aurobindo pharma ltd borapatla , hyderabad - ciigbc award... · 4 no. of circulation pumps for ......

1st & 2nd September 2010

CII 11th National Award for Excellence in Energy

Management 2010

Aurobindo Pharma Ltd Borapatla , Hyderabad

Company’s Profile Aurboindo Pharma Ltd head quartered at Hyderabad, Andhra Pradesh, India

Robust product portfolio: Antibiotics, Anti retroviral, CVS, CNS, Gastroenterological and Anti Allergic.

Turnover of about 3,500 crore. Exporting to 125+ countries with 70%+ of revenues from international Operations. Employee base:8000+

The company’s manufacturing facilities are approved by several leading regulatory agencies like US FDA, UK MHRA, WHO, Health Canada, MCC South Africa, ANVISA Brazil

The company’s robust product portfolio is spread over 6 major therapeutic/product areas encompassing. The company is marketing these products globally in over 100 countries

FY 04-05

FY 05-06 FY 06-07 FY 07-08 FY 08-09 FY 09-10

International Sales

8.4 bn 10.9 bn 13.9 bn 16.0 bn 20.9 bn 24.9 bn

%%%5%Domestic Sales 5.8 bn ` 6.1 bn 8.3 bn 9.5 bn 9.4 bn 9.6 bn

Process Profile & Growth

Pilot PlantResearch &

DevelopmentActive Pharma

IngredientsFormulation

Process Profile

Company’s Growth

Energy Conservation Projects 2009-10

Utility

v Process: Reaction+ Distillationv Original design: Thermic fluid was being

used as media of heating & cooling for both process.vModification: Distillation process does

require heating only, hence direct steam is used for the above process.

Direct steam utilization for process reactors in place of Single Fluid Heat Transfer System in I Block

Direct steam utilization for process reactors in place of Single Fluid Heat Transfer System in I Block

S.No Description

Previous system

Modified System

1 Process Vessels (ID:SRI 011,12&13) 3 3

2 Steam Consumption/Day 11.3 MT 9.9 MT

3 Steam Cost/Day---(a) 9492 8332

4 No. of Circulation Pumps for Therminal 3 Nil5 Power Consumption / Day 168 KWH Nil

6 Power Cost / Day ---(b) 603 Nil

7 Therminal Make up /Day 8 KG Nil

8 Therminal Cost/Day --( c) 2800 Nil

Total Cost /Day = (a)+(b)+( c) 12895 8332

Differential Cost/Day Rs.4563

Annual Savings = Rs.1.37 Millions

Investment is Negligible

Switch over from multiple boilers to single boiler with high efficiency & over bed FBC to under bed FBC boiler

v Old SystemThree boilers of capacity 8TPH + 3TPH (coal fired) +6TPH (FO) Fuel :

Fuel Used : Mixed coal (Imported 80% + Indian 20%) Operation : Continuous duty

Firing : Over bed -FBCSteam to fuel ratio is 5.0-5.2 kg

Manual coal feeding to 3TPH boiler having low efficiency with steam fuel ratio of 4.0v Present SystemWe installed Higher capacity boiler 27.5 TPH which is designed for imported/Indian coal with Under bed firing This boiler operation is in fully automatic mode (SCDA system) and with all facilities like VFD’s for fans, economizer, vertical pumps etc.Average steam generation /hr – 18 TonsSteam to fuel is :5.4 kg of steam/kg of coalTotal fuel consumption / day = 80 MTFuel Savings/day = 5.382 MTAnnual fuel savings = 340 x 5.382 MT = 1829 MTAnnual fuel cost savings = Rs.6.4 MillionsInvestment Made on New Boiler : 30 Millions

AFBC Boiler 27.5 TPH @ 14.5 KG/CM2

AFBC Boiler – Operation Thro SCDA System

Introduction of High Efficiency CoolingTowers–1800TR

v Highlights : Cooling Towers with easy cleanable Raschingrings in place of PVC fills sheets, FRP Blades & Absence of Gear Box. v No of Cooling Towers – 3 Nosv Capacity of Cooling Towers – 600 TRv Chilling plant compressor discharge pressure was reduced by 1.8kg/cm2 (when compared to other blocks utility systems)v Every 1 kg/cm2 reduction would save 5% power consumptionv Operating Compressors HP = 480 v Advantage of power cost /day = 480 x 0.75 x .65 x 24 x 3.7 x 0.8= Rs.1662v Annual savings = Rs.0.565 Millionsv Investment is not considered as it is part of plant requirement

High Efficiency Cooling Tower

High Efficiency Cooling Towers at L&M Block Utility

Cooling Tower Cross Section - Inside

Honey comb fills

Rasching Ring Fills

Steam Condensate recovery from SRP Plant ,L &M and Utility Blocks

Steam condensate recovery pumps (PPPU) were installed in L&M Blocks and Utility PlantAfter Installation Of PPPU Boiler feed water temperature increased from 66 – 71 Deg.CentTotal steam condensate recovered from the above Areas/day = 154 KL

Coal consumption/Day= 70.5 MT

Fuel saving / Day = 70.5 x 0.009 =0.634 MT

Coal Cost / MT = Rs.3550

Fuel cost savings/Day = 0.63 x 3550 = Rs.2250

Fuel saving/Annual = 2250 x 340 = Rs.0.78 MillionsInvestment made on procurement of pumps-06 nos = Rs.1.28 Millions

Simple Payback Period = 18 months

Steam Condensate Recovery Pump

Pressured Powered Pump Unit

Energy Conservation Projects-Electrical

v Energy saver in lighting circuit panel to maintain constant voltage between 200-210 to reduce the power consumption & lamps failure.

v Achieved savings is 15%

v Illumination levels . 200-220 lux

Energy Saver In Lighting Circuit

Energy Saver In Lighting CircuitLighting Load Particulars Utility, L&M Blocks - 2009 -10

Year Power Consumption (KWH) Savings (KWH) Saving Cost(Rs)Mar-09 36800 5520 20700.00Apr-09 32580 4887 18326.25May-09 34000 5100 19125.00Jun-09 23230 3484 13066.88Jul-09 32560 4884 18315.00

Aug-09 37080 5562 20857.50Sep-09 48500 7275 27281.25Oct-09 46280 6942 26032.50

Nov-09 54540 8181 30678.75Dec-09 56800 8520 31950.00Jan-10 51,200 7680 28800.00Feb-10 50500 7575 28406.25Mar-10 58000 8700 32625.00

Total 562070 84310.5 311948.00Investment Made = Rs 0.35 MillionsSavings Achieved - 84,310 kwhSavings Achieved = Rs.0.31 MillionsEnergy Savers Installed Between 2007-10 = 2x200 = 400 KVA

v Process: Reactors +centrifugesv Reactors: Requires variable(2to3) speeds at

different intervals for homogeneous mixing & maximum output. RPM-30-50v Centrifuges: Requires two different speeds and

highest rpm requires at last stage.RPM varies from 200 to 700.

VFD’S installed for process equipment’s in L & M Blocks

VFD’S installed for process Equipment’s

Differential power consumption per day=333 kwh

Differential power consumption per annum= 1,06,560 kwh

Total Cost savings /Annum = 106560 x 3.7 = Rs.3,94,272

Investment made on procurement of VFD’s = Rs.2,65,000Simple payback period = < 9 Months

Total no. production blocks- 4 NosTotal estimated savings = 3,94,272x4=Rs.1.57 Millions

Investment Made = Rs.1.28 Millions

Simple Payback Period <9 Months

Total Installed VFD’s Between2007-10= 3850HP(Rs.10Million)

VFD’S Installed for Process Equipment in L & M Blocks

VFD Control Panel

Incentives thro Load factor control

v APCPDCL: As per APSEB rule HT cat. I (A) provides incentive provision for HT consumers of Above L.F. of 0.70 are eligible for 25% incentive.

v Suitable capacity capacitor bank panels installed to maintain uniform power factor of 0.96

Energy Saving Projects-Electrical

Power Consumption vs Bill Payment

Year KWHM.D

(Aver)P.F

(Aver)

Load factor (Aver) Bill Paid INR Incentive INR

2007-08 27608292 4220.07 0.959 0.77 99448103 101675092008-09 27813200 4302.5 0.95 0.76 97132528 9564045.2009-10 31702372 4910.52 0.966 0.74 111181034 5340507

Total 307761666 25072062

Incentive received from APSEB on improving Load factor thro capacitor bank panel & auto power factor controller

Description Uom QtyInstalled Capacitor Bank Panel EA 4Investment Made INR 6.0 MillionsIncentive Received 2007-10 INR Rs.25 MillionsSimple Pay Back period < 4 Months

06 Aug 2010 Aurobindo Pharma Limited. 22

Capacitor Bank Panel

Energy Conservation Projects-Process

v One of production block reactors using conventional anchor agitators having low efficient mixing resulted quality as well quantity was affected.

v New high efficient agitator –Double flight helix with bottom anchor type provided high yield & quality though power consumption per batch is increased.

v The additional power cost is meager with respect high yield benefit.

High Efficiency Agitators for Reactors

High Efficiency Agitators for Reactors (SRI 011,12,13 – 3 Nos) in I Block

Description Before Modification After Modification

Vessel Volume 5000 Ltrs 5000 LtrsNo of vessels 3 3Agitator Mechanism Conventional

Anchor Double Flight Helix with Bottom Anchor

RPM 50-56 30-40Power consumption 15 kw / Vessel 37.5 kw / vessel

Power consumption/day923 kwh 2093 kwhBatch Size 800 kg (Dry weight)1200 kg (Dry weight)Product Yield 1.73 1.77Production/Day 3.2 MT 5.06 MTAnnual Production = 900 MTTotal Saving/Annum = 900000x500x0.04=Rs.18.0 Millions ( A )Additional Power Cost/ Annum =Rs.0.78 Millions - (B)Extra Investment on High Efficiency Agitators= Rs.3.6 Millions (C) Net Savings in the First Year = (A) - (B) + ( C )= Rs. 13.6 MillionNet Savings From First Year onwards = (A) - (B)= Rs.17.2 Millions

Pay back period -3 months

High efficiency Agitator -Double Flight Helix with Bottom Anchor

High efficiency agitators for Reactors (SRI 011,12,13 3 Nos) in I Block

Conventional Anchor Agitator

Before Modification After Modification

RCVD: Rota cone vacuum dryer rotates at slow speed and material blending at lower side. Drying of material indirect heating with hot water cirulation in jacket.A complicated system with vacuum pump+ hot water system

FBD: Fluid Bed Dryer having facility hot air direct contact with material and due to fludisation the drying of material is faster.the above shall be used only for flowable character product materials. A simple system consists of air heater which is being heated by steam . Batch time was reduced from 16 hrs to 2hrs and production capacity enhanced

Replacement of RCV Dryer with Fluid Bed Dryer


Description Rotary Vacuum Dryer Fluid Bed DryerEquipment Capacity 1200 KG 400 KGBatch drying Time 16-18.0 Hrs 2.0 HrsNo batches /day 3 12Total output/day 3500 KG 4800 KGNo of Equipments 3 3Power requirement /Equipment 11.25 kw 22.5 kw

Total Power consumption/day 486 KWH 97 KWH

No of Operators /day 11 Persons 6 PersonsEquipment Cost 7.5 Lakhs 17.0 Lakhs

Annual Power Savings = 43170 x 10 = Rs.4.31 Lakhs -- (a)Man power cost savings/Annum = 950 x 300 = Rs.2.85 Lakhs -- (b)Total Savings = (a) + (b) = 4.31+2.85 = Rs.0.716 MillonsDifferential Investment made = 3 x 9.5 = Rs.2.8 MillionsSimple payback period is less than 4 years


Fluid Bed Dryer

Rotary Cone Vacuum Dryer

Previous System Present System

High Efficiency SiftersvPrevious system: Mechanical vibrant sifters having

disadvantage of frequent clogging of powder due to vibration levels are inadequate and high power consumptionvDouble deck sifter: innovative technology with counter

weights to adjust vibration levels in both directions of horizontal & vertical. The above facility is benefited to set vibration levels as per product requirement.

v Benefits: Reduction of batch time up to 65%v Powder emission losses reducedv Power consumption reduced up to 75%

High efficiency Sifters for process materials sifting

S.N Description High Effice Sifter Conventional Sifter

1 Sifter Size 30’’ dia 30’’ dia2 Power requirement 0.5 HP 2 HP3 Batch Time 1.5 Hr 5 Hrs5 No of sifters 6 86 Loss of Product Nil 600 Grams/day7 Loss of product cost

Negligible Rs.3000 (Average Rate)

8 Power consumption/day

16.8 KWH 225 KWH

9 Power cost/day 64 85510 No of Operators/day 7 persons / day 13 Persons / day11 Man power cost/day 1330 247012 Sifter Cost 3.2 Lakhs 1.5 LakhsTotal Savings/Day= Sum of 7+9+11 = 3000+791+1140 = Rs.4951 Annual Savings = Rs.1.49 MillionsDifferential Investment made = 6 x 1.75 = 1.0 MillionsSimple payback period is less than a year

High Efficiency Vacuum System

Previous: Steam ejector system having limitation of low vacuum and solvent lossModified: Imported Oil ring vacuum pump with in built condenser to trap solvent traces which having double benefit solvent recovery and avoiding oil contamination of vacuum pump.About 30% reduction in batch time is nothing but production capacity enhanced .

Installation of High efficiency vacuum Pumps for process drying application (VTD)in L & M Blocks

Description Previous Present System

Batch Drying Time 16 Hrs 10-12 HrsSteam jet ejector system with back up booster Vacuum Pump

Rs.1056 Nil

Steam Consumption cost /hr–32

Power Consumption cost / hr – 11 kwhOperating cost /system/Batch

High efficiency Vacuum Pump

Nil Rs.203

Power Requirement = 5.5 kw

Operating cost /system / Batch = 5 x 11 x 3.7 Differential operation cost /System/Day Rs.853Operational cost Savings/10 Sys/Day=10 x 853 Rs.8530Average Annual Savings = Rs.2.44 MillionsDifferential Invest Made on High efficiency pumps =Rs.1.45 Millions

Simple Payback Period <8 months

Total Installed Pumps Between 2007-10 =39 Sets (Rs.15 Millions)

Installation of High efficiency vacuum Pumps for process drying application (VTD)in L & M Blocks

High efficiency Vacuum System

Present System

Steam Ejector + Booster Vacuum Pump

Previous System

Energy Conservation Projects -3Years

Energy Saving Projects- 3 yearsS.N

o Title Year Annual saving (Rs Million )

Investment (Rs

Million )

Payback

1 Direct steam utilization for process reactors in place of Single Fluid Heat Transfer System in I Block

2009-10 1.34 Negligible Immediat

e

02 Mechanical Draft Cooling towers Replaced With Natural Cooling Tower in K-Block

2009-10 0.261 NIL

Surplus CT Used, Invet not considered

03 Introduction of high Efficy Cooling Towers –1800 TR

2009-10 0.756 NIL

Part of Process Requirmen

04 Process simplification by introduction of Forced Evaporation technology in place of conventional Reactors results increase in product to 3 multiples and energy reduced by 2 Times

2009-10 43.66 7.87 <2 Months

05 High efficiency agitators in I Block

2009-10 11.4 3.8 <3 Months

06 Installation of High efficiency vacuum Pumps for process drying application 10 sets

2009-10 2.44 1.44 < 8 Months

07 VFD’s Installed for process equipments

2009-10 1.97 0.12 < 8 Months

S.No

Title Year Annual saving (Rs Million )

Investment (Rs Million

)

Payback

Energy Saving Projects-3 years


S.No Title YearAnnual Saving (Rs. Millions)

Investment (Rs. Millions)

Payback

08 Incentive received from APSEB on improving Power factor thro capacitor bank panel & auto power factor controller

2007-10 25 0.6 < 8 Months

09 Hydro pneumatic pumps for utility application in place of conventional pumps

2009-10 3.8 3.0 < Year

10 Introduction of High efficiency equipment for powder process-sifters

2009-10 1.49 0.1< Year


S.No Title Year

Annual Saving

(Rs. Millions)

Investment (Rs.

Millions)Payback

11 Wind driven exhaust fans for plant sheds

2009-10 0.24 0.297 <13

months

12 Steam condensate recovery improved from SR Plant, MEE ,L & M Blocks

2009-10 0.738 1.3 < 2 years

13 Replaced RCV Dryer with Fluid Bed Dryer in I Blocks

2009-10 0.71 2.8 < 4 Years

14 Steam to fuel ratio increased by switch over from over bed FBC to under bed FBC boiler

2009-10 6.4 30.0 < 5.0

years

Energy Saving Projects-3years

S.No Title Year

Total annual saving

(Rs Million )

Investment (Rs Million ) Payback

15 Around 220 computers are put in sleep mode. (After 3 minutes monitor will get off automatically when not inuse

2008-09 0.022 NIL Immediate

16 Orifice provided in Hand Wash & Utensils cleaning line in main canteen (Water saving 20 KL/day)

2008-09 0.06 NIL Immediate

17 Effluent Water reduced by 19 KL /Day by strict monitoring and segregate steam condensate

2008-09 1.53 Negligible Immediate

Energy Saving Projects-3years

S.No Title Year

Annual saving

(Rs Million )

Investment

(Rs Million )

Payback

18 Increment in frequency of condenser de scaling schedule for Utility chilling Compressor. Stoppage of 01 nos RT circulation (40HP)

2008-09 0.612 Negligibl Immediate

19 Stoppage of primary pump in +5 chilled water system.A Closed loop circulation system adopted

2008-09 0.58 0.01 <1 month

20 Conversion of V belt to Flat belt Drive System on Chilled after compressor -150

2008-09 0.214 0.0069 <3.5 months

Energy Saving Projects-3 yearsS.No Title Year Total annual

saving (Rs Million )

Investment (Rs Million

)

Payback

21 After replacement of air pre -heater & Refractory on 8 TPH Boiler, fuel consumpon is reduced by 4%

2008-09 1.76 0.665 <4.5 months

22 Condensate recovery increased to 50% from 40%

2008-09 0.33 0.3 <11 months

23 VAT Light replaced with timer controlled VAT Light for Process Vessels – 50 Nos

2008-09 0.048 0.09 <22 months

24 Replaced existing Boiler feed water Horizontal centrifugal pump (50 hp) with vertical pump(20 hp)

2007-08 0.166 0.130 <8 Months

25 Energy saver in lighting circuit

2007-08 0.522 0.31 <7 months

Bench MarksS.no Description Standard Present Bench Mark

APL

1Refrigeration System(VCRS):(+) 5 Deg.Cent

0.8 KW/TR

0.9-1.0 KW/TR 0.9 KW/TR

2Refrigeration system(VCRS):(-) 15 Deg.Cent

1.8 KW/TR

2.4 KW/TR 2.1 KW/TR


1.95 KW/TR

2.6 KW/TR 2.2KW/TR


2.8 KW/TR

3.2KW/TR 2.9 KW/TR


2.9 KW/TR

3.3KW/TR 3.1 KW/TR


6.55 KW/TR

7.8KW/TR 7.2 KW/TR

Bench marks

S.no Description Standard Present Bench Mark APL

8 Compressor Air Generation

0.12 KW/NM3

0.14 KW/NM3

0.125KW/NM3

9 Compressor Nitrogen Gas Generation

0.48 KW/NM3

0.65 KW/NM3

0.55KW/NM3

10 Fuel to steam Ratio Imported Coal 6.5 5.5 5.76

11 Steam Condensate Recovery 64% 78%

06 Aug 2010 Aurobindo Pharma Limited. 45

Year

Annual Energy consumptionProduction

in Tons Thermal

Type of fuel Tons Rs Million

2007–08 Coal 10200 30.28 825.572008–09 Coal 11450 42.83 942.89

2009–10 Coal 13807 46.23 1194.5

Specific Energy Consumption - Thermal

YearAnnual Energy consumption

Production in Tons

ElectricalKWH * Million Rs Million

2007–08 28.28 90.49 825.57

2008–09 30.19 99.54 942.89

2009–10 35.25 120.3 1194.5

Specific Energy Consumption - Electrical

Innovative Projects

Introduction of Forced Evaporation technology in place of conventional Reactors- production capacity 3 multiples enhanced and energy cost reduced by 2 Times. Objective v Reduction of Power Consumption & Enhancement of production

capacityBottle Neck v Concentration of Product thro Water Evaporation in Reactor takes

long time due to lower heating surface area . Evaporation rate goes slow when volume of reaction mass is reduced. Plant capacity is 2.79 MT / Month & Power Consumption is 175.82kw /kg

De Bottle Neck v Introduction of Forced Circulation Evaporation technology to

concentrate the product after evaporating the water in reaction mass

Benefits & Savingsv Power Reduction : From 175.82 to 87.99 units/kg product.v Capacity enhancement: 2.79 to 10.MT/monthv Annual saving : 8.6 kwh Millions & Rs 31.9 Millions Investment Rs 6.0 Millions

Innovative Project 1-Anti Depression Drug-Process Simplification

Reactors( (6 Nos)

Adsorption Column

Final Concentration

Crystallization

Filtration

Drying

Finished Product

Carbon Treatment

Previous – Batch Reactor

Aqueous Solution

Modified – Forced Circulation Evaporator

Process Flow Diagram


06 Aug 2010 Aurobindo Pharma Limited.50

INNOVATIVE

PROJECT - I

Modified – Forced Circulation Evaporator

Previous – Batch Reactor

Forced Circulation Evaporator Set up

Batch Reactor Set up


Power Consumption Comparison between Previous & Modified Setup

S.No Description Previous Modified UOM

1 Product Output/ Month---(A) 2790 10000 Kg2 Process Power Consumption--(B) 43273 231222 KWH3 Utility Power Consumption--(C ) 142871 227908 KWH4 SRP Power Consumption--(D) 12516 104444 KWH5 ETP Power Consumption---(E) 1953 7200 KWH6 Steam Power Consumption--(F) 8932.3 28146.3 KWH7 HVAC Power Consumption--(G) 281000 281000 KWH

Power Consumption/Month=H=Sum (B to G) 490545 879921 KWH

Power Consumption / Kg of Product=I=H/A 175.82 87.99 KWH/KG

Production/Annum= 98111 KG

Power Saving achieved/Annum=98111x87.99=8.63 kwh Million

Cost Saving achieved/Annum = Rs.31.94 Millions


Innovative Project 2 - EHS Objectivev Reduction of Steam & Power Consumption for Evaporating the

Effluent.v Enhancement of Plant Capacity-compact system.v Recovery of Solvents from Effluents. Bottle Neckv Evaporation of Effluent in conventional Reactors v Steam Consumption is 1.0 Kg / Kg of Effluent.v Power Consumption is 0.045 KWH / Kg of Effluent.v Plant capacity is 30 MT/Day.De Bottle Neckv Introduction of Stripper Column to recover solvents,Multiple

Effect Evaporator & ATFD(Agitated Thin Film Evaporator) for drying the solids.

v Using Stripper Column Vapors to one effect as a utility for evaporating the Effluent to reduce the Steam Consumption from 0.3 to 0.24 kg

Investment Rs.80 Millions

High TDS effluent evaporation thro MEE System

Reactors -05 No

Batch Reactor

Effluent Form Plant

Modified Setup

Primary Treatment

Effluent Form Plant

Primary Treatment

Multiple Effect EvaporatorStripper

Mixed Solvents to Solvent Recovery for Rectification

ATFD

Condensate to Low TDS Plant

Dry Solids to TSDFCondensate to Boiler

Steam

Steam

Previous Setup

Vapors to 2nd Effect


Dry Solids to TSDF


Steam

Steam Condensate to Boiler

High TDS Effluent Evaporation Thro MEE SystemInnovative Project 2 - EHS

Multiple Effect Evaporation System

High TDS Effluent Evaporation Thro MEE System

Conventional Reactor Evaporation System

Previous System Present System

Innovative Project 2 - EHS

S.No Description

Batch Reactor

MEE System UOM

A) Steam Consumption 1 Stripper Steam Consumption 0 0.174 Kg / Kg

2 Multiple Effect Evaporator Steam Consumption 1 0.213 Kg / Kg

3 ATFD Steam Consumption 0 0.021 Kg / Kg Total Steam Consumption 1 0.408 Kg / Kg

Differential Steam Consumption / Kg of Effluent=1-0.408 = 0.592B) Power Consumption

4 Power Consumption 0.045 0.03 KWH / Kg

Differential Power consumption /kg of Effluent= 0.045-0.03=0.015Effluent Generation/Day = 200 MT Power Saving/Annum= 10.8 KWH Million Steam Saving/Annum = 42624 MTCost Saving/Annum = 39.96 + 319.68 = Rs. 35.9 MillionsProject Investment = Rs.80 Millions Pay Back Period < 3 Years

High TDS Effluent Evaporation Thro MEE SystemInnovative Project 2 - EHS

Innovative Project 3– Utility

S.No DescriptionNo of System

(1 set)KWH/Day

KWH/ Annum

1Hydro pneumatic pumps

30 hp x 3No's 732 254480

2Conventional Pumps

30 hp x 3No's 1152 403720

Power Comparison between Hydro Pneumatic pumps vs Conventional Pumps

Innovative Project 3-Utility

Differential Power Saving = 1,49,240 kwh/annum

No of systems = 07

Total Power Saving/annum = 07 x 149240 = 10,44,680 KWH

Total Power cost Saving/annum = 1044680 x 3.7 = Rs.3.86 Millions

Differential Capital Investment = Rs.3.0 Millions

Simple payback period < Year

Supply of chilled/CT water for process

which requires intermittently.

Hydro Pneumatic Pump System

Hydro Pneumatic Pumps at Central

Utility

EHS -Implementations

Investments in EHS 2009-10S.n.o Details Cost (Rs.Million)

Safety

1 Nitrogen Blanketing System 4.0

2 Fire Detection & Alarm system 2.5

3 Earth Rite system 1.3

4 Fire Hydrant system(L&M Blocks) 7.0

5 Sprinkler system 2.8

Environment

6 Multi-Effect Evaporator including ATFD 31.4

7 R.O.Plant 10.0

8 HTDS Plant 15.5

9 LTDS Plant 37.2

10 Miscellaneous expenses 27.2

Total 138.9

EHS - Implementations

Utilization of waste material

S.No Hazardous waste 2007-08 2008-09 2009-10

1 Spent Carbon 142.64 141.98 96.222 Organic Residue 88.07 282.62 320.43

Mixture of spent carbon & organic residue being used as auxiliary fuel in cement industries

– Nagarjuna Cements Limited, Nalagonda

- Anjani Cements Limited, Nalagonda

- P R Cements Limited, Nalagonda


ISO 14001:2004 re-certification audit – Oct.2009• During the re-certification audit by NQA for compliance to ISO

14001 standards, one minor non-conformance was identified & the following OFIs were identified by the auditors

1. Clause No.4.5.2 : There was no endorsement of review and approval of the analysis of environmental parameters measured byStartech Labs (Minor NC)Action taken : Reports of Ambient Air Quality measured by Startech Labs have been reviewed and approved.

• Clause No.4.5.5 : Internal EMS auditors may be retrained to improve / retain auditing skills to ensure effective internal auditsAction taken : Internal EMS auditor training carried out for all EMS auditors


ISO 9001:2008 Certification

Valid till October 2012

ISO 14001:2004 re-certification audit – Oct.2009

Environment Management system re-certified by M/s.NQA upto Nov.2012


Green belt developmentS.No. 2007-

082008-09

2009-10

Actual Planted (Nos)

8200 10500 12600

Plantation of around 31,000 plants at L&M blocks, K-block area, D&E block & near F&G blocksSurvival rate : 85%

Variety of plants : 30

such as Gulmohar, Neem, Eucalyptus, Kanuga, Bamboo, Badam, Dooranta, Acchalipa, Vepa, Tekoma, etc.

View of plantation activity near F&G block


ENVIRONMENT AWARENESS – Celebration of World Environment Day, Recitation of Environment Pledge, Tree plantation & competitions


Renewable Energy–Wind Driven Ventilators

Wind driven turbo ventilators for plant sheds:

Air ventilation & Illumination both have been improved by installing Turbo ventilators

Equivalent of power /Ventilator= 0.125 Kwh

Size of Ventilator = 28’’ DIA

Area coverage/ Ventilator = 210 sft

No of wind driven ventilators = 54 Nos

Power Saving/ Annum = 59130 KWH

Power Cost Savings/annually=Rs. 0.224 Millions

Investment Made = Rs.0.297 Millions

Simple payback period <14 Months

Wind Driven Ventilators Fixed on Top of Building

MethodologyüEnergy team (known as Energy Squad) comprises of all level

employees-Assistant ,Executive, Manager & Senior Management. Certified Energy manager is leader of group.

üFocused Area are defined.

üTargets are set with respect to bench marks.

üRegular meeting (Fortnight) for reviewing.

üImplementation of approved projects

üEnergy conservation monitoring formats updation

üResults monitored & shared with Senior Management

üResults are reviewed by Corporate Engg Deptt on monthly basis.

Energy Monitoring FormatDAILY ENERGY METER READING REPORT,DATE:11/06/2010

S.no Area Panel TAG Today Yesterday Units consumed

1 A-BLOCKMCA102

15367 15360.2 8162 A-BLOCK(AHU) MCA103 11851.8 11844.7 8523 B-BLOCK MCB101 62931.9 62897.5 4128

4 SUB PCC-1MCD003,005,006,007,MCE001,002,003,

SRP,LIGHTING 36356.6 36345 13925 SUB PCC-2 C,H& SRP BLOCKS 37636.8 37611.3 30606 K-BLOCK MCK101 5537.7 5534.7 3607 K-BLOCK MCK102 20810.4 20784.5 31088 K-BLOCK MCK103 7666.8 7664.7 2529 K-BLOCK MCK104 2568.9 2568.9 010 K-BLOCK MCK105 5608.3 5599.4 106811 K-BLOCK MCK106 1535.6 1533.4 26412 CENTRAL UTILITY MCU001 53044.1 53014.6 354013 CENTRAL UTILITY MCU002 34758.2 34734.1 289214 CENTRAL UTILITY MCU003 22699.3 22698.6 8415 CENTRAL UTILITY MCU004 38645.1 38625.1 240016 CENTRAL UTILITY MCU005 51773 51754.4 223217 CENTRAL UTILITY MCU006 19900.1 19891.2 106818 CENTRAL UTILITY MCU007 29559 29532.8 3144

Future ProjectsProposed energy conservation projects for year 2010-11vFlat belt drive system for Multiple chilled water compressor – 800 hp –saving potential -6-8%vHigh efficiency agitators for balance equipment of 300 HPvHigh vacuum pumps -12nos.(Imported) are planned for product drying in place of conventional pumps with saving potential of about 130 hp.vVFD’s for some of process equipments like reactors & centrifuges about 300 HPvHydro Pneumatic Pumping systems (08 Nos–about 800 hp) with considering energy saving potential about 18 %vLVD Lamps in place of GSL /HPSLV Lamps and estimated Power savingsvEnergy efficient inline helical gear boxes about 200 for process vessels in place of worm & worm wheel gear boxes.vOil free refrigerant technology for vapor compression chilling plants with potential saving of 20% is under considerationvWind driven air ventilators planned–160 Nos which in turns power saving kwh - 0.172 Millions vSolar heating system for Dehumidifier s in place of electrical heaters

ReplicationS.No Project Associates

1

Mechanical Draft Cooling towers Replaced With Natural Cooling Tower in K-Block

M/s Sidhant Equipments Pvt Ltd, Pune

2 Introduction of high efficiency Cooling Towers – 1800 TR

M/s Southern Cooling Towers Ltd, Kolkata

3

Stoppage of primary pump in +5 chilled water system.A Closed loop circulation system adopted

M/s. Corporate/Plant Engineering

4 High efficiency agitators in I Block M/s GMM Pfaudler Ltd, Hyderabad

ReplicationS.No Project Associates

5 Conversion of V belt to Flat belt Drive System on Chilled after compressor -150 M/s Elgi , Chennai

6 Installation of High efficiency vacuum Pumps for process drying application in L & M Blocks – 10 sets

M/s Toshniwal Systems & Instruments Pvt Ltd,Mumbai

7 Hydro pneumatic pumps for utility application in place of conventional pumps

M/s Entex Pvt Ltd,Chennai

8 Wind driven exhaust fans for plant sheds M/s Ganesh Engineering,Vadodara

9 VAT Light replaced with timer controlled VAT Light for Process Vessels – 50 Nos

M/s Baliga Lighting Pvt Ltd,Chennai

Savings Summary 2009-10

No of Projects Implemented

Year of Implementation

Annual Electrical Savings KWH Million

Thermal/ Coal Saving (MT)

Annual Savings R.s. Millions

Invest. Made Rs.Million

Payback

15 2009-10 28.89 2044 113.8 56.96< 8

Months

Thank You

aurobindo pharma ltd borapatla , hyderabad - ciigbc award... · 4 no. of circulation pumps for ......

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