ON-SITE RENEWABLE ENERGY USING PROCESS WASTE

MYSORE FACTORY

INTRODUCING HUL : INDIA ’S LARGEST FMCG COMPANY

OUR HISTORY

In the summer of 1888, visitors to the Kolkata harbor noticed crates full of Sunlight soap bars. With it, began an era of marketing branded Fast Moving Consumer Goods (FMCG).

• Deep Roots in local Culture, 75+ years in India wit h leading market position across categories• Touches lives of two out of three Indians• 8 HUL brands in the 2014 Brand Equity Top 25 Most t rusted Brands List• Over 16,000 employees , annual turnover of INR 30,1 70 crores (FY 2014 – 15)

WE REMAIN COMMITTED TO OUR STRATEGY

We Will Develop New Ways of Doing Business with the

Aim of Doubling the Size of Our Company While Reducing

Our Environmental Impact and increasing our positive

social impact

VISION

BRU PORTFOLIO

R&GInstant Coffee Cappuccino (Ice & Hot)

Out Of Home

Hot Tea Shop

Mysore Factory Hosur Factory

MANUFACTURING LOCATIONS

GREEN CO JOURNEY

• WFE Installation• Spraying Pattern Optimization• Agro-waste Boiler Installation

• WFE Installation• Spraying Pattern Optimization• Agro-waste Boiler Installation

• Flash Steam and Condensate Recovery• Screw Based Air Compressor

Installation• Heat Recovery from ICC Column• VAM Chiller

• Flash Steam and Condensate Recovery• Screw Based Air Compressor

Installation• Heat Recovery from ICC Column• VAM Chiller

20102010

20122012

20132013

20142014

• IE3 Motors Installation • Spent Water Recycling• Condensate Recovery Phase 2• Vacuum Pump Water recirculation by cooling• Westphalia Sludge Recycling • Recycling ETP treated water through RO

• IE3 Motors Installation • Spent Water Recycling• Condensate Recovery Phase 2• Vacuum Pump Water recirculation by cooling• Westphalia Sludge Recycling • Recycling ETP treated water through RO

• IE3 Motors Phase 2• LED Lighting Phase 1• Online In-house Spent Burning• MMB Uptime Improvement• Spray Drier Efficiency Improvement• VFD and Interlocks for Energy Optimization• Planetary Gear Boxes• Lighting Timers

• IE3 Motors Phase 2• LED Lighting Phase 1• Online In-house Spent Burning• MMB Uptime Improvement• Spray Drier Efficiency Improvement• VFD and Interlocks for Energy Optimization• Planetary Gear Boxes• Lighting Timers

Green-Co “Silver”Rating

Electrical Energy Efficiency

Steam Efficiency

MANUFACTURING PROCESSGREEN COFFEE BEANS

GB Cleaning

Roasting

Granulisation

Extraction Clarification

CHICORY PLANT

CHICORY TUBER

ROASTED/DICED CHICORY CUBES

CHICORY CUBES

CHICORY EXTRACTION

EVAPORATION SPRAY DRYING

UNDERSTANDING SPENT

Roasted Beans

Granulated Beans

Spent Waste @ 90% moist

Hot and Pressurized Water

Coffee Liquor

SPENT GENERATION

IS THE MAJOR

CONTRIBUTORLiquid Waste17.8%

Spent Waste73.8%

Other Solid Waste8.3%

Waste Contribution –Mysore Factory

COST• Increasing cost prices of Briquettes with inflation• Relatively lesser no. of briquette suppliers leading to MONOPOLY• High Cost involved in truck handling and sun drying of spent

WASTE• Unilever’s vision on reducing Environmental impact•Generated Waste is among the highest among HUL sites• Elimination of waste is not possible as it is inherent in instant coffee processing• Costs involved in sending the waste outside and drying• Very less no. of players having infra to handle such quantity of spent leading to monopoly

MIDAS TOUCH - Lets convert this waste into the FIRE OF GOLD

Waste

THE GOLDEN FIRE !

Waste

Cost

Reduce Cost

while

Reducing

Waste !!

EXECUTION FLOW

Extraction Water : 180 Deg, 24 bar

ExtractionColumn

Coffee Liquor

Coffee Beans

Spent water for recycling

Coffee Spent waste@ 90% Moist

Spent Silo

Spent @ 70% Moisture

SP

Dry Fuel

Feeding

Steam for Process

Wet

Fuel

Feeding

Spent Waste @ 90% moist

CHALLENGESFACED AND THE

CORRECTIVE ACTIONS TAKEN

Extraction Water : 180 Deg, 24 bar

ExtractionColumn

Coffee Liquor

Coffee Beans

Spent water for recycling

Coffee Spent waste@ 90% Moist

Spent Silo

Spent @ 70% Moisture

SP

Dry Fuel

Feeding

Steam for Process

Wet

Fuel

Feeding

Spent Waste @ 90% moist

K 1

K 3

K 2

K 4

K 5K 6

K 7

K 8

K 9

K1

K2

K3

K4

K5

K6

K7

K8

K9

Extraction Water : 180 Deg, 24 bar

ExtractionColumn

Coffee Liquor

Coffee Beans

Spent water for recycling

Coffee Spent waste@ 90% Moist

Spent Silo

Spent @ 70% Moisture

SP

Dry Fuel

Feeding

Steam for Process

Wet

Fuel

Feeding

Spent Waste @ 90% moist

M

70 mm

GB

110 mmCompression Ratio –

1.57

Output moisture is directly dependent on the compression ratio

Compression Ratio

Output Moisture

BEFORE –

70%

Moisture

BEFORE

Without Capacity

Loss

AFTER –

60%

Moisture

MGB

60 mm110 mm Compression Ratio –1.83

Moisture Reduced

from 70% to 60% !!

AFTER

BEFORE

Flash Steam from

Squeezed spent at 80

degrees

Steam ingress into the bearing

Hot Spent at 100 degrees

AFTER

Flash Steam from

Squeezed spent at 80

degrees

Oil Seal

Provided

Hot Spent at 100 degrees

BEARING FAILURE

ELIMINATED !!

BEFOREFeed

Front View

Side View

Bar Screen

Bar Screen

Radial Load

Bending Load High due to distance

BEFORE

200 mm

AFTERFailure Point

100 mm 100 mm

Screen Damage

Eliminated !!!

SupportSupport SupportSupportSupportSupport

Additional Support

M GB

High Moisture in Silo resulting in pressure fluctuation in boiler

Spent Silo

Spent @ 90%

Moisture

Increased Screw press Capacity

by 12.5%Pulley Diameter Decreased to increase

RPM

Extraction Water : 180 Deg, 24 bar

ExtractionColumn

Coffee Liquor

Coffee Beans

Spent water for recycling

Coffee Spent waste@ 90% Moist

Spent Silo

Spent @ 70% Moisture

SP

Dry Fuel

Feeding

Steam for Process

Wet

Fuel

Feeding

Spent Waste @ 90% moist

K1

K2

K3K4

BEFORE

SPENT SILO

SCREW CONVEYOR

Agri Boiler

Screw Conveyor at Silo bottom is run at both the directions

to Supply both to Agri Boiler and Truck

High Maintenance due to regular FORWARD

AND BACKWARD MOTION

High Capacity Motor due to High Length

Supply to EITHER MMB OR TRUCK

Resulting in INCONSISTENT

SUPPLY OF SPENT

Motor Load

Length of Conveyor

SPENT SILO

SCREW CONVEYOR

AFTER

TWIN DISCHARGE

Only ONE-DIRECTIONAL

motion of CONVEYOR

Two Openings made at Silo Bottom

One to Conveyor and Other to Truck

Reduced

Maintenance

Agri BoilerReduced

Motor

Capacity

ELIMINATED

machinery

dependence on truck

feeding

Reduced Conveyor Length from 7.5 m

to 6 mANGLE OF REPOSE > 45 degrees to

Ensure SMOOTH FLOW

Spent Conveying

Problem

ELIMINATED

01530404550Angle of Re-pose

Extraction Water : 180 Deg, 24 bar

ExtractionColumn

Coffee Liquor

Coffee Beans

Spent water for recycling

Coffee Spent waste@ 90% Moist

Spent Silo

Spent @ 70% Moisture

SP

Dry Fuel

Feeding

Steam for Process

Wet

Fuel

Feeding

Spent Waste @ 90% moist

K1

K2

K3K4

K5K6

DRY SPENT

BEFORE

� No Control on Quantity of Fuel : 70:30 to be maintained

� Temperature and Hence Steam Fluctuation

MMB Furnace

BRIQUETTE

Normal Temp

HIGH Temp

Safety Issue

NO CONTROL ON FUEL

QUANTITY !!

RAV for Controlled

feeding@ 10 RPM

0.5 TPH

DRY SPENT

� Safety Issue of Dumping Eliminated

� Controlled Mixing of fuel as per ratio

MMB Furnace

BRIQUETTE

Normal Temp

NORMAL Temp

AFTER

Briq @ 1.5 TPH

Extraction Water : 180 Deg, 24 bar

ExtractionColumn

Coffee Liquor

Coffee Beans

Spent water for recycling

Coffee Spent waste@ 90% Moist

Spent Silo

Spent @ 70% Moisture

SP

Dry Fuel

Feeding

Steam for Process

Wet

Fuel

Feeding

Spent Waste @ 90% moist

K1

K2

K3K4

K5K6

K7

BEFORE

M GB

Distance from one side wall of furnace

Quantity of wet Spent in furnace (Small scale trial)

Screw Conveyor

2200 mm

75 mm

25 mm

Distance from one side wall of furnace

Quantity of wet Spent in furnace (Small scale trial)

Screw Conveyor

M

AFTER

PRESSURE FLUCTUATION

ISSUE ELIMINATED!!

GB

2200 mm

50 mm

Extraction Water : 180 Deg, 24 bar

ExtractionColumn

Coffee Liquor

Coffee Beans

Spent water for recycling

Coffee Spent waste@ 90% Moist

Spent Silo

Spent @ 70% Moisture

SP

Dry Fuel

Feeding

Steam for Process

Wet

Fuel

Feeding

Spent Waste @ 90% moist

K1

K2

K3K4

K5K6

K7

K8

BEFORE

� Flying ash settling in 3rd pass bottom conveyer. It is getting accumulated over a period

and forced to stop the Boiler for cleaning

7 Days

15 Days

20 Days

AFTER

�Provided online Ash removal system with conveyer.

�Ash will be removed online without built inside.

�Boiler Uptime increased %

MMB OPERATING

TIME INCREASED

FROM 20 – 45 DAYS !!

Extraction Water : 180 Deg, 24 bar

ExtractionColumn

Coffee Liquor

Coffee Beans

Spent water for recycling

Coffee Spent waste@ 90% Moist

Spent Silo

Spent @ 70% Moisture

SP

Dry Fuel

Feeding

Steam for Process

Wet

Fuel

Feeding

Spent Waste @ 90% moist

K1

K2

K3K4

K5K6

K7

K8

K9

SPENT WATER RECOVERY

Spent Water Collection Silo

Spent Water from Screw press

Filter Press

Centrifuge

Spent Water Use Back in Process

WATER AND SOLIDS

RECOVERY

Solid Waste to

Boiler

BENEFITS

THANK YOU