18th national award for excellence in energy management...
TRANSCRIPT
Presented By :
Harvinder Rathee (Head – Engineering)
Kushal Trivedi (Sr. Manager – Engineering)
18th National Award for Excellence in Energy Management 2017: 30, 31 August & 1 September
What Arvind ?1
Textile – Process Flow
2
Methodology toward Energy Conservation
3
Projects
4
Case studies
10
GHG Reduction
6
Certifications and Award
7
8 Renewable Energy
9
Contents
2020 Goals
Benchmarking5
Who we are?
$1.3Bn Indian conglomerate
Interests in Textiles, Retail, Advanced materials,
Environmental solutions
and Real estate
Founded in 1931 during Swadeshi
movement
Among Global top 5 organized Denim
manufactures and pioneers of Denim in India
Every 2 secondsan Arvind manged brand apparel is sold in India
Our fabric can go around the
earth
~6 times
Own or manage
30 brands (International and domestic) in India
1 lac acres of farmland under organic cultivation
22 global patents
for environmental solutions
Largest Fire Protection
Fabric Producer in India
Arvind’s leading practices to ensure environmental sustainability
Water One of the largest
Zero Liquid Discharge plant in
Asia at Gandhinagar
Use of Sewage water from nearby
communities as process water
Energy
Chemicals
100% process water from
recycled water
India’s most energy efficient textile unit, awarded three years in a row
One of the largest solar roof-top plant in Gujarat
Specific energy consumption
reduced by 20% over last four years
Robust quality check established
for incoming chemicals
In house state of the art IQC
lab
Globally first textile mill to sign a
pact towards zero discharge of hazardous
chemicals
ISO 14001 SA 8000 ISO 9001 ISO 50001 BS OHSAS 18001
Certifications
TopRank
NECA
2014 2015
2016MOST INNOVATIVE ENVIRONMENTAL PROJECT
Highest number of ECerts in
Textiles Sector – PAT 1
Recognitions
A : Organized National Level Workshop in Best practices in Energy Efficiency in Textile Sector ; BEE , State Designated Agency (GEDA) and Industries brought at same platform; 42 Industries from all over India Participated
B : 5 days Internal Capacity Building Program Organized at our campus on Energy Efficiency
Knowledge Exchange Workshop
A B
Raw Material
Spinning
Yarn Dyeing
Weaving /Knitting
Processing Finishing
Inspection
Textile – Process Flow
Continuous & Proactive Efforts
Internal Audit Team formation for Energy
Management
Assistance from External Team
– EESL
– TERI
– Thermal audit from Expert
Strong Management Will & support
Methodology
Energy Committee –Chaired by Head
(Engineering )
Energy Team -Shirting
Energy Team Bottom weight
Energy Team -Knit
Ene
rgy aud
it Te
am
Energy Conservation Organogram
Methodology toward Energy Conservation
71406659
62625626
2013 - 14 2014 - 15 2015 - 16 2016 - 17
Electrical Energy (KWHr/Tonn)
Specific energy consumption – Internal bench marking
75210 7487566627
59686
2013 - 14 2014 - 15 2015 - 16 2016 - 17
Thermal Energy (KJ/Kg)
21 % reduction in four years
Benchmarking for Year 2017-
18
No. of Projects : 31
Total Amount Invested : Rs. 196 Million
Cost Saving Achieved : Rs. 344 Million
Reduction in GHG emissions : 68756 Tons of CO2
Thermal Energy Saved : 18760 Tons of coal
Electrical Energy Saved : 263.7 Lacs kWh
Encon Projects Implemented in the years 2014-15 , 2015-16 & 2016-17
S.
No.Title of Project
Annual
Savings,
(Rs. million)
Investmen
t
(Rs
million)
1 VFDs in Auto Coner Machines 2.0 1.3
2Installed of VFD with Pressure Transducer for 28 nos. Re-
winding Machines & blow room Waste collection system 10.1 5.4
3Installed of VFD on the following Blowers in Pressure
Dryer of Dyeing Machine4.3 1.4
4 Replaced of the existing Pumps by more efficient Pumps 3.3 3.1
5 Installed of VFD on Feed water pumps in ETP 1.4 0.4
6Eliminated of Cooling Tower & pumping by installing HR
PHE in Gas engine 3.0 0.0
7Replaced of old Screw air compressors with Energy
efficient centrifugal air compressor 37.1 20.7
8Replaced of 6 nos. pump set with 2 nos. of Energy
Efficient pump set in FFP area Central ETP2.0 1.6
9Installed O2 sensor & Insulation improvement in steam
boilers16.1 4.2
10 Installed of two PHE in 4.3 MWM & 4 MWM Gas Engine 17.1 6.8
Total 96.4 44.9
Projects Year 2014 - 15
Projects Year 2015 – 16
S.
No.Title of Project
Annual
Savings,
(Rs.
million)
Investment
(Rs. million)
1Replaced of 36 Watt TFL by 18 Watt LED lamps in Loom shed,
spinning & Ware house shed 24.3 19.5
2Optimized Compressed air System i.e. reduction in pressure drop &
increase Pipe Size with close loop for entire generation & User End 40.0 7.5
3
Replaced of old air dryers with High size new Refrigerant Air dryer
(Large size SS Pre cooler) to avoid line loss & replaced Demister
pad of old ref. dryer with New SS Mess
18.2 6.4
4 Replaced of Raw water pump with right capacity & Head EE pumps 5.9 5.1
5Replaced of 6 nos. of Cooling Water Pumps & Process Water
Pumps with 2 nos. of right Size EE pumps in Shirting Pump House6.0 3.1
6Installed of PNLD in Air compressors & dryers drain & drain water
Diverted to Cooling tower make up5.7 1.3
7Installed of day light sheet/ Translucent Sheet in Bottom & Knit
Process House 0.7 1.2
8 Insulation improved in 20 & 30 TPH boilers 1.2 0.5
9 Installed of Economizer in 15 & 8 TPH boiler 21.3 6.9
10 Replaced of faulty Steam Trap in Khakhi division 7.6 4.7
11 Heat Recovery from process effluent water @ 85 C Effluent 15.4 9.9
Total 146.4 66.1
Projects Year 2016 – 17
S.
No.Title of Project
Annual
Savings,
(Rs.
million)
Investment
(Rs. million)
1Installed PNLD on Air dryer drains (Qnty -12) & reused Condensed
water to cooling tower makeup 11.7 2.5
2 Installed APH in 20 LkCal & 15 Lkcal Thermic fluid Heater 27.1 50.1
3 Installed natural Draft CT for air Compressors 18.2 6.1
4 Insulation Improvement in steams lines 5.9 5.1
5 Installed PPPU Pumps for Sizing Condensate (80 KL / day) 9.9 6.8
6Installed 450 CFM low pressure 4.5 barg air compressor for
Cleaning application 5.7 1.3
7 Conversion of negative Suction Effluent pumps to positive Suction 0.7 1.2
8Replaced of forced draft cooling tower to natural draft CT in air
compressors 1.2 0.5
9Heat recovery Unit, humidity sensors, fabric moisture sensor in
thermic Fluid stenters Exhaust air 13.5 6.9
10 Installed of 175 kW sloar panels in shirting office area 7.6 4.7
Total 101.5 85.2
Case Study - 1
STENTER Machine
Stenter ( 8 Chamber ) – Cost Analysis
Machine Cost, 16%
Labour Cost, 11%
Maintenance, 5%
Spare Parts, 3%
Electricity , 12%
Heat Energy, 48%
Others , 5%
ENERGY COST = 60 % i.e. Rs 750 / 1000 mtr of fabric
Thermal Energy = 8.00 lacs Kcal/ HrsElectrical Energy = 125 units / hrs
considerationsPower Rate Rs 7.81 / unitCNG Rate Rs 23 / SCM
Fabric Moisture sensor, Exhaust humidity, Fabric temperature sensor
Energy Cost Rs 750 / 1000 mtr
fabric
Energy Cost Rs 480 / 1000 mtr
fabric
Annual saving = Rs 91 LacsInvestment = Rs 20 Lacs
Stenter Exhaust
Temp. 190 deg c / 140 deg C
Exhaust Thermal Energy is still available here
Stenter Exhaust• Heat of Exhaust gases is
used to heat the fresh air• Reduce heat demand by 15
to 20 % for finishing• For dry heat setting to 30
to 35 %
Stenter Exhaust
• Energy Saving of up to approx. 30 % with 190 deg C dryer temperature
Energy Cost Rs 480 / 1000 mtr
fabric
Energy Cost Rs 384 / 1000 mtr
fabric
Annual saving = Rs 44 LacsInvestment = Rs 45 Lacs
Case Study - 2
CARDING Machine
Case Study 2 - VFD in Waste Collection
Waste
- 600 Pa
Carding M/C
Waste Collection
SCHEMATIC DIA. OF WASTE COLLECTION SYSTEM
Case Study 2 - VFD in Waste Collection
Primary Filter
Secondary filter Exhaust fan
- 600 Pa
- 600 Pa Duct loss
- 50 Pa- 75 Pa
- 300 Pa
-1625 Pa
-150 Pa-250 Pa
- 2100 Pa
-800 Pa
CLEAN CONDITION
(MINIMUM)
CHOCK CONDITION
(MAXIMUM)
Negative Pressure required
by M/C Supplier (-600Pa
Minimum M/C operating
Cond.)
-600Pa -800Pa
Duct Loss -600Pa -600Pa
Primary (Disc) Filter losses -50Pa -150Pa
Secondary(Rotary) Filter
Losses
-75Pa -250Pa
Exhaust Losses -300Pa -300Pa
TOTAL -1625Pa -2100Pa
-2250(Considered for final design including unforeseen losses; Air & Duct losses)
Case Study 2 - VFD in Waste Collection
SCHEMATIC DIA. OF WASTE COLLECTION SYSTEM
Case Study 2 - VFD in Waste Collection
Primary Filter
Secondary filter Exhaust fan
Pressure Transmitter
VFD
Project Duration :2016-17Annual Electrical Saving :3.45 Lakhs kWhProject Cost :Rs. 1.5 millionAnnual Saving :Rs. 2.7 million
Case Study 2 - VFD in Waste Collection
Case Study - 3
Compressor – Moisture drain
Case Study 3 – PNLD in compressed air system &condensate make up to cooling tower
Manually Drain (Air + Water)
Air In @ 0 Barg Air Out @ 7 Barg Dry Air Out @ 6.5 Barg
Before
Compressed Air System (46,000 CFM network) All Compressors drain provided with needle ( notch) valves All Dryers’ drain provided with mechanical bucket type drain Problems with above system Lot of Air Loss in Air compressor drain even needle valves fully closed Dryer drain found frequently choked & stopped. Damaged pneumatic tools when any dryer drain chocked, line flushing require to remove moisture from lines, lot of
compressed air loss Header pressure was not maintained so, start additional compressors to meet
requirement
Manually Drain (Air + Water)
Air In @ 0 Barg Air Out @ 7 Barg Dry Air Out @ 6.7 Barg
After
Tangible benefit : Air Pressure Increased – By avoiding air Drain loss Quantity of make up water Reduced Inlet water temperature of air compressor reduced, Performance increased Intangible benefit : Better housekeeping as less leakages and oil spillages
Cooling Tower Make Up Tank
Case Study 3 – PNLD in compressed air system &condensate make up to cooling tower
Project Duration :2016-17Annual Electrical Saving :15.3 Lakhs kWhWater saving :Avg. 0.8 KL per
day in Monsoon Project Cost :Rs. 2.50 millionAnnual Saving :Rs. 11.70 million
Case Study 3 – PNLD in compressed air system &condensate make up to cooling tower
Installed Day Light sheets at Process Shed
Turbo ventilator to exhaust hot Air form Process Shed
200kW X 14 Nos. Wind mill @
Costal Area of Saurastra, Gujarat
Renewable Energy Front – 12 % Renewable Energy
GHG Reduction
11
11.5
12
12.5
13
13.5
14
2013-14 2014-15 2015-16 2016-17
13.7 13.6
13
12.1
Gate To Gate GHG/TON
- 11 %
2020 Goals
EMS
Energy & GHG
Water Use
Waste water / Effluent
Air Emission
Waste management
Chemical management
Sustainable RM
“ Improve, Measure & Report ”
“ To reduce specific energy consumption by 15% ”
“ To become water positive
“ Improving the quality of waste water/ effluent ”
“ To reduce overall Emissions by 10% ”
“ Zero Hazardous chemicals, turning Green , ZDHC”
“ To increase the share of sustainable raw material to 40% ”
Focus Areas
“ To reduce ETP sludge and improve in-houserecycling of waste”
Draft Future Strategy Planning
Thank You