arvind limited division. ankur textiles. ahmedabad · in 1987 arvind entered in to export market....

© Confederation of Indian Industry

ARVIND LIMITED

Division. ANKUR TEXTILES. Ahmedabad

Presentation on Energy saving

Focused on power saving by

Alternative Operations of Aerators

in

ETP and STP Aeration Tank.

Presented By :

R. S. Patel.

(Head – Engineering)


Brief introduction on Company/Unit

• Arvind Limited Started in 1931- with Aim to produce high end Super fine fabric with 52560 Spindles and

1122 looms.

• First year turn over was Rs 45.76 Lakhs which reached to 11000 plus cr. Rs. Last year .

• In 1987 Arvind Entered in to Export market.

• By 1991 Arvind was third largest Denim manufacturing company in the world.

• In 1997 State of Art textile unit was started at Santenj having largest of it kind in Shirting, gabardine and

Knits.

• It is ISO 14001 and ISO 9001 Company. Our labs are NABL - ISO 17025 Certified.

• World famous brand like Levis, Lee Wrangler are our customer. Mega mart and The Arvind store are our

channels.

• Beside Textiles Arvind is in following business.

TE

XT

ILES


Woven fabric –Life Style-Voiles – Ankur Textiles..

- Ankur is one of the oldest working composite Textile mill

in Ahmedabad started in 1914.

- In 1979 Arvind Group take over this unit.

- In last five year our turnover growth is @ 12% and

planned to reach 500 Cr. by FY20.


1. Sp. Energy Consumption in last 3 years


In Textile there are lots of variances like type of raw material (Cotton, poly, P/C,

Modal, viscos, lycra, nylon etc.), Count of yarn (From 6 to 170) and

construction of fabric. There are no national or global standard norms of

specific energy consumption. Industry have to fix its bench marks on the basis

of past consumption data. BEE had given targets to individual industry under

PAT scheme and industry takes Energy saving actions to achieve PAT targets.

Ankur have formed Energy conservation team, constant follow-up and audit of

day to day energy and water consumption.

With our continuous efforts we achieved 9 % saving in thermal and 41% in

Electrical energy in last 3 years.

2. Information on Competitors, National & Global benchmark


ENCON PROJECTS IMPLEMENTED

During the year, 2015-16 &2016-17&2017-18

No. of Projects : 32

Total Amount Invested : ₹ .90 Million

Cost Saving Achieved : ₹ 30. Million

Electrical Energy Saved : 27.59 Lacs kWh

Thermal Energy Saved : 1569 MTOE


3a. Energy Saving projects implemented in FY 2015-16

ELECTRICAL Sr. Project Energy saving step details

Project Description Saving Investment Pay Back Period

KWH/Year ₹/Year ₹ Months 1 L E D Project 160 No LED fittings in place of

fluorescent fitting

37628 310431 136000 5.3

THERMAL Sr. Project Energy saving step details

ProjectDescription Saving of coal Investment Pay Back Period

MT/Year ₹/Year ₹ Months 1 Fuel Saving by

Effimax Installation of EFFIMAX

monitoring system on 8

MT/Hr FBC Boiler

250 1395000 1000000 8.6

2 Fuel saving by

replacement of

boiler

Installation of 8 MT/Hr FBC

boiler in place of 6 MT/Hr

smoke tube boiler

1418 7912440 8000000 12.1

Total 1668 9307440 9000000 11.6

SAVING + INVESTMENT in FY-15-16 1668 9617871 9136000 11.4


3b&c. Energy Saving projects implemented in FY 2016-17-18

ELECTRICAL

Sr. Project Energy saving step details

Project Description Saving Investment Pay Back Period

KWH/Year ₹/Year ₹ Months

1 LED Project 730 Nos of LED fitting in place of

Florescent fitting

170767 1314906 548000 5.0

2 Power saving by

LED

Replacement of 28 Nos of High bay

lights of 400 Watts by 120 Watts LED

fittings

65856 507091 224000 5.3

3 Power saving by

LED

Replacement of 7 Nos of High bay

lights of 400 Watts by 120 Watts LED

fittings compound light

8232 63386 56000 10.6

4 Power Saving

DC Drive convert to invertor drive in

WARPINGM/C

117600 905520 110000 1.5

5 Power Saving Replacement of PUMP in ETP

2NOS 30HP INSTALL 20HP

84000 646800 48000 0.9

6 Power Saving Replacement of compressor motor

pulley.

241500 1859550 30000 0.2

7 Power Saving Replacement of Aerators motors in

ETP 2Nos 30HP INSTALL 20HP

84000 646800 800000 14.8

Continue…




ProjectDescription Saving Investment Pay Back

Period

KWH / Yr ₹ / Yr ₹ Months

8 Power Saving Installed Doffing motor on Card m/c 21000 161700 48000 3.6

9 Power Saving Installed Invertor on Roll folding m/c. 7000 53900 30000 6.7

10 Power Saving Installed invertors on 8 Stenters for

Exhaust

123200 948640 120000 1.5

11 Power Saving REPLACE AUTO CORNER M/C 2NOS (138

were replaced by X5 mopdel)

161700 1245090 25000000 240.9

12 Power Saving Installed Invertor in Boiler I D Fan 1 Nos

M/c

64680 498036 75000 1.8

13 Power Saving Installed Temerature controller in

compressor Cooling Fan -1 no M/C

9450 72765 10000 1.7

14 Power Saving Replaced Auto Corner suction motor

pulley in 2 m/cs

30800 237160 10000 0.5

15 Power Saving Installed Invertors 10 Nos SFAN/RFAN in

Winding Dept.

420000 3234000 320000 1.2

Continue…




ProjectDescription Saving Investment Pay Back Period

kwh / Yr. ₹ / Yr. ₹ Months

16 Power Saving Installed Fibre roof for day light in Jet

dyeing area.

3528 27166 50000 22.1

17 Install Monitor roof in Godown -

removed 24 - 40 W tube lights in top

floors

3528 27166 500000 220.9

18 Low eff to high eff. Replaced Low eff. Stenter by High eff. 283073 2179662 19300000 106.3

19 Energy Saving by

Alternative operation of

ETP and STP Aerators

Total 7 nos of Aerators are put on

alternative drive.

346302 2666525 175000 0.8

20 Save Energy and water

consumption through

Water Pressure control

To maintain water pressure at 1.5

Kg/cm2 round the clock by installing

invertors and pressure transdudar on

water supply. Reduced water

consumption by 145 KL/day.

89436 688657 60000 1.1

21 Invertors on H Plant fan

mptors

Invertors on H plant fans- Total 6 nos

(Spinning)

252000 1940400 150000 0.9

22 Invertors on H Plant fan

mptors

Invertors on H plant fans- Total 4 nos

(Weaving)

134400 1034880 100000 1.2

SAVING + INVESTMENT Electricals in FY: 16-17-18 2722052 20959800 47764000 27.4



THERMAL


ProjectDescription Saving of coal Investment Pay Back

Period

₹/Year ₹ Months

1 Thermal Energy Installed Invertors in Stenter M/c for Exhaust 8

m/c.

824600 200000 2.9

2 Stenter upgradation Replace low efficiency Stenter by high eff. stenter

m/c

1543800 15000000 116.6

3 Steam Trap

Replacement

Replaced 36 No. thermodynamic trap by float type

trap, Reduced steam cons. 6%

310000 180000 6.9

4 PRV on Machines Installed 15 No Pressure Reducing Valves on 15 No.

comby m/c to reduce steam pressure 5.5 to 3.0 bar

365800 150000 4.9

5 Steam cut off switch

on 5 No. Drying range

m/cs.

Installed 5 Nos. of steam cut off switches when

m/c is stopped.

1463200 25000 0.2

6 Reuse of Hot Water Started recirculation and reuse hot water 70000

ltr/day.

899000 60000 0.8

7 Collection of

condensate water

Installed additional pump. 706800 250000 4.2

16-17 -18: TOTAL SAVING + INVESTMENT (Thermal) 6113200 15865000 31.1

16-17-18 : TOTAL SAVING + INVESTMENT (Electrical) 20959800 47764000 27.4

16-17-18 : TOTAL SAVING + INVESTMENT (Ele. + Thermal) 27073000 63629000 28.2


1) REPLECMENT OF COMPRESSOR MOTOR PULLY

power consumption - 155 x 23x 350 = 1247750 KWH/year power

consumption - 125 x 23x 350 = 1006250 KWH/year 1247750 1006250

saving kwh 241500

2) Save Energy and water consumption through Water system Pressure

control

To control water pressure at 1.5 Kg/CM2 Round the clock by installing

invertors and pressure transducer on water supply. Reduced water

consumption by 145 KL/day.

3) Total 5 no of Aerators of ETP and 2 Nos of Aerators working continuously

Power consumption .705672 KWH/year. Total 3 no of Aerators of ETP and

two no Aerators of STP are working Alternatively with invertor and two

Aerators of ETP working Alternatively. Power consumption 359370

KWH/year

4. Innovative Projects implemented


Thought process for power saving

Micro organisms such as bacteria and protozoa can use the small

particles and dissolved organic matter, not removed in primary

treatment, as food.

Aeratio ta k o tai s “soup" of starved i ro es alled a tivated sludge.

They are aerobic organisms so need Oxygen to survive and

requirement of dissolve oxygen is proportionate to the input pollutant

load.

Design of any aeration tank is done for DO level of 2.5 mg/ltr.

As our input load of COD, BOD is lesser to design load DO was

remained 3.5 to 4 mg/ltr.

Excess DO was consuming unnecessary Electrical Energy.

We started thinking various options to reduce DO level.

First option is to reduce Speed of Aerators by installing VFD.


Energy Saving By Innovative implementation


Aeration Tank Details

We have total 3 nos. of aeration tanks for

secondary treatment

Location Capacity KL HP of each

Aerator

Nos. of

Aerator

ETP 1600 25 2

ETP 1200 15 3

STP 1000 20 2


DATA SHEET


Photographs


-We have installed 512 KW Solar panels on our roof top.

Beside of Energy to conserve natural resources...

(1) We have installed Sewage Treatment Plant having 15 KLD capacity. WE

take raw sewage from Corporation drainage line, treat it and use as

process water. ( 65 % of total process water is used from this STP) This is

first textile unit in India having such a large plant.

(2) We started rain water harvesting in under ground bore well.

5. Utilisation of renewable energy sources


Reduction in CO2 emission in 2017-18 is 9 % in

quantity and 24% in per ton of production in last three

years.

7. GHG Inventorisation

Quantity in Ton

Sr. No Co2 Emission Source 2015-16 2016-17 2017-18

1 Electricity Consumption 22260 16501 12667

2 CNG Gas 491 487 473

3 Coal 26273 26496 30222

4 DOC - Agro Waste Fuel 77 881 1294

5 Total 49102 44365 44656

6

Quantative % Saving Compare

to 15-16 9.65 9.05

7 Producton in MT 4037.23 4666.93 4869.67

8 Ton of Co2/Ton of Production 12.16218 9.506326 9.170259

9

Per Ton Production % Saving

Compare to 15-16 21.84 24.60


9. Team work, Employee Involvement & Monitoring


Endless Efforts to conserve

energy and natural

resources are must.

Thank you all.

arvind limited division. ankur textiles. ahmedabad · in 1987 arvind entered in to export market....

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