

33.3032.05

2017-18 2018-19 2019-20

Total emission Ton CO2 / Ton of Final Product

Energy

Management

Waste/GHG Management

Renewable

Footprint

WaterManagement

• KL/Mnc-2.47• Water recharge potentetial-300k KL• CGWA and SWB compliance.

2019-22

• Offsite Solar plant-9MW• Biomass Boiler- 8TPH• Renewable footprint-100%

2019-22

• GHG reduction by 50% over 2010-11 baseline

• Single use plastic banned initiative• Exploring environment friendly

biodegradable Material

2019-30

• GJ/Mnc-4.79• Unit/Mnc-784

2019-22

Greenovation (Journey) Future readiness

विचार से आकार

तक

Energy saver for ACs

Stoppage of screw conveyor during idle run

Removal of Cyclone in DRF

Improvement in Power factor

PMD steam optimization

TEAM WORK, EMPLOYEE INVOLVEMENT & MONITORING

Stage 1

Stage 2Stage 3

Stage 5

No of ideas

Ideas Impleme

nted

731 473 235 12 6

Ideas Go-ahead

Ideas for Unit

Panel

Projects for

Divisional Finals

Stage 6

Representation at i4i

Stage 7

Projects for BM

panel

4

Stage 4

1

Green Supply Chain-PolicyAll ITC Units continue to pursue efficient use of raw materials through focused efforts on waste elimination/reduction. Moreover, as most of ITC’s Businesses are vertically integrated, this provides the Company unique opportunities for exercising greater control over optimum utilisation of raw materials, recycling/reuse of wastes as well as efficient logistics.

Haridwar Printing & Packaging Business Factory Supplies Major Raw Material (HLP) implemented following energy conservation project

Title of Project Year Name of the VendorAnnual Saving

(KWh)

Occupancy sensor fitting in officers toilet, meeting room and lab

2018-19 PPB Haridwar 12880

Replacement of AHU fan with energy efficient EC motor

2019-20 PPB Haridwar 35680

GREEN SUPPLY CHAIN

Tobacco waste

Cigarette paper

Agro wasteBio mass boilerConvert into biomass fuel

Plan FY 2020-21

Waste paper Paper bricks Hot water generationHot water

WASTE MANAGEMENT

Waste material VendorUse of the

waste

Used pallets

TVT Chennai Reused

PPB Haridwar Reused

PPB Munger Reused

Used Bobbin core

Max Speciality Films Limited Mohalli

Reused

General metalized Nasic Reused

RGL Manesher

Waste cigarette Paper and HLCs

PSPD Kovai Recycle

PSPD Bhadrachalam Recycle

100%

FUEL SUBSITUTION WITH UTILIZATION OF PROCESS WASTE

Smart FSP

Smart Services

Making Services Smarts for Improved Reliability

Tracking Machine Health for Predictive maintenance

One Touch Flavour Preparation and Integrity

SAP integrated Leaf Integrity System

Leaf Integrity System

Flavor PI System

Real time SMS alerts on Process Deviations

iPQRS SMS Alerts

Escalation Alert

SMS to IC QUIS

Mobile Alerts

First Alert

SMS to Shop Floor Managers

Consecutive Alert

SMS to Specialists

Real-time Data on Mobilie app Communication for better Monitoring & Control

Connected PMD

Smart sensors for Temperature, Vibration

and Noise detection

Email alerts generation on deviation in

parameters

Smart Services

Making Services Smarts for Improved Reliability

Vibration monitoring of Cold Plasma motors

Vibration monitoring of SMD DRF Motors and

alerts generation

Industry 4.0

Solar Plant & Streetlights in local communities

Investment: Rs. 55 lakhsTotal Solar street light installed: 100

Title of Project YearName of the

VendorAnnual

Saving (KWh)

Occupancy sensor fitting in officers toilet, meeting room and lab

2018-19 ITC Haridwar 12880

Replacement of AHU fan with energy efficient EC motor

2018-19 ITC Haridwar 55480

Biogas plant in local community

EnCon awareness session to Employee

Awareness EnCon session to contract workmen

EnCon awareness in nearby villagers

Encon –Beyond Boundaries

29

Solid waste management Process Waste Management

E-Waste (Management) Rules, 2016

1. All e-waste sent to authorised re-cycler2. Submission of Annual return in Form-33. Storage maximum up to 180 day4. Disposal with Manifest system

1. All Bio waste sent to authorised incinerator2. Consent from Pollution control board3. Monthly report submission to UPPCB4. Scheduled review and audit

Bio-Medical Waste Management Rules, 2016

1. Segregated collection of all C & D waste2. All C&D waste sent for land filling 3. Quarterly reporting in sustainability report4. Scheduled review and audit

Construction and Demolition Waste Management Rules, 2016

Green Building Certification

(Platinum Rating)

0 5 10 15 20 25

Energy Conservation

Water Conservation

Indoor Environmental Quality

Site Selection & Planning

Material Conservation

Innovation in DesignAttempted

Waste collection

Waste segregation

Vermi Compost

GREEN SUPPLY CHAIN MANAGEMENT

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THANK YOU