national award for excellence in energy management … · 2020. 9. 9. · installation of meters in...
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August, 2020
NATIONAL AWARD FOR EXCELLENCE IN ENERGY
MANAGEMENT AND EFFICIENCY
Plant Profile
Ambernath Plant
Product Market Segment/Application
Fatty Acids Cosmetics, Tyre Industry, PVC
Processing
Fatty Alcohols Cosmetics, Personal Care,
Specialty applications,
industrial applications
Glycerin Pharmaceuticals, Humectants,
Cosmetics
Surfactants Detergents, Oil Drilling,
Cosmetics, Toot paste,
shampoo
Speciality Products
and Oleo Derivatives
Cosmetics(Creams, lotions,
conditioners), Compliment to
our fatty acids and alcohols.
• Pioneer in manufacturing of Oleochemicals in
India.
• State of Art facility in Valia and Ambernath
• Exports to more than 80 countries
AMBERNATH PLANT
ENERGY DISTRIBUTION
Total energy distribution- Ambernath Plant
12.6%
87.4%
Total energy distribution, %
Electrical (Grid Electricity and DG )
Thermal (Natural gas, HSD, Furnace Oil, Biomass Briquette)
TOE: 9866
Year Total Energy [GJ]Production [t]
2017/2018 4,01,879 64,041
2018/2019 3,87,105 63,782
2019/2020 4,11,294 63,831
AMBERNATH PLANT
PERFORMANCE
Specific energy consumption and GHG reduction trend
41.8%
GHG reduction
from FY15/16
6,217
476
6,033
424
6,275
420
6,069
336
6,443
277
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
MJ/T of product kgCO2/Ton of product
Total Energy GHG
SPECIFIC ENERGY AND SPECIFIC GHG FY16 FY17 FY18 FY19 FY 20
Reason for Increase in energy:
1. Use of Briquette Boiler
2. Product Mix
Renewable energy portfolio
17.2
25.4
31.8
45.9
61.7
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
FY16 FY17 FY18 FY19 FY 20
% Renewable
44.5%
Increase from
FY15/16
Major Changes in last 3 years
• Utilization of Waste as Fuel in
Boiler
• Installed Biomass Briquette
boiler
• Displaced 16.5% Natural Gas
• Energy Policy
• ISO 45001:2018
Implementation
AMBERNATH PLANT
ENERGY REDUCTION TARGET
Specific energy reduction target
TARGET (GJ/MT) 2019/20 2020/21
Total 6.44 6.31
SHORT TERM TARGET
TARGET (GJ/MT) BASELINE, 2010-11 2025
Specific Energy Consumption (Total) 9.5 5.7
LONG TERM TARGET- 40% from base year
AMBERNATH PLANT
ENERGY CONSERVATION PROJECTS
Energy conservation/efficiency projects; FY19-20
Future project planned- FY 21
Project 1:
Mechanical Vapor Recompressor
Idea Proposed: To have Mechanical vapor
recompressor to ensure zero liquid discharge in
plant
Current: Multi Effect Evaporator for ensuring zero
liquid discharge
Investment: 1.1 Cr
Tentative Savings: 7.6 Mkcal
Project 2:
Evaluation of Heat Recovery in Sulfonation Plant
Idea Proposed: Use of Novel heat exchanger to
recover heat from hot SO3 gas at 250 degree and
use hot air in another plant
Current: Cascade cooler is used to reduce the
temperature of SO3
Investment: 45 lakhs
Savings: 0.123 Mkcal
Future project planned- FY 21
Project 3:
Water Jet Vacuum System in fatty acid distillation
plant
Current Scenario: Vacuum is generated using
Steam Boosters, Steam Ejector along with Vacuum
Pump.
Proposed: Water Jet Vacuum System in place of
them to generate vacuum and save energy
Investment: 11 lakhs
Benefits:
1. Steam Savings/annum- 237 tons of Steam
2. Energy Savings- 29.51 MWH/annum
3. Reduced load on cooling tower
4. No maintaince cost of Vacuum Pump
Project 4:
Evaluation of Product Vs Feed Heat Exchanger
Heat Load: 1.27 Lakhs Kcal
In/out Product temp: 95/55
In/out Feed Temp : 35/74
Investment: 15 lakhs
Under Evaluation for best heat exchanger
technology
Energy conservation Project FY 20
Installation of VFD in MP Boiler
Initial: 6TPH Boiler,
multistage Pump with three way control valve used
Description: VFD installed in pump instead of Three way valve with water level feedback to
ensure optimum utilization of Pump
Investment: 7 lakhs
Savings: 410 KWH/day~ 1.47 Lakhs KWH/annum
Monetary Benefit: 12.6 lakhs/annum
Energy conservation Project FY 20
Initial Status: Three Cooling tower Pump; 1 pump for AOS Plant and 2 pumps for Other plant
requirement
Step 1: AOS Plant Study:
Initial Head by design: 50 M
Detailed study requirement showed;
actual requirement: 35 M
Steps taken: Installed new pump with
required head and flow
Savings: 370 units/day ~
1.29 lakhs units/annum
Step 2: Plant Pumps:
Initial Head by design: 50 M
Detailed study requirement showed;
actual requirement: 30 M
Steps taken: Stopped one pump;
Installed VFD on other to ensure
required flow and head
Savings:5.57 lakhs units/annum
Energy conservation Project FY 20
Reduction of Compressed Air Pressure in plant:
Before: Compressed air pressure 5.8 kg/cm2
Idea: to reduce the air pressure to required pressure~4
kg/cm2
Steps taken: 1. Installed pressure transmitter at user
points and consumption pattern tracked
2. Daily reporting on air pressure
consumption
Result: Reduced pressure to 4.8 kg/cm2 gradually
observing the plant stability
Thumb Rule:1 Kg/cm2 pressure drop can reduce
power consumption by 5 to 6%.
Savings: 150-200 KWH/day
Investment: 0.6 lakhs
Innovation Project- Optimizing use of Nitrogen Plant and reducing
energy
Measurement
What can be measured, can be
controlled
Installation of meters in plant
Usage Study
Studied the whole plant
1. Hydrogen Plant
2. Tank Farm Flushing and Blanketing
Control of Usage
1. Shared information to plant in terms of
simple graph
2. Observation- air compressor power
consumption remained the same –550 to 640 kWh per
day
Innovation Project- Optimizing use of Nitrogen Plant and reducing
energy
Air Compressor
Compressed Air consumption is
practically the same whether running at 100% or 10% N2
consumption
Brain Storming
Circuit Control Change
In house team studied the circuit –
Converted the existing machine to “On
Demand” N2 generator
“No nitrogen” usage –Standby Mode
Nitrogen use phase-Operational Mode
Benefits and Investment
Investment for Meters-0.8 lakhs
1. System work in auto
2. Plat team aware and Conscious about
consumption
3. Power: 250-350 KWH/day
Utilization of Waste as Energy
Pitch as Fuel MT/year GCV(kcal/kg)Heat Value(M
kCal/annum)
2017/18 3553 9800 34819
2018/19 2855 9800 27979
2019/201934* 9800 18953
*Pitch is going down as we have shifted to briquette boiler
Utilization of Renewable Energy Resources
Year Renewable Energy System
Implemented On-site
Annual GJ
Generation
% of Total Energy (GJ)
at site
2019-20Biomass Briquette Boiler(GJ) 183455 44.6
Solar Roof Top (GJ) 787 0.19
BIOMASS BRIQUETTE BOILER
Reduced Carbon di-oxide emissions by
more than 10291 tons of CO2 eq
Solar Roof Top
GHG Inventorization
1. NG
2. HSD
3. Refrigerant
Scope 1
Grid Electricity
Scope 2
1. Employee Conveyance
Scope 3 1. Carbon Discloser- GIL- B
rated last year
2. Third Party GHG Emission
Verification
3. Overall Energy Saving
Report with CO2 emissions
Ambernath
Total GHG Emissions
2018/2019 2019/20
t CO2, Godrej, Scope 1 9,725 6121.4775
t CO2, Godrej, Scope 2 11,727 11754
t CO2, Godrej, Scope 3 _ 55.46
t CO2, Godrej, ( Scope 1&2) 21,451 17875.48
Specific GHG Emissions (kg of CO2/ton) 336 227
Supply Chain- Sustainable Procurement and
Sustainable Palm Oil
Sustainable Procurement Policy
- Self Assessment Questionnaire
- Site Visits
- Supplier Meet
- Email for sharing best practices
Systems and procedures implemented for green
procurement
Policies & Compliance
Sustainable Procurement Policy
Sustainable Palm Oil Policy
Sustainable Palm Oil Policy : Action Plan
Formulation of Supplier Audit
Source
:http://www.godrejindustries.com/chemicals/policies-
compliance.aspx
Supply Chain- Sustainable Palm Oil Policy
Sustainable Palm Oil Goals and Action Plan:
1. 100% Sustainable PO/PKO &Derivatives by
2025
2. 100% transparency upto mill and refineries
level
3. Commitment to Zero Deforestation in supply
chain
Strategies to achieve:
1. Doing risk assessment in supply chain and
acting on same
2. Being part of collaborations like Action of
Sustainable Development (ASD) and RSPO
3. Publishing report on development on public
domain
TRAINING & AWARENESS
OVERVIEW
Environment day and Energy conservation week
Energy Pledge
In plant- Classroom training
External Training
ENERGY MANAGEMENT SYSTEM
OVERVIEW
Energy management cell
Plant head
Production Utility Project Mechanical Purchase Electrical Instrumentation
The team compromises of employees ranging from ground floor to top management to complete the cycle.
Energy monitoring and review
SoFi Enterprise Sustainability Performance Software for Sustainability Management and
Data analysis and reporting
Review
Monthly
Review
Quarterly
Review
Plant Level &
Corporate Level
GILAC Level chaired by
Mr. N B Godrej
Governing Council at
Group Level chaired by
Mr. J N Godrej and Mr. N
B Godrej
Half yearly
ReviewDaily
Review
Plant Level
Daily reports
Automation- Monitoring and reporting
OVERVIEW
Remote Monitoring of SCADA System
Technology Used: FactoryTalk ViewPoint Software
Make: Rockwell Automation
• Software loaded server installed and connected to PLC & SCADA fibre optic ring network.
• Access given to plant HODs. Remote monitoring started for three process plants (AOS, FADP-2,FADP-5).
• Plan to installed remaining process plants (7 nos.) in Sept-2020.
Benefits:
1) Provides quick, easy access to critical information from the process plants using the simplicity of a webbrowser.
2) Supports multiple browsers and client devices for increased flexibility.
3) Allows easily web enabled without requiring application changes.
Investment: 3.25 lacs
• After successful completion, Plant Head & Factory Head can access any process plant from anywhere.
Online Reports
Online reports for-
1. Steam
2. Nitrogen Purity and Consumption
3. Air Consumption
4. Steam Trap Monitoring
5. Plant Parameter Monitoring
6. Electricity Consumption
7. Water Consumption
Comparison with the Norm provided from Supplier or our last best result
Daily Steam Report
Steam Trap Monitoring
Trap is OFF
Temperature trend move
downwards
Trap is ON,
Temperature trend
move upwards
Steam Trap Monitoring:
Whenever a traps malfunctions the system will generate alarms. Performance of thesetraps recorded in the form of trend and shared with Engg. Team and Process team inthe form of automated mails
Awards and recognition
Golden Peacock Award- Environment
Management- 2019
Best factory in Safety in Group Group-
Godrej Group Award
Godrej Group award for commitment to
Good and Green- 2019- from last two
years
Golden Peacock Award- Human
Resource Management -2019 Golden Peacock Award- Environment
Management- 2019OYCE Young Engineer Award in IICHe
Competition – Mr. Kalpesh and Mr.
Rahul from Ambernath team
THANK YOU FOR YOUR TIME AND CONSIDERATION