HETERO

Warm WelcomeTo

Judges & Delegates

19th CII National Award Competition for

Excellence in Energy Management – 2018

HICC, Hyderabad

« Mr.G.Venubabu

(AGM- TSD, EnMR) Mr B Sambi Reddy

(AGM ELE AMR)

Presentation Team

Dr. BPS Reddy, (CMD, Hetero Group

of Companies)

HETEROCompany Profile

Column

ANFD

REACTOR

DISTILLED

RECEIVER

ANFD

ML’S

RECEIVER STORAGE

TANK

PHARMASTORES

STORAGE TANK

16

Recovered

Solvent

REFLUX

REBOILER

3

HETERO* Process Flow in Our HLL-I Kazipally

* Major Equipment's (Process Equipment's and Utilities)

+5,-5,-15,-20,-40,-70°C chillers

Air Compressors

Nitrogen Plants-500,300m^3/Hr

Cooling Towers- 1000TR,750TR

Boilers- 16TPH, 8 TPH

Reactors- 1KL to 10KL

Filters ( ANFD’s, CF)

Dryers TD,VTD,Spray,FBD,ATFD,RCVD)

Vacuum Pumps (DRV,ORV,Jet)

3

7

2

250+

12

11

HETERO

100+

200+

50+

HETEROEnergy Policy and Certificate

To

Produce

Steam

For General

Application

To Produce

Electricity

Energy Usage In HLL-I(Percentages are in terms of GJ)

HETERO

Consumption

A-BLOCK, 2.26%

B-BLOCK, 3.70%

C-BLOCK, 3.55%

D-BLOCK, 5.18%E-BLOCK, 0.46%

F-BLOCK, 1.24%

G-BLOCK, 0.73%

H-BLOCK, 2.36%

I-BLOCK, 4.35%

J-BLOCK, 4.10%

K-BLOCK, 4.16%L-BLOCK,

0.61%

M-BLOCK, 0.89%

KILO LAB,

0.76%QC, 1.51%

MB, 0.53%WH-1, 0.62%WH-2, 0.26%

FSA-1&2, 1.39%

FSA-3, 0.41%

QC(O), 1.60%

WH(O), 0.74%FSA(O), 0.39%

SB-2, 14.26%

SB-4, 27.45%

8 TPHB & RO,

0.27%

16TPHB, 3.37%

200TR CHILLER,

1.90%

LIGHTING, 1.20%

PUMP HOUSE, 0.25%

CANTEEN, 0.11%

ETP, 6.49%

R&D, 0.14%

QA, 0.25% PWS, 1.20% SRS, 1.18%

333

Lakh Units

Consumed in

2017-18

Energy Contribution of Different Sections-

2017-18 HETERO

More than 4%

contributed

section is

considered as

Significant

Energy use

area

Focused Areas:

1. Service block –

IV

2. Service block –II

3. ZLD

4. PD-I block

5. PD-J block

6. PD-K block

7. PD- D block

41.17 43.1938.22

32.4735.32

Overall Specific Energy Consumption (Kwh/Kg)

6.15

3.69

0

2

4

6

8

2016-17 2017-18

CAP4.25

2.33

0

1

2

3

4

5

2016-17 2017-18

SAN

40

25

0

10

20

30

40

50

2016-17 2017-18

GEM

12

11

10.5

11

11.5

12

12.5

2016-17 2017-18

ATM

HETERO

14

13

12.5

13

13.5

14

14.5

2016-17 2017-18

IMA

820

870

942

740760780800820840860880900920940960

Production (Tons)

Kwh/Kg decreased In

Products

857734 739

647 630 613 610 662

12.6 10.1 10.7 9.4 8.2 8.5 9.1 90

100200300400500600700800900

Sol.Qty Qty/ KG

63%57% 56%

49%

72% 73%70% 70%

0%

10%

20%

30%

40%

50%

60%

70%

80%

1 2 3 4

Before ModificationEfficiency

After ModificationEfficiency

1.011.08

1.020.97

0.730.65

0.7 0.69

0

0.2

0.4

0.6

0.8

1

1.2

1 2 3 4

Before ModificationKWh/TR

After ModificationKWh/TR

* Specific energy consumption in Chillers

* Solvent loss minimization and decrease in consumption/Kg of production

HETERO

HETERO

0.9

98

0.9

99

0.9

99

0.9

98

0.9

98

0.9

98

0.9

96

0.9

96

0.9

99

1.0

00

0.9

97

0.9

91

0.984

0.986

0.988

0.990

0.992

0.994

0.996

0.998

1.000

1.002Power factor

0.9

9

0.9

91

0.9

98

0.9

98

0.9

98

0.9

99

0.9

99

0.9

99

0.9

99

0.9

99 0

.998

0.9

99

0.984

0.986

0.988

0.99

0.992

0.994

0.996

0.998

1

Power factor

* Installation of Capacitor Bank 400 KVAR & 300 KVAR to maintain Power factor

Before Modification

After Modification

HETERO

HETERO

S.No. Title of Project Year

Annual

Electrical

Saving,

Million kWh

Annual

Electrical

Cost

Saving,

Rs Million

Annual

Thermal

Saving,

Million

kcal

Annual

Thermal

Saving,

Rs Million

Total

Annual

Savings,

Million Rs

Investment

Made

(Rs million)

1 Capacity enhancements of products 2017-18 1 7.2 - - 7.2 30

2Increase the condenstate recovery by

installing the steam traps.2017-18 - - 2365 5.256 5.256 0.174

3Installation of Chiller flow meters for existing

chillers2017-18 0.77 5.39 - - 5.39 2.465

4Replacing the old fixtures by fitting FLP LED

lights2017-18 0.0040 0.0281 - - 0.0281 0.309

5Installation of capacitor banks, filters for

existing capacitor banks and power saver2017-18 0.5 3.5 - - 3.5 0.23

6Installed HK vaccum pumps 150 m3/hrs 5HP

motor2017-18 0.13 0.88 - - 0.88 1.36

7 Modified all utility lines for better efficiency 2017-18 1.2 8.4 1363 3.64 12.04 3

8Installation of AOD pumps to minimize

Process pumps2017-18 0.0381 0.127 - - 0.127 0.42

9 Installation of HCL gas generation plant 2017-18 - - - - 15.04 4

10 Modifications in Cooling towers 2017-18 - - 62 0.13 0.13 1.13

11Data Logging system for STEAM Flow meter

Readings2017-18 - - 1773.9 3.942 3.9 0.2

Total 3.642 53.53301 50.68365

* Projects for 2017-18 year

HETERO

Innovative Energy Saving Projects-

2017-2018

HETERO

Advantages:

✓ Solvent Loss minimization by better heat transfer

✓ Time Cycle reduction-power consumption

decrease

✓ Maintenance costs decreases

✓ No need of chemicals dosage

✓ RO membranes and equipment life time increases

✓ RO permeate % increases

✓ Make up water quantity decreases

✓ Frequent line holes or punchers can be decreases

by avoiding corrosion

UOMCOOLING

TOWERS

Investment Lakh INR 3.3

Annual savings Lakh INR 60

Annual Energy Savings Units 2,10,000

Pay back period Month Below one month

* Installation of Electronic Anti scale System for Cooling tower Pipe lines

1/4

Found clean

inner surface of

pipe lines

clean heat

exchangers

with out scale

formation

HETERO* Installation of filter System to remove TSS from Cooling towers water

Advantages:

✓ Maintains cooling tower Efficiency

✓ Maintains efficient Heat transfer in Condensers & heat exchangers

✓ Which helps to increase Productivity

✓ Saves power

✓ Minimizes blow down time & maintenance cost

✓ Saves water treatment chemicals

✓ Saves treated water (helps increases COC)

PARAMETERSINPUT

ANALYSIS

OUTPUT

ANALYSIS

SLUDGE

ANALYSIS

TSS 272 95 252

TDS 5360 5240 4940

pH 7.78 7.81 7.79

COD 6454 6401 6450

2/4

HETERO* Installation of Zero Air loss Automatic Drain Valve System

Advantages: ✓ Protects the Energy loss

by discharging the condensate based on the collection level

✓ Auto drain system

✓ Integrated dirt screen sized amply to reduce the maintenance

✓ Convenient to installation and maintenance

❖ Annual Energy Savings:

66500 Units

❖ Annual saving: 5.32 lakh

INR

❖ Investment: 10,000/piece

❖ Pay Back: less than a

Month

3/4

HETERO* Installation of Liquid-Liquid Extractor System

(Continuous counter current )

♦ Recently we installed 8 kl capacity liquid liquid Extractor in our HLL-I site

UOM

Investment Lakh INR 10

Annual saving Lakh INR 9.8

Annual Energy savings Million Kcal 3,835

Pay back period Months 12 Months

✓ Getting high efficiency

✓ Continuous process

✓ There is no heating or cooling media require

✓ Low maintenance cost

✓ Easy to operate

✓ Less manpower require

BEFORE AFTRE

LLE FEED GC LLE OUT PUT GC

n-hexane THF others n-hexane THF others

Purity% % Purity%

57.36% 34.37% 8.20% 99.30% - 0.26%

62.50% 35% 2.30% 99.49% - 0.50%

67.44% 28.91% 3.10% 99.45% - 0.35%

4/4

HETERO

Road Map Projects-

2018-2019

Tubular Reactor for reduction of particle size

which reduces the down stream powder

processing.

✓ Economix mixing system for improvement in mixing

with reduction in power consumption.

HETERO

✓ Aids in particle size reduction which results in less

consumption of air compressor for downstream

powder processing by using Homogenizer and

sonicator

* Upcoming Projects for 2018-19 year

1

2

3

1/2

✓ Newreka Catalyst ® for elimination of effluent

treatment through MEE.

HETERO

4

S.No. Title of Project

1Installation of Cirrus VEC System for liquid Nitrogen to emission control and

solvent recovery

2 Installation of 173 TR (+5°C) Chiller

3 All Insulation & steam line leakages rectification

4 Installation of chiller line cleaning Copper strip (Anti scale system)

5 Proposed for HCL gas generation operation on Automation system

6 Installation of PPU pumps for steam condensate

7 Installation of filters for chiller lines

8 Trails on Tubular reactor

9 Installation of LED bulbs in existing areas

10 Installation of capacitor power banks

11 Installation of VFDs to required process equipment's

12 Installation of AOD pumps to minimize load on PP

13Reconciliation of nitrogen, air consumption by implementation of flow

meters.

2/2

HETERO* Zero Investment Projects

S.NO Title of Project

Total Annual

Savings in

Lacks

Investment

1High power consumption operations Will be planned

based upon the tariff .30 0

2 Changing the coal blending ratio for 16 TPH Boiler 28 0

3In CAP product Capacity Enhanced from 1.2 MT to 5 MT

by reducing the Solvent Volume & separation tub used29.64 0

5In GTB product Capacity Enhanced by using available

ANFD from 1.2 MT to 2.5 MT by 108 %13.26 0

6In APO product Capacity Enhanced by using available 2KL

Receiver from 0.6 MT to 0.9 MT by 50%4.54 0

7In IDBA product Capacity Enhanced from 1.8 MT to 4.2

MT by 133% by reducing the Solvent volume20.16 0

8In SAN product Capacity Enhanced from 3 MT to 7 MT by

133% by reducing the Solvent volume22.08 0

TOTAL SAVINGS IN LACKS 147.68

ParametersOrdinary

Bike

Electric

Bike

Savings/

Bike

Savings (Rs/Km) 1.23 0.021.19

Cost 66 k 34 k 32 k

Fuel Type Petrol Electricity -

CO2 emission/Mileage (kg) 2.31 1.32 0.9

Mileage (km) 65/ Lit80/ Full

charge

HETERO* Distributed Electric Bikes to employs

♦ To reduce fuel pollution , motivate people to drive electric bike

HETERO

Installed FLP-LED bulbs of 70 Nos in place of CFL bulbs

Installed Solar street light of 5 Nos in out site

Replaced Aluminum Blade with FRP blades for all cooling

towers

Renewable Energy Source

Provided Variable Frequency Drive (VFD’s) to all Cooling

towers, Reactors, ANFD’s, CF’s, AHU’s, Chillers

* Energy Saving Initiatives By Energy Management Team in our Unit

1

2

3

4

By giving a Miss call, we are getting each & every chiller

temperature Instantly.

Installed Energy Efficient Motors (IE 3 ) of 20 Nos in place

of existing motors.

Installed of compact pressured powered pump package unit

of 4 Nos

HETERO

5

6

7

8 Installed float type Steam traps of 50 Nos in place of old

traps

HETERO

✓ Getting 90 to 95 °C temperature condensate from unit which leads to benefit

the boiler.

✓ There is less consumption of fuel to generate steam due condensate

✓ Make up water % decreased

✓ Flash steam reduced due to close loop lines

✓ Eliminates pre-heating water system

1

2

34

* CPPPPU installation layout in our Unit

✓ Constructed 2000 kl storage Capacity

tanks-3 Nos & and 160 kl-5 Nos for Rain

water collection

✓ Saved 1200 kl water consumption due

to proper utilization of rain water

HETERO* Rain Water Harvesting System

Applications in different area's :

✓ For cooling towers

✓ Fire Hydrant System

✓ Washroom purpose

✓ Gardening

Domed shape Roof tops

Pipe lines

❑ Generation of Organic waste: 1) Canteen food 2) Garden waste.

❑ By using Organic waste converter (OWC) machine we are Feeding the

waste to Earth warm which generates compost for the Trees.

❑ In FY 2017-2018 around 21 Tons waste generated which used as a

compost.

HETERO

2012-13 2013-14 2014-15 2015-16 2016-17 2017-18

837

11601388

1562

2652

3412

CO2 reduction by Plantation(In MT)

* Utilization of waste and CO2reduction

HETERO

Steam Flow Meters Chillers Flow Meters

Energy Consumption

Indicators

Steam Flow Detection

System

Water Parameters Detection

Instrument

* Energy monitoring system in Our HLL-I Unit

Energy consumption

Monitoring System

✓ Daily review of source wise Energy Consumption

✓ If the consumption exceeds the baseline, then analysis will be done for the

deviation for relevant areas with the help of HOD

✓ Identification of Significant energy deviations

✓ Investigation for the significant energy deviations

✓ Responding according to the investigation

✓ Discussion of Energy Performance in monthly over heads meeting with all

HOD’s and Management

✓ External technical audits & Internal assessment by certified internal auditors,

and implementation of corrective actions if any non conformities during

assessment to improve the energy performance

✓ Every Saturday has declared as leaks arresting day

✓ Every Monday has declared as insulation checking day

✓ Frequent uninformed audits and inspections

✓ Coal crushing is done only in Night time, Unit price Rs 5.5

* Energy Monitoring Methodology HETERO

❖BSI-ISO:50001:2011 certification Audit for EnMS

* ENERGY AUDITS BY EXTERNAL AGENCIES IN OUR UNIT

❖Flash Steam recovery Identification by Forbs Marshall

❖Steam traps Operational Survey by Forbs Marshall

❖Chemical Dosage for Evaporative Condensers in Utility

Section

❖Internal Energy Audits Twice in a Year

HETERO

Employee Awarenessand

Motivation ☺

HETERO

✓ Longer Lasting

✓ CO2 reduction

✓ Safer and easier to install

✓ Distributed Each Employee -2Bulbs

✓ 9 Watt capacity

✓ With 3yr warranty

✓ Every Month you can save Rs 16/-

/BULB by Installing LEDs

* LED BULBS DISTRIBUTION-2017-18(3000 No's)

HETERO1/3

HETERO

* Distributed Clay Made GANESHA to Employees (Eco-Friendly)

-1500 Nos * On the Occasion of world Environment Day Distributed Jute

Bags to Employees (Eco-Friendly Bags)-1500 Nos

2/3

❑ Conducting EnMS awareness training classes to all employs in our Unit

❑ Every month we are conducting Mock drills of Fire- Fighting, first Aid,

SCABA etc in plant premises

❑ As a Energy point of view-Giving training on Boiler operation, steam trap

operation, On job training, Any new mechanical equipment operation

like- compressor, vacuum pump, chillers etc

93

9798

96

90

91

92

93

94

95

96

97

98

99

Training Attendance of EnMS 2018

(%)

HETERO3/3

Training Motivation & Team work Appreciation

Energy Awareness

Pledge Awareness

HETERO

HETERO

CII-Award 2015-16

CII-Award 2016-17

Establishment of EnMS 2015-16

Awards & Certificates

Hetero Honored with “ IP

Excellence in India” Award

2018

HETERO

V

S -STEAM LOSS

A -AIR (COMPRESSOR) LOSS

V -WATER LOSS

E -ELECTRICITY LOSS

E

N

E

R

G

Y

E

N

VI

R O N ME

N

T

« Mr.G.Venubabu

(AGM- TSD HLL-I, EnMR)