cii national award for “excellence in energy management - 2010” · pdf...

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1 CII National Award for “Excellence in Energy Management - 2010” ITC Limited, PSPD, Unit - Kovai 1 & 2 Sep 2010 Energy Management Cell : R Nandha kumaar SRB Dinesh Kumar A Vinoth kumar Company Profile: • ITC Ltd is a multi business Corporate with Environmental Philosophy of Trusteeship related to social & environmental resources, aligned to the pursuit of economic objectives. • PSPD – Paperboards and Specialty Papers Division, Rs 3234 cr business having four manufacturing units •Unit: Kovai is One of the units, located 42 km north of Coimbatore, Tamil Nadu -Production capacity of 1,00,000 t/ year -Manufacture Duplex Board from 100 % recycled fiber -ISO 9001, ISO 14001 & OSHAS 18001 certified PSPD, KOVAI

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Page 1: CII National Award for “Excellence in Energy Management - 2010” · PDF file · 2010-09-07CII National Award for “Excellence in Energy Management ... replaced with LP steam 4

1

CII National Award for “Excellence in Energy Management - 2010”

ITC Limited, PSPD, Unit - Kovai

1 & 2 Sep 2010

Energy Management Cell :

R Nandha kumaar

SRB Dinesh Kumar

A Vinoth kumar

Company Profile:

• ITC Ltd is a multi business Corporate with Environmental Philosophy of

Trusteeship related to social & environmental resources, aligned to the pursuit of

economic objectives.

• PSPD – Paperboards and Specialty Papers Division, Rs 3234 cr business having

four manufacturing units

•Unit: Kovai is One of the units, located 42 km north of Coimbatore, Tamil Nadu

-Production capacity of 1,00,000 t/ year

-Manufacture Duplex Board from 100 % recycled fiber

-ISO 9001, ISO 14001 & OSHAS 18001 certified

PSPD, KOVAI

Page 2: CII National Award for “Excellence in Energy Management - 2010” · PDF file · 2010-09-07CII National Award for “Excellence in Energy Management ... replaced with LP steam 4

2

Process Flow - Block diagram

TL wire

FL wire

BL wire

Dryers, MG,

Calender

Press: Suction + bi nip Temsec

Coaters Top : Blade+ Rod Back : Blade

Board machine

ETP Treated Effluent for Irrigation

Petax filter

Cogen Power Plant

Steam

Water Treatment

Water from River

Condensate recovery

Fuels

DM Plant

Power: 8 mw

Sp Power: 570 kWH/ T of FNP

Emission: SPM

<50ppm

Sp. Water: 11.5 m3/T of FNP

Reel & Rewinder

Rewinder

Sheeter : 2 & godown : 3

Finishing House

Despatch

Stock Preparation

Waste Paper Storage

Screen+ 3

centricleaner

Pulper

Pulper

Hot Disperser.ONP +

Mag

Pulper

SOP & CBS

Screen+ 3

centricleaner

Screen+

centricleaner

Hot Disperser.

PSPD, KOVAI

Certifications & Awards: Unit - Kovai

• ISO 9001 : 2000• ISO 14001 : 2004• OSHAS 18001 : 2007• British Safety Council Award 2007 :• British Safety Council Award 2008 :• British Safety Council Award 2010 :

Certifications:

Awards:• “Excellent Water Efficient Unit” – CII National award for

Excellence in Water Management 2007, 2008 and 2009.

PSPD, KOVAI

Rating

Rating Rating

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3

GFTN Membership & FSC Certification

• ITC – First Indian Company To Gain WWF’S GFTN Membership• The GFTN is WWF’S initiative to eliminate illegal logging whileencouraging Improved and sustainable forest management practices to enable industries trading in or procuring forest goods to minimize their forest footprint•FSC certified for using pre and post consumer waste paper

PSPD, KOVAI

T G

8 MW

Coating kitchen Q = 1TPH

PV fans HE Q = 2TPH

M/C Driers Q = 19TPH

Stock preparation Q = 5TPH

VAM Q =0.3TPH

Thermo compressor Q=2.5TPH

Coater HE Q=3.5TPH

MG Hood HE Q=0.75TPH

HP Steam Q=54.5TPH

LP extraction Q=35 TPH

MP Bleed Q=7 TPH

Stock Preparation – 205 kWh/ ton

Board Machine & CCK – 225 kWh/ton

Utilities – 100 kWh/ ton

Finishing house – 17 kWh/ ton

HVAC & Lighting – 13 kWh / ton

Intake pump house– 10 kWh /ton

Mill Overall Energy BalancePSPD, KOVAI

48.5 Hz

Deareator Q = 8TPH

To condenser Q = 14TPH

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4

Specific Power Consumption:

722

650

605

570

450

500

550

600

650

700

750

Un

its/

To

n o

f FN

P

2006 - 07 2007 - 08 2008 - 09 2009 - 10Year

PSPD, KOVAI

21 % Reduction

Specific Steam ConsumptionPSPD, KOVAI

3.09

2.94

2.67

2.51

2

2.2

2.4

2.6

2.8

3

3.2

To

n o

f st

eam

/ T

on

of

FN

P

2006 - 07 2007 - 08 2008 - 09 2009 - 10Year

18.8 % Reduction

Page 5: CII National Award for “Excellence in Energy Management - 2010” · PDF file · 2010-09-07CII National Award for “Excellence in Energy Management ... replaced with LP steam 4

5

Energy conservation Projects:

• Chest Agitators• Pumps• VFD Applications• Fans & blowers• Process and Equipment Modification• Lightings• Steam and Condensate System• Renewable Energy

PSPD, KOVAI

Energy Conservation Projects:Agitators

PSPD, KOVAI

0.5460.219Nil2007-08Optimisation of Top Liner Pulper sequence

2

0.3460.1380.152009-10Replacing of chest agitator motors from 1000 rpm to 750 rpm (5 Motors)

4*

0.7370.735Nil2007-08Agitator interlocking with pump§ No. of agitators - 4

1

2007-08 (3 no)2008-09 (3 no)2009-10 (2 no)

Year Implemented

0.45

Invest.in Rs Million

1.1530.831Trimming of chest agitator vanes ( 8 agitators φ1550 tο φ1000 )

3*

Annual SavingsRs Million

Annual Elecsavings Units Million

ProjectsS No

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6

Energy Conservation Projects: Pumps

PSPD, KOVAI

0.2520.10Nil2008-09Combining of CC1 and CC2 condensate separator tank vacuum pump

4

0.20.080.012008-09Optimisation of TL silo-2 make up pump operating parameter

3

0.7560.3020.0252007-08Fresh water Booster pump optimisation

1

1.0420.3850.2252007-083 pumps replaced with energy efficient pumps

2

YearImplemented

Investmentin Rs Million

Annual SavingsRs Million

Annual Elec. Savings Units Million

ProjectsS No

Energy Conservation Projects: PumpsPSPD, KOVAI

0.020.0080.0052009-10Trimming of pump impeller from φ390 tο φ380

6

0.2940.840.072009-10Providing anti friction coating in intake well pump

8 *

0.1680.0670.022009-10Providing NRV in delivery line of save all supply chest pump

7

0.1380.0550.052009-10Trimming of pump impeller in Stock tower pump from φ390 tο φ370

5

Year Implemented

Investmentin Rs Million

Total Annual SavingsRs Million

Annual Electrical Savings Units Million

ProjectsS No

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7

Energy Conservation Projects: VFD

PSPD, KOVAI

1.2060.4820.5802007-08Power plant cooling water pump VFD installation

2*

0.4580.1830.32009-10Filler HD tower 45kw VFD installation

4

1.00.4051.32008-09No 1 pulper VFD installation

3*

0.3580.1430.2312007-08Raw water pump VFD installation

1

Year Implemented

Investmentin Rs Million

Annual SavingsRs Million

Annual Elec. Savings Units Million

ProjectsS No

Energy Conservation Projects: Pocket Ventilation Fans and Blowers

PSPD, KOVAI

0.2520.101Nil2007-08Dryer Exhaust hood fans operation optimisation

2

0.8420.337Nil2007-08Pre MG Hood Exhaust fans utilisation

1

Year Implemented

Investmentin Rs Million

Total Annual SavingsRs Million

Annual Electrical Savings Units Million

ProjectsS No

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8

Energy Conservation Projects: Process and Equipment Modification

PSPD, KOVAI

0.160.0640.302009-10Compressed Air - pressure control system

3

2.000.8257.02008-09Trivac and ceramic tops for wire section

2*

0.0520.0210.492009-10Replacement of inefficient air conditioners

4

0.320.130.252008-09Correction of Equipment alignment to reduce friction loss

1*

Year Implemented

Investmentin Rs Million

Annual SavingsRs Million

Annual Electrical Savings Units Million

ProjectsS No

Energy Conservation Projects: Lightings

PSPD, KOVAI

0.0400.0200.0922007 -08Lighting system replaced by CFL and MH lamps

3

0.0420.0210.0902007 -08Copper ballasts are replaced with electronic ballasts

2

0.1350.054Nil2007 -08Lighting Transformer tapping regularisation at power plant

1

Year Implemented

Investmentin Rs Million

Annual SavingsRs Million

Annual Electrical Savings Units Million

ProjectsS No

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9

Energy Conservation Projects:Steam and Condensate System

0.552670.052008-09Replacing of MP line to thermo compressor and condensate header

3

2008-09

2007-08

2007-08

Year Implemented

0.02

0.320

0.320

Investmentin Rs Million

1.04501MP steam to MG recirculation replaced with LP steam

4

0.706333.36Heat recovery from Blow down water in boiler

2

1.487740.57Steam and condensate recovery system in paper machine

1

Annual SavingsRs Million

Annual ThermalSavings Tons of lignite

ProjectsS No

PSPD, KOVAI

Energy Conservation Projects: Steam and Condensate System

14.1466664.42009-10Providing the De-superheating station near user end

8

2009-10

2008-09

2008-09

Year Implemented

2.0

3.2

0.30

Investmentin Rs Million

7.03300Installation of thermo compressor in turbine bleed line

7*

4.162005New loop line of 250 mm dia provided to reduce line loss

6

0.35167LP Steam to PV 1 replaced with flash steam

5

Annual SavingsRs Million

Annual ThermalSavings Tons of lignite

ProjectsS No

PSPD, KOVAI

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10

0.687123 (T of Lignite)

0.9732007-08Solar water heater cooking system in canteen

1

2008 -09 (10 no)2009 -10 (28 no)

2007 -08

Year Implemented

0.77

0.073

Investmentin Rs Million

0.01591,825 Units

Solar lighting around the boundary of the plant

3

0.0094,000 Units

Solar water system for Guest house

2

Annual SavingsRs Million

Annual Thermal/ ElecSavings

ProjectsS No

Energy Conservation Projects: Renewable Energy

PSPD, KOVAI

Summary of Energy Savings: 2007 -10

PSPD, KOVAI

47.82523.06321.1499661.9230.7342009 -103

14.412.3410.2846.129404.1841.7032008 -092

4.13.1289.2132.8741196.936.3392.9842007 -081

Rs Million

Rs Million

Rs Million

Tons of Coal or oil

Rs Million

Units Million

Payback months

Invest. Made

Annual Savings

Annual thermal savings

Annual Elec. Savings achieved

Year of Implementation

S. No

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11

Innovative Project 1: Stock HD Pulper VFD

Past Scenario:

• HD pulper was running with fixed speed through out the batch process.

• In the time of feeding and discharge the fixed speed is not required

• Power consumption (kwh) per ton – 24.688

• Total cycle operation - 26 mins, current consumption 120 to 340 amps

PSPD, KOVAI

Present Scenario:• Installed 200KW VFD for the pulper • Speed during feeding (75% ) and

discharging ( 75 % ) is reduced.• Pulper rotor speed varied based on raw material.• Total cycle operation - 26 minutes,

current consumption 100 to 275 amps Idea generated : Process Operator

0 to 2 min :Feeding2 to17 min :Pulping17 to 26 min :Discharge

• Project Summary:• Power consumption per ton without VFD: 24.688 kWh• Power consumption per ton with VFD : 11.577 kWh• Savings per ton : 13.1 kwh• Savings per annum : 3,94,965 KWH • Savings per annum : Rs 9,87,413• Investment :13.0 Lakhs

Innovative Project 1:Stock HD Pulper VFD

PSPD, KOVAI

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12

Innovative Project – 2Energy saving in TG by providing Thermo Compressor

Past Scenario:• Normal operating Avg. electrical

load at island mode is 6.6 – 6.8 MW (Design- 8 MW)

• While operating 6.8 MW , the bleed pressure available at outlet of TG was only 9.6- 9.8 Kg/sq.cm. (Instead of 11 Kg/sq.cm)

• Because of low pressure board machine drying capacity was affected.

• Maintained steam pressure 11 Kg/sq.cm by supplying thro’ PRDS.

• Due to Bleed not drawn from TG, HP steam consumption increased by 2.5 TPH.

PSPD, KOVAI

Present Scenario:• Thermo compressor installed in TG Bleed steam line to boost the pressure. •After installing Thermo compressor 11 Kg / sq.cm pressure obtained in bleed line from TG. •HP steam consumption reduced to 1.25 TPH•Idea : From EM cell discussions

Project Summary:Past additional HP steam consumption - 2.5 TPHPresent additional HP Steam Consumption - 1.25 TPHSavings by providing TC - 1.25 TPH X Rs.750 (HP Steam Cost)Total cost of project - 20 LakhsSavings per month - 6 lakhsPayback of the project - 3 months

Innovative Project - 2 Energy saving in TG by providing Thermo CompressorPSPD, KOVAI

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13

Innovative Project 3 VFD Applications – CT pump

Past Scenario:• Normal operating TG condenser steam

load varies from 8 to 14 TPH• Cooling water flow to condenser was

1700 cu.m /hr.• Cooling Water T : 2 – 4 0 C• Condenser design T : 9 0 C• Condenser Cooling water requirement

1200 cu.m / hr• Motor power : 160 Kw, 960 rpm

PSPD, KOVAI

Present Scenario:• TG condenser steam load varies 8-14

TPH• Cooling water flow < 1200 cu.m/ hr.• Cooling Water Delta T :5-6’C• Temp set : 41’C for O/l water- Motor Speed : 600 rpm (Avg.)- Idea : tech transfer from our Tribeni

unit

Project Summary :Power saving : 850 KWH / day

: 2,97,000 units / annumCost savings : 7.5 Lakhs / annumInvestment : 14 LakhsPay back : 22 months

Innovative Project 3 VFD Applications – CT pump PSPD, KOVAI

Page 14: CII National Award for “Excellence in Energy Management - 2010” · PDF file · 2010-09-07CII National Award for “Excellence in Energy Management ... replaced with LP steam 4

14

Innovative Project - 4 Antifriction coating of Pump

Past Scenario:

• Pump Q=330 (350) cu.m/hr

• Pump head=130 (135) M

• Motor power = 250 KW

• Vibration = 7 -9 mm/s

• Power drawn = 240 KWH

PSPD, KOVAI

Present scenario:• Antifriction coating provided for Pump casing

inner by Belzona.• Pump flow =350 cu.m/hr• Pump head=140 M• Motor power = 250 KW• Vibration = 1.5 -2.0 mm/s• Power drawn = 212 KWH•Idea : From Utility AET

Project Summary :Power savings - 28 KWHNo. of units savings - 280 units / dayAmount of savings - Rs.1,000 / dayInvestment - Rs.75,000Pay back time - 75 days

Innovative Project - 4 Antifriction coating of Pump

PSPD, KOVAI

Page 15: CII National Award for “Excellence in Energy Management - 2010” · PDF file · 2010-09-07CII National Award for “Excellence in Energy Management ... replaced with LP steam 4

15

Innovative Project - 5 Stock Chest Agitators

Past Scenario:

• Pulp Chest no. 1,3,8,10, and fibre recovery chests agitator was running with 1550 mm diameter.

• Agitators motor was 37kw running with 1000 rpm.

• Current consumption : 31.5 kWH

PSPD, KOVAI

Present scenario:• Chest no.1,3,8,10 and fibre recovery chest agitators

diameter reduced to 1000mm.• Agitators motor changed to 37kw running with 750 rpm.• Current consumption – 27 kWh

•Idea origin : Mech technician

Project Summary :Savings for one chest:Power savings : 4.5kwhPower savings per annum : 36,180 Units

(for 5 no = 1.81 Lakh units)Savings per annum : Rs.90,450Investment for motor : Rs.93,000Payback Period : 12 months

Innovative Project - 5 Stock Chest Agitators

PSPD, KOVAI

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16

Innovative Project - 6Pumps alignment correction

Past Scenario:

• Pumps are running with higher misalignment and vibration levels.

Present scenario:

• 150 Equipments selected and studied the vibration level .• 28 Critical equipments short listed for alignment study.• 10 Equipments having higher misalignment corrected.• Tools used – Laser alignment tool• Agency engaged - SKF Limited

PSPD, KOVAI

16.32Total power saving

0.838.3639.192.13.755M.Ply TCC PUMP10

0.55.065.5732.03.4118 UP SCREEN FEED PUMP9

3.627.5931.172.46.9457 DR DISCHARGE PUMP WEST8

0.39.229.4972.76.811PETAX FEED PUMP7

0.66.1066.7028.623.218.5MG HOOD EXHAUST FAN6

2.418.4820.891.83.930FEED AERATION PUMP -55

1.918.220.063.44.330FEED AERATION PUMP -44

2.719.15321.8891.72.430FEED AERATION PUMP -33

3.520.10723.6167.723.955SAVE ALL CHEST PUMP2

0.0132.2332.246.514.590MG HOOD RECIRCULATION FAN1

UnitsAfterBeforeAfterBeforeKW

Velocity in mm/s - RMSPower savings (Kwh)

Vibration DatasMotor Rating

Machine NameS.No

Project Summary :• Total power savings - 16.32 Kwh

1.29 lakhs Units / annum•Additional benefits :§ Increased life of Equipments.§ Reduced maintenance cost

Innovative Project - 6Pumps alignment correction PSPD, KOVAI

Page 17: CII National Award for “Excellence in Energy Management - 2010” · PDF file · 2010-09-07CII National Award for “Excellence in Energy Management ... replaced with LP steam 4

17

Innovative projects 7: Replacement of High vacuum suction box in Paper machinePSPD, KOVAI

Past Scenario:• Tops of High suction box was made by HDPE which has very high Friction

co-efficient due to which load taken by Drive system was High.• This also had restriction in applying more vacuum for process Requirement

(Drying).

Present Scenario : • Three High vacuum suction box tops are replaced with Ceramic material

which has low friction co-efficient.• This helped in reducing the drag load to the drives, resulting in power

savings and increasing the vacuum level.

Project Summary:Savings of power per annum : 8.25 Lakhs unitsAnnual Savings : 20 LakhsInvestment : 70 LakhsPayback Period : 42 months

PSPD, KOVAI

Innovative projects 7: Replacement of suction box tops in Paper machine

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18

Bench Mark (BM) –Specific Energy consumption

Specific power Consumption

Specific Steam Consumption

685

550 570

722

450

550

650

750

Uni

ts /

ton

of F

NP

National BM InternationalBM

2009 -10 2006 -07

2.42.2

2.51

3.09

22.22.42.62.8

33.2

ton

of st

eam

/ to

n of

FN

P

National BM InternationalBM

2009 - 10 2006 -07

PSPD, KOVAIRoad Map to achieve International Bench Mark:•Periodic Energy audits by internal Energy Management Cell and External Consultants.

•Reduction of 500 kwh 530 units/ton

Steam and condensate system revamping in Board machine

Replacement of rotary to stationary siphon

•Combination of cascading and blow through system

• Reduction of steam 0.3 ton / ton of FNP 2.2 ton / ton of FNP

•Increasing the usage of bio fuel

•Utilisation of Renewable Energy in more areasBenchmark Standards Source: TERI

CO2 Emission Reduction: VCS project

PSPD, KOVAI

• Plant Details - 8MW Cogeneration with 60TPH steam generator.• Fuel used:

– Biomass : De-oiled Rice Bran, Saw Dust, Wood Chips, Tamarind Shell– Fossil Fuel: Coal, Lignite

Utilisation of Agro Residue Biomass in Co-Generation System:

• Project validated and verified• VER’s certified till March ‘09 : 1,72,000• Expected annual VER’s : 70,000

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19

We at ITC Limited Paperboards and Specialty Papers Division are totally committed to continuously improve our Energy performance in all our activities, products and services.To meet above goals we will strive for

Maximization of cogeneration Adopting appropriate energy conservation technologies for all the projects. Replacement of energy inefficient equipment with energy efficient equipment. Conducting conservation studies including audits by engaging external specialists in the respective areas. Creating awareness among employees and nearby population through campaigns, publicity about the need for energy conservation. Bench marking of energy consumptions by comparing with the international levels. Recognizing the efforts of employees in energy conservation initiatives and suitably rewarding them monitor closely and controlling the energy consumption by utilizing effective energy management systems. Maximizing the recovery of waste energy. Reducing Specific Energy Consumption at least by 2% annually.

PRADEEP DHOBALEChief ExecutiveITC Limited- Paperboards and Specialty Papers Division

PSPD, KOVAI

Energy Policy:

Energy Management Organisation Chart

Unit Management Committee

AET - Utilities

Energy Management Cell

AET – Stock Preparation

AET – Board Machine

AET – Finishing House

Utility PACT –3 teams

Stock Preparation PACT – 3 teams

Board Machine PACT – 4 teams

Finishing House PACT – 2 teams

PSPD, KOVAI

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ENERGY MANAGEMENT CELL KPOV’s 10 - 11

1) Energy consumption reduction• Power reduction : 5000 units / day - 3.5 % reduction• Steam reduction : 1.2 TPH - 4 % reduction• Water reduction : 300 KL/day - 10 % reduction• Compressed Air : 200 Cfm - 15 % reduction

2) Energy Audits planned for 10 - 11:• Power Quality and Power distribution Audit: Aug 2010• Overall energy Audit: Jul -10• Steam and Condensate System Audit: Oct - 10

3) Identification of two Encon Projects per month and co-ordination for implementation.

4) Knowledge sharing on energy conservation – Minimum two per month

PSPD, KOVAI

Review : Sustenance & Improvements

• Daily area wise Energy consumptions are monitored

• Energy consumptions reviewed, variances analyzed & corrective actions planned in- Daily AET’s and production meetings- Weekly Energy Management cell meeting- Monthly Performance review by Unit Steering Board. - Designated Energy Manager and Encon Members facilitates the reviews.

• Implementation status of suggestions from PACT members ( workmen ) are reviewed in monthly performance reviews.

• Energy consumption trends, Encon project status and new project proposals are reviewed in Monthly Operational group meetings.

PSPD, KOVAI

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Daily energy consumption Monitoring Report

PSPD, KOVAI

Online Energy monitoring systemPSPD, KOVAI

•ELAN for Continuous Energy Monitoring and Electrical Energy Report Generation.

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22

Energy Audits:PSPD, KOVAI

Oct 2010Steam and Condensate System AuditKadant Johnson, UK16

Aug 2010Power Quality and Distribution AuditPOET Consultancy 15

July 2010Overall Energy AuditUVK Rao and Associates14

Dec 2009Process & effluent water system Cholamandalam MS Risk services13

Sep 2009Boiler Energy audit Venus energy audit system12

June 2009compressed Air system auditGodrej & Boyce Mfg. Co. Ltd.11

Jan 2009compressed Air system auditDilzer Consultancy10

Dec 2008Electrical Energy audit by Equipmentalignment correctionSKF Limited,9

Sept 2008Power quality audit Conzerv8

July 2008Lighting surveyLoyal agencies ( GE electric )7

June 2008Steam & condensate System AuditKadant Johnson, UK6

July 2007Lightning surveyPOET consultants5

June 2007Water AuditConfederation of Indian Industry4

March 2007Steam trap system auditForbes Marshall 3

April 2006Overall Energy AuditTERI2

June 2004Overall Energy AuditM.K.Raju Consultants Pvt. Ltd.,1

YearSubjectAgencyS.no

Workmen Participation –Lean Manufacturing ActivitiesPSPD, KOVAI

Quality Improvement SchemeSuggestion Scheme

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23

PSPD, KOVAI

Involving local Community

Energy conservation Awareness

Checklist for Hole reduction prepared and implemented for effective control at machine stage.

Complaints regarding "hole" formation on sheetsstill appearing. For the period April to Nov.09 15 complaints on the matter received. Though at the machine stage checks it has come down to less than 200 monthly in comparison to sept 09. The corrective action taken needs to be reviewed for its effectiveness.

09.12.2009

Copy of SOP’s displayed in all sheeting converters and trained all concern

Communication of SOP formulated for external sheeters need to be ensured effectively for its execution by the service providers.

09.12.2009

Constructed designated detoxification arrangements for chemical containers. SOP for detoxification displayed and trained all concern

A detoxification programme not found in place for disposal of chemical containers categorized as hazardous waste, It is not washed and rinsed of its contents thoroughly. Certain drums of sodium hydrosulphite stored at scrap yard found contaminated with residual chemical lumps etc.

09.12.2009

Corrective and Preventive actionIMS NCR - DNVDate of Audit

Implementation of Corrective / Preventive Action from

ISO certificationPSPD, KOVAI

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24

Renewable Energy utilization -Solar water heating system for

Canteen cooking

• Water used for cooking in canteen is pre heated in solar panels

•Water temperature raised from ambient to 80 0 C

• Saving of LPG cylinders 55 nos / month

PSPD, KOVAI

Renewable Energy utilization -Solar systems

• Solar water heater for Bachelor Hostel• Solar fencing for company compound• Solar street light 11watts – 38 Nos

PSPD, KOVAI

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25

Best practices on Energy conservation:

• Our purchase policy includes purchasing of only star rated (minimum 4 star) domestic and industrial appliances

• All Our Vendors, suppliers and customers are informed on Environmental Health and safety standards in all purchase orders as they are necessary to meet the norms

• Free CFL distribution to local village households in replacement of incandescent bulbs

• Energy Conservation awareness created in local community by conducting awareness rallies, marathon, training and educating school children

• Energy conservation ideas are shared through Lotus notes & Intra Net (Bhatra net)

PSPD, KOVAI

Waste Utilization & Environment Preservation

• Solid Waste Recycle positive:• Raw Material:

Only Waste paper used as Raw material• Fly Ash :100 % fly ash generated sent to reuse in Cement (Malabar cements), fly ash brick making.

• ETP Sludge :100 % generated sludge sent to reuse in coarse board making

• ETP bio Sludge :100 % converted to Manure and used in our own agriculture field

• Process plastics :100 % sent to ACC cements for firing in kiln.

• Process Sludge :100 % fired in COGEN boiler.

• Energy Conservation : - Invested Rs 11.5 cr for Energy conservation in last four years.- Evaluation & improvements through regular audits.

• Facilities & Processes are environment friendly:- Online stack monitoring – SPM, SOx, NOx and continuous AAQS to improve environmental standards.

PSPD, KOVAI

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Preservation of Environment

Green Belt Development:

• 220 acre under cultivation using treated effluent.

• 1,04,082 trees of various species

• Long term tie up with Tamilnadu Agricultural University to monitor and study the impact of treated effluent on soil & ground water.

Tree Population

19627

2442534222

7268083630

104082

0

20000

40000

60000

80000

100000

120000

No

of

tree

s

2004 -05

2005 -06

2006 -07

2007 -08

2008 -09

2009 -10

PSPD, KOVAI

PSPD, KOVAI

Energy conservation awareness in Local Community

• Training on Efficient use of LPG in the unit for local community

• Creating awareness on Energy conservation on Domestic Appliances for local community

• Creating awareness on use of renewable energy to local community

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Energy conservation Awareness & free CFL Distribution

Distribution of free CFL lamps to 245 households in THEKKAMPATTY – 14 Dec 2009

Awareness to Local Community

Distribution of free CFL lamps to 265 households in MADUR 16.11.2009

PSPD, KOVAI

Energy conservation Awareness In local community

Awareness Marathan from Karamadai to Thekkampatty on Energy conservation Day -2009

Environment Awareness in Karamadai

Taking environment protection Oath at Thimmampalayam village on Environment day -2010

PSPD, KOVAI

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Wealth Out Of Waste: WOWPSPD, KOVAI

International Recognition For ITC’s WOW Project

ITC’s Wealth Out Of Waste (WOW) Project Received The Prestigious Papyrus AwardPresented By the Bureau Of International Recycling (BIR)

Areas Covered :HyderabadChennaiBangaloreCoimbatoreVishakapatnam

Current Waste paper Collection : 4000 MT/month

Recycling of 1 ton of waste paper saves 17 trees and 32,000 liters of water

•ITC has been ‘Carbon Positive’ Five years in a row (sequestering/ storing twice the amount of CO2 that the Company emits).•‘Water Positive’ Eight years in a row (creating two times more Rainwater Harvesting potential than ITC’s net consumption).•Solid Waste Recycling Positive (Reusing/Recycling more solid waste than generated).•All Environment, Health and Safety (EHS) Management Systems in ITC conform to international standards.

PSPD, KOVAI

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THANK YOU

PSPD, KOVAI