THE ENERGY STORY : A PRESENTATION BYHimanshu Agrawal, Milind Bhandarkar, Ajit Patil, Rajdeep Hegde

Products

Viscose Filament Yarn

Pot Spun Yarn 46 TPD

Continuous Spun Yarn 9 TPD

Tyre Yarn 17 TPD

Caustic soda (& allied

chemicals)

63 TPD

Carbon disulphide 54 TPD

Sulphuric Acid 200 TPD

Utilities

Power 24 MW

Water Treatment Plant 17000 M3/day

Effluent Treatment Plant 13500 M3/day

Raw Material

38%

Power & Fuel20%

Salary Wages

19%

Stores9%

Others14%

Energy is the second largest

contributor to the cost

Energy cost = Rs. 180 Crores

SPECIFIC ENERGY CONSUMPTION

56238.41

53735.76

54670.83

50293.69

47000

48000

49000

50000

51000

52000

53000

54000

55000

56000

57000

2013-14 2014-15 2015-16 2016-17

6643.72

6336.34 6336.85

6220.32

6000

6100

6200

6300

6400

6500

6600

6700

2013-14 2014-15 2015-16 2016-17

Specific Thermal Energy Consumption in KJ/Kg of Equivalent Production

Specific Electrical Energy Consumptionin Kwh/Ton of Equivalent Production

(SEC is based on PAT Data equivalent production; baseline of 2013-14)

CENTURY RAYON :: THE BEST AMONG INDIAN COMPANIES

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

CR 71 68 68 67 66 67 67 67

Competitor 1 67 72 69 69 70 66 74 73

Competitor 2 79 78 80 77 75 74 72 74

Electrical Power Consumption in kwh/Million Mtrs of Yarn

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

CR 273 248 232 226 217 210 206 206

Competitor 1 215 213 202 205 208 217 222 232

Competitor 2 312 291 301 291 294 319 346 337

Steam Consumption in Kgs/Million Mtrs of Yarn

ACHIEVING ENERGY EFFICIENCY : A MULTI-PRONGED APPROACH

A well built Organization wide structure

Targeted energy plan

Innovation & use of new technology

Continuous energy monitoring

Energy Audits

TQM culture & suggestion scheme ensuring involvement of all

Renewable energy exploration

Very well maintained equipment and machineries

Reduce, Reuse, Recycle

Energy week celebration

ENERGY CONSERVATION MANAGEMENT SYSTEM

Energy TeamRayon

EM-01, EA-03

Quality Circle(Rayon)

Energy TeamTC & CSY

EM-02

Quality Circle(T/C & CSY)

Energy TeamChemical

EM-01

Quality Circle(Chemical)

Energy TeamAuxiliary

EM-01

Quality Circle(Auxiliary)

Energy TeamBH-PH

EM-02, EA-03

Quality Circle(BH-PH)

Quarterly Review

MonthlyReview

FortnightlyReview

Apex Energy committeeChaired by Business Head

Target2.2%

ENERGY TARGETS : RAISING THE BAR CONTINUOUSLY

2011 2012 2013 2014 2015 2016

Target 1.50 1.80 2.00 2.00 2.20 2.20

Achieved 1.97 1.45 2.00 2.09 1.80 1.95

0.00

0.50

1.00

1.50

2.00

2.50

3.00Savings Purely from Energy Schemes in Rs Crores/Year

USE OF NEW TECHNOLOGY & INNOVATIVE APPROACH

Sr. No.

Project DescriptionSavings/Year Investme

nt LakhsRs.

Lakhsunits

Lakhs Rs.

1Replacement of conventional cooling Towers with Mist cooling tower

3.94 25.61 90.00

2Power Generation from LP Turbine utilizing pressure reduction across control valve

4.53 29.45 38.00

3 Mist Condenser for CSY degasser (2Nos) 2.98 22.34 22.00

4 Jet Type Cooling Tower in place of Induced draft Tower 0.76 4.90 4.00

5Higher head acid cooling PHE pump & sending the cooling water directly to cooling tower

0.88 6.57 3.60

6Turbine gland recovery pump by direct feeding of steam to feed water tank in Boiler House

0.06 0.45 1.00

7Reduction in Condensate Pump Loading by feeding Feed Water condensate to direct to Feed water tank & running of small capacity pump in Boiler House

0.02 0.10 0.30

MIST COOLING TOWER

Investment 90 Lakhs Rs.

Power Saving

47 kw x 24 hrs x 350 days = 3.94 lakhs kwh/annum

Financial saving

3.94 x 6.5 Rs/kwh= 25.61 lakhs Rs/annum

Pay Back Period

42 Months

Rayon Engine room had cooling tower No. 1 & 2 (cross flow) & Cooling Tower No. 3, 4, 5 & 6 (Counter flow). Approach of these cooling tower was ranging between 4° C to 5° C.

These were replaced by Mist cooling tower in year 2016, which doesn’t have any moving part (no fan, no motor, no gear box), no fill, no wooden structure hence no Maintenance.

This resulted in saving of fan power and also improved Chiller power consumption thanks to lower approach of 2 deg C.

JET COOLING TOWER

Investment 4 Lakhs Rs.

Power Saving

2 x 4.5 kw x 24 hrs x 350 days = 75600 kwh/annum

Financial saving

0.756 x 6.5 Rs/kwh= 4.9 Lakhs Rs/annum

Pay Back Period

10 Months

In Boiler House one induced cooling tower having two induced draught fans, was installed to cater various plant needs. These fans had motors of 4.5 KW each.

This cooling tower was replaced with new Jet cooling tower in Jan’17. The draft in such tower is created by water jets.

This resulted in saving of fan power and also the cost of maintenance.

LP TURBINE

Investment 38 Lakhs Rs.

Power Generation

452669 Kwh in year 2016

Financial saving

4.53 x 6.5 Rs/kwh= 29.45 Lakhs Rs/annum

Pay Back Period

15 Months

Total 4 TPH Steam throttling for Boiler Feed water heating. 2.3 kg/cm2 to 0.2

kg/cm2 for 35 oC to 80oC and 2.3 kg/cm2 to 0.25 kg/cm2 for 80oC to 105oC

through PRDs.

LP Turbine was installed in August 2015 to reduce Steam pressure from 2.3 kg/cm2 to 0.25 kg/cm2 & supplying to Feed water Tank & Dearator tank simultaneously producing avg. 60 kw power.

ENCON PROJECTS IN PREVIOUS YEARS

Projects Undertaken Investment (in Rs. Lakhs) Savings (in Rs. Lakhs)

19

33

18

23

27

36

0

5

10

15

20

25

30

35

40

20

11

-12

20

12

-13

20

13

-14

20

14

-15

20

15

-16

20

16

-17

73

144

536

299 294 294

0

100

200

300

400

500

600

20

11

-12

20

12

-13

20

13

-14

20

14

-15

20

15

-16

20

16

-17

197

145

200209

180

195

0

50

100

150

200

250

20

11

-12

20

12

-13

20

13

-14

20

14

-15

20

15

-16

20

16

-17

Transformer

Humidification

Cooling towers

Steam Belts LightsSulphur system

Compressors

VFDsPiping system

Motors Pumps FansElectrol

yser

3.50 4.10 4.25 5.75 8.20 8.35 8.90 16.76 30.52 33.58 40.00 54.78 71.12 84.97

Total accumulated savings/Year

69 Lakhs kwh52 MT coal

375 Lakhs Rs

Total Investment : 589 lacs Rs.

ENCON PROJECTS IN LAST TWO YEARS

Savings in Rs. Lakhs/yr

Sr. No.

ENCON PROJECTSLakhsUnits

Savings (Rs.Lakhs)

1 Optimization of Air washer & Exh. Fan power consumption 1.62 12.12

2Reduction in water lifting due to arrest of leakages and old-line replacement

1.56 11.77

3Optimization of HF frequency on high denier & Color Spinning m/cs

2.29 15.24

4 Segregation of high wattage pot motors 1.16 6.38

5 Optimization of no. of circulation fan running in AT Dryer 0.87 5.7

6Reduction in unloading time of Air Compressor by decreasing speed.

0.12 0.9

7 Energy saving by reduction in DG set Lube oil pump running hrs 0.103 0.78

8Reduction in flash steam loss & Desuper heating water pumping power in Boiler House

5 MT Coal

0.32

ENCON PROJECTS WITH NIL INVESTMENT (LAST 3 YEARS)

Steam consumptionPower Consumption

REAL TIME ENERGY MONITORING

PAT CYCLE -1

ENERGY REDUCTION TARGET 598 MTOE

RECOMMENDATIONISSUANCE OF 12420 ESCerts By Ministry of Power

PAT CYCLE -2

SEC REDUCTION TARGET 1.8392 TO 1.7294 (6%)

SEC for year 2016-17 (w.r.t base year 2014-15)

1.78 (3.22%)

Compliance Assessment Year : 2014-15Ministry of Power (Govt. of India)

PERFORM, ACHIEVE & TRADE (PAT) CYCLE -1

LIST OF ENERGY AUDITSName of the Agency Area

Period 2005-2010

Green Audit by CII, Hyderabad Complete Plant

Madura Compressor, Kalyan Compressed air system

Marco Blower, Kolkata Exhaust system

Pack Plast, Kota Air washer system

CII Complete Plant

Period 2011 – till date

Bapat Energy Consultant Engine Room

Schneider Electric India Pvt. Limited Complete Plant

Forbes Marshal pvt.Ltd. Complete TC-CSY Plant

Ecube Motors

TUV India Pvt Ltd Complete Plant

Venus Audit Systems Boiler House

It has been a soul searching journey since year 2000 by Century Rayon as far as energy conservation is concerned. Above is a list of major audits we carried out in after 2005.

Identification of Energy Loss during Energy Week

RED TAG

PlantNo. of Red Tags Identified

2012 2013 2014 2015 2016

TC & CSY 11 60 51 78 19

Rayon 20 216 159 64 100

Chemical 126 39 4 44 11

Auxiliary 40 290 330 270 320

Total 197 605 544 456 450

INVOLVEMENT OF ALL

USE OF RENEWABLE ENERGY

Solar heater for hot water

Solar street light

Wind ventilators on roofs

Solar Day lighting System

Total savings realised: Rs. 30 lakhs per annum

IMPROVED MAINTENANCE HELPING THE CAUSE

Laser Alignment Thermography Vibration analysis

2011-12 2016-17 % Reduction

CSY plant 16 8 50%

PSY plant 10 4 60%

Electrical 56 32 43%

No. of breakdowns

/ Year

UTILIZATION OF WASTE

70-80 Kg of Canteen food waste produce 60 Kg of Manure per

day.

Recyling of Canteen Waste

Food Waste Convertor

Currently about 0.5% of our total coal energy requirement is being met through fuel from waste

0

50

100

150

200

250

300

350

400

2013-14 2014-15 2015-16 2016-17

Industrial Waste used as Fuel (MT/Yr)

Publication of Energy Bulletin.

Quiz Competition for Staff & Workmen.

Presentation on ENCON by External Faculties

Poem, Slogan & Poster Competitions.

Best Energy Conservation scheme Competition.

Energy loss / Wastage Identification (Red tags).

Training & Tips on Energy conservation for Workmen.

Drawing Competition & Awareness Programme for School Children.

ENERGY CONSERVATION WEEK CELEBRATION

REDUCTION IN CO2 EMISSION THROUGH ENCON PROJECTS

Plantation of Trees in Century Rayon

2013-14 2014-15 2015-16 2016-17

425

95007050

(M3 / day) Uses

2013-14 800• Lime batch

preparation

• CS2 deashing

• Fly Ash quenching

• Degasser Vacuum System

• Gardening

• Dust suppression

2014-15 1000

2015-16 2300

2016-17 2300

Recycling of Treated ETP Water

0

2000

4000

6000

2012-13 2013-14 2014-15 2015-16 2016-17

8500

FUTURE ROADMAP

Solar energy

HF power of spinning machines

Fans

Cooling towers

Pumping systems

Insulation

No. of energy saving schemes already identified : 18

Total calculated saving : Rs. 138 Lakhs

Total estimated investment : Rs 205 Lakhs

SOME ENCON PROJECTS ALREADY PLANNED FOR 2017-18

Sr. No.

Project DescriptionSavings/Year Investme

nt LakhsRs.

Lakhsunits

LakhsRs.

1 Increase the LP turbine load factor from 77% to 90% 0.75 5.67 Nil

2 Energy efficient pumps 5.81 43.69 100.00

3 Mist Condenser for CSY Degassers (2Nos) 2.93 22.00 30.00

4 LED lights 0.34 2.65 15.90

5 Change of V belts to flat belts 0.59 4.50 4.90

6 VFDs on pumps 0.14 1.08 2.50

7 Modified rewinding for CSY m/c old Rolls motors 0.33 2.50 1.35

8 Automation of turbine back pressure control. 218 MT 11.99 30

9 AFBC Boiler CBD automation 150 MT 8.25 12

10 Using HP steam from Acid plant for Boiler feed water heating 907MT 19.85 8

11 Rescheduling of DG set trial from 8 days to 15 days. 4.8 KL HSD 2.69 Nil

No. Details of Awards Year Organization

1 CII Award for Excellent Energy efficient Unit 2015 CII

2ICC Award for Excellence in Energy conservation & Management

2013 ICC

3State Level Award in “Excellence in Energy Conservation & Management” 1st Prize in Textile Sector

Every year since 2006

till 2016

Maharashtra Energy Development Agency (MEDA)

4National Award for “Energy Efficient Unit” in Energy Conservation

2005-2006 CII

5Winner of Platinum Award at 14th Annual Greentech Safety Award – 2015

201514th Annual Greentech Safety Award – 2015

6 Green Tech Environment Award 2014 201415th Green Tech Environment Award

7Water resources management in chemical

industry2005

Indian Chemical ManufacturersAssociation, Mumbai.

AWARDS