30-31st August, 2017

NATIONAL AWARD FOR EXCELLENCE IN ENERGY

MANAGEMENT AND EFFICIENCY

Agenda

• Plant Profile

• Good and Green

• Plant performance for last three years

• Overview of Energy Management System

• Energy conservation projects

• Innovative projects at GIL- Valia

• Best Practices implemented on Energy front amongst associates

• Way Forward

Plant Profile

• Market Leader in Oleo Chemicals and

surfactant in India

• Integrated Oleo Chemicals complex

established in 1990

• Two plants of Fatty alcohol at one

location

• Caters to the raw material needs of

consumer good sectors – Personal care,

home care, tyre industry and specialized

applications

• Exports to over 80 countries across 6

continents

Godrej Industries (Chemicals), Valia plant

Products

Fatty Acids & Glycerin

Fatty Alcohols

Surfactants

Cosmetics

Toiletries

Rubber

Polymer

Pharmaceutical

Humectants

Cosmetics

Industrial applications

Personal Care

Laundry

Shampoos

Conditioners

Toothpaste

Cosmetics

Detergents

Key Categories Applications Key Customers

GOOD & GREEN

OVERVIEW

Our journey

We aspire to create a more

employable Indian

workforce, build a greener

India, and innovate for

'good' and 'green' products

We are furthering this

commitment through

'shared value' initiatives

that create both social

and business benefits

We articulated our

commitment towards

building a more inclusive

and greener India –

Godrej Good & Green

2011 2017 2020

Our goals

Achieve zero waste to landfill,

carbon neutrality and a positive

water balance, while reducing

specific energy consumption by

30% and increasing the use of

renewable energy by 30%

Train 1 million youth in skills

that will enhance their

earning potential

Generate a third of our

portfolio revenues from 'good'

and/or 'green' products

Ensuring

Employability

Greener

India

Product

Innovation

VALIA PLANT

ENERGY DISTRIBUTION

Total energy distribution

12%

88%

Total energy distribution, %

Electrical (Grid Electricity and DG )

Thermal (Natural gas, HSD, Furnace Oil, Biomass Briquette)

Major Changes in last three

years

• Three Biomass Briquette

boiler

• Displaced approximately 60%

Natural gas.

• Reduced SEC by 4.5%

• Reduced Carbon di-oxide

emissions by 58000 TCO2

VALIA PLANT

PERFORMANCE

Specific energy consumption Change to Total

Specific Energy Consumption

Years SEC, GJ/T

(Total)

% Reduction

(FY 11)

2010-11 13.2 0.00

2011-12 14.3 8.21

2012-13 13.1 -1.02

2013-14 12.0 -8.79

2014-15 11.9 -9.79

2015-16 12.1 -8.49

2016-17 11.5 -12.89

Specific Green house gas emissions Scope1+2

Specific GHG Emissions

Years kg CO2 Eq/T % Reduction

(FY 11)

2010-11 930 0.0

2011-12 1004 8.0

2012-13 1005 8.1

2013-14 948 1.9

2014-15 818 -12.0

2015-16 686 -26.2

2016-17 599 -35.6

Renewable energy portfolio

Renewable Share in Total Energy

Years %Renewable % Increase

(FY 11)

2010-11 1.35 0.0

2011-12 1.60 17.9

2012-13 1.82 34.3

2013-14 1.75 29.5

2014-15 20.0 1380.2

2015-16 40.3 2873.5

2016-17 44.2 3162.9

Greener India impact

Goal

% reduction in specific

energy consumption

Reduce specific energy

consumption by 30%

Achievement

Increase renewable

energy sources by 30%

Become carbon

neutral

Have a positive water

balance consumption

% of total energy consumption

from renewable sources

% reduction in specific

greenhouse gas emissions

% reduction in specific

water consumption

% reduction in specific

waste to landfill

Send zero waste

to landfill

VALIA PLANT

ENERGY REDUCTION TARGET

Specific energy reduction target

TARGET (GJ/MT) 2016-17 2017-18 2018-19 2019-20

Total 11.5 11.0 10.25 9.50

SHORT TERM TARGET

TARGET (GJ/MT) BASELINE, 2010-11 2020

Specific Energy Consumption

(Total)

13.2 9.24 (30% reduction

from FY11)

LONG TERM TARGET

VALIA PLANT

ENERGY CONSERVATION PROJECTS

Energy conservation/efficiency projects FY17

Name of the projects Investment (lakh) Savings Annually

Lights replaced with LED 90 7.3 Lakhs Kwh

Installation of heat recovery unit at reformer outlet 2212 Lakhs MJ

Air pre heater at 18B3 outlet 1212 Lakhs MJ

NG recovery from the compressor for reformer 218 Lakhs MJ

Raw water pump replacement 11 lakh Kwh

Energy conservation/efficiency projects FY17

Name of the projects Investment (lakh) Savings Annually

Fatty acid production by De- acidification route rather

than conventional splitting-distillation routeNil

Electricity- 1.69 lakhs Kwh

Steam – 2928 MT

Material Conserved – 24 MT

Water flow measurement had helped in various

energy saving projects 2 2.14 Lakhs Kwh

Heat exchanger for recovering heat from product line

section 21 and 1815 24.5 Lakhs MJ

Replacement of the V belt by cogged belt0.32 68571 Kwh

Energy conservation - innovation

Heat Pipe

GIL, recently installed a Heat Pipe (which has a

higher heat transfer coefficient as compared to

other heat exchangers) for extraction of heat

from a medium grade source in their spray drier

for manufacturing a Sodium Lauryl Sulphate

powder/needles. The savings is around 15

Lakhs per annum. Its going to save around

60,000 M3 of NG. The total investment was

around 7 lakhs with payback less than a year

Compressor Heat Recovery

GIL, started preheating the boiler feed water

with help of heat coming out of compressor. The

source water at 33 C was heated up to 48 C

with a flow of 8m3/h. Its is saving around 375

MT of Briquettes annually. Apart from it the

cooling of compressor is resulting around 24000

Kwh saving in power consumption.

Waste to Energy PLASMA GASIFICATION

Plasma gasification takes all types of waste and

converts into energy and vitrified slag. Plasma

extracts the carbon and hydrogen from the

feedstock and converts it into syngas which is used

to power a syngas engine which will cater for self

consumption. The slag generated by the plasma

gasification is a vitrified slag which can be used as

construction material and laying roads. Thus there

is absolutely Zero waste.2TPD Plasma waste to

energy plant at GIL,

Valia

Benefits:

1. Able to Process 2TPD waste

2. Replacing 2.85 lakhs of NG annually

3. Savings around INR 88 Lakhs as waste deposal cost

New Briquette Boiler

Godrej Industries Limited having a time bound goal

of becoming Carbon neutral has installed third

briquette boiler at our Valia factory. This is going to

reduce our further dependency on Natural Gas. It

is proving 2.5 Million Kcal for heating thermic fluid

and 6TPH Steam for process.

Third Briquette boiler

at GIL, Valia

Benefits:

1. NG Replaced by 4735 M3/day

2. Around 12000MT of CO2 Eq reduction

Life Cycle Assessment for SLS and SLES

We have conducted Life

Cycle Assessment of our

two products SLS and

SLES

.

Environmental Parameters (Per ton of product) SLS SLES

Global Warming Potential

(kg CO2)638 1050

Blue Water Consumption (t water) 19.7 16.2

Acidification Potential (kg SO2 equiv.) 12.4 11

Eutrophication Potential (kg PO4 equiv.) 1.66 1.26

Human Toxicity Potential (kg DCB equiv.) 2430 1650

Terrestrial Ecotoxicity Potential (kg DCB equiv.) 14.60 10.50

Supply Chain

• We have formulated a sustainable procurement

policy to go deep into the value chain and to

hand hold our suppliers for environmental and

social sustainability.

• We have reduced our Scope 3 (inbound and

outbound) emissions by 30% diverting our

finished good from JNPT to Hazaria port. Which

is reducing the transport distance by 516 Km.

Distance from JNPT to Valia 370

Distance between Hazira to Valia 112

Way forward

• Reduce specific

energy by 30%

• Caron Neutrality

• Renewable energy

Process Reengineering and Process Innovation

Investing in clean technologies

Life Cycle assessment of various products

Evaluating Green Chemistry

Integrating energy conservation education and

enhancing supplier performance

TRAINING & AWARENESS

OVERVIEW

Environment day and energy conservation week

Energy Conservation Week Leakage Tagging

“Train the trainer” “Awareness sessions”

Suggestions schemes

57suggestions

42Implemented

ENERGY MANAGEMENT SYSTEM

OVERVIEW

Energy management cell

FACTORY HEADCORPORATE GROUP

ENERGY TEAM

(CORDINATORS)ENERGY MANAGER

SMALL GROUPS

(TEAM MEMBERS)

• Strategic Planning

• Quarterly Review

• Project facilitation

• Strategic Planning

• Monthly Review

• Daily Monitoring

• Monthly Review

• Daily Monitoring

• Identification and execution

of projects• Daily Monitoring

• Annual Activity Plan

• Initiate activity to improve monitoring

• Equipment performance Analysis

• Conduct Internal Workshop

• Daily Monitoring of Specific

Energy

• Assisting in execution of

projects

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

AWARDS AND RECOGNITION

OVERVIEW

Awards and recognition

GIL, Valia plant received the CII

Greenco silver rating in 2015

Godrej Industries has ranked on the

CDP India’s Climate Disclosure

Leadership

CII National Award for Excellence in

Energy Management - 2016

CII Innovative project awards - 2016

CONTACT US

www.godrejgoodandgreen.com

THANK YOU FOR YOUR TIME AND CONSIDERATION