Presentation Flow: Watt Apollo Tyres 3/25/2013. Mapping of Carbon foot print. Energy Consumption reduction.

Transcription

1 Watt Apollo Tyres K. Sunil 22 nd March, 2013 Presentation Flow: Mapping of Carbon foot print Energy Consumption reduction Results achieved Usage of Renewable Energy Zero water Discharge Actions initiated Challenges 1

2 Mapping Carbon Footprint Mapping activities. Indian Operations. Phase 1 -Carbon footprint undertaken in manufacturing locations excluding guest houses and offices within plant premises. This will be done in Phase 2 Head Office & Sales Offices European Operations. Activities are part of Life Cycle study being undertaken by Tyre Industry on Tyres in Europe African Operations. Plan to be undertaken in

3 Scope 1, 2, 3 Breakup: Overall for Indian Operations Scope 1: Coal, Natural Gas, Furnace Oil, Diesel, Petrol, Refrigerant Scope 2: Electricity Scope 3: Procurement, Dispatch, Employee Business Travel, Employee Daily Commute Scope 1&2 - Carbon Emissions (CO 2 Equivalent) / Production (Tonnes) for 3 plant locations is 1.14 Scope 1 Emissions Breakup: Overall for Indian Operations. Scope 1 Contribution 38.6% 3

4 Energy Consumption reduction Energy :Methodology for Improvement Ideal Condition Break through improvements Theoretical Loss Technological Changes Process Changes Improvements / Kaizens Opportunity Loss Efficiency Improvements Process Optimisation Daily Management apollotyres.com Recoverable Loss Waste Elimination Leakages Air, water, steam Heat loss Idle running 4

5 Energy Management System Adjust & Analyse Regular bench marking exercise between processes Cross Plant audits to identify the improvement opportunities is carried out in all the plants. Analyse gaps & plan corrective actions. Monitoring & Checking Installation of Energy meters, Flow meters for air, water & steam for all processes in the plants. Policy Act Energy budget is prepared every year based on previous years performance and input from audit & benchmarking. Plan Continual improvement Check Do Planning For Ownership, stratification of budget into deliverables of various work centers of the plant is done and then this is also part of the individual members KRA. Implementation & Operation Evaluate Compliance : Daily MIS is prepared & Monitored for variance Monitoring is done at review meetings at various levels of operation. We believe that we can conserve only what we can measure Total Power Consumed (Kwh/Kg) With year as base

6 Total Steam Consumption (Kg/Kg) With year as base Total Water Consumption (Ltrs/Kg) With year as base

7 Usage of Waste Heat / Renewable Energy At Baroda Plant Project with GAIL Background : GAIL was venting out waste heat from their plant in Baroda. GAIL would use this waste heat for generating Steam in boilers. This steam would to be supplied back to ATL for its exclusive use 7

8 Overview of GAIL Operation Earlier COMPRESSOR#1 COMPRESSOR#2 TO THE ATOMSPHERE DEG.C. TURBINE#1 TO THE ATMOSPHERE DEG.C. TURBINE#2 TO THE AMOSPHERE DEG.C. COMPRES SOR#1 COMPRES SOR#2 Present TURBI NE#1 TURBI NE#2 TO WHRBS TO WHRBS TO WHRBS TO ATM DEG.C WHRB #1 TO ATM DEG.C WHRB #2 TO ATM DEG.C WHRB #3 STEAM STEAM STEAM COMPRESSOR#3 TURBINE#3 COMPRES SOR#3 TURBI NE#3 STEAM SUPPLY TO ATL Project Benefits Description Flue Gas Emitted in Atmosphere before the project Energy Conservation Unique Project Original scenario Present Scenario C C. FO and LNG GAIL is running all Gas Turbines in open cycle Waste Heat Recovery (No Fuel) GAIL will convert all Gas Turbine in close cycle after successful commissioning of steam conversion project with ATL Benefits Reduction in temperature in GIDC Area Conservation of precious Fossil fuels Horizontal deployment of concept for Environment and Energy conservation 8

9 Summary Baroda Plant ATL is receiving 1100 tons of steam per day at 25 Kg/ cm 2 from GAIL Steam received from GAIL is being used in process as well as for power generation. Reduction of more than 51000tonsof CO 2 per annum from this project. Beyond this, 23% (28 MnUnits )of the total power requirement of Baroda plant is met by Wind power. Chennai Plant. Wind power meets 13% of the power requirement of the plant. (20 Mn Kwh/Year) There is a statutory requirement of meeting 3% of total power requirement through solar power by Dec 31, 2013 Pune Plant. FO based Boiler was replaced with Bio-mass based Boiler. There is a reduction of nearly 9000 tons of CO 2 per year. apollotyres.com 9

10 Scope 3 Mitigation Approach Indian Operations Impart Awareness. Environment awareness initiative was launched in partnership with Centre for Environment,Research & Education (CERE) amongst workforce for behaviour change focusing on :» Energy» Water» Waste» Bio Diversity Action Plan to be designed in targeting focused engagement with employees, vendors, suppliers and contractors. Zero Water Discharge - Plan Indian Operations We have started the journey to go for Zero water discharge as phase1. Our Chennai plant is a Zero Water Discharge plant. Complete mapping of water consumption across all our manufacturing locations has been undertaken. We are analysing the data to identify further improvement areas. Future Targets Phase1 mapping will be completed for Indian operations in Target setting would be taken up, after Phase 2 is completed, in the course of next financial year. 10

11 Apollo Way To Move Forward (GHG Emissions) Measure, Set Targets Reduce Offset Establishment of baseline Roll-out: Entire operations Internal/External Benchmarking Target setting Monitoring Energy/Resource Audit Technology Intervention Focus on HVACR equipment Stakeholder Engagement Renewable Energy Projects Energy Efficiency Projects Challenges. Biomassproduction is at present in the un-organised sector and its continuous availability is a concern. Since this would create a major business risk, consumers are forced to use Boilers capable of using multiple fuels which would affect the combustion efficiency. As on today, the payback of Solar based power stations are very high--- nearly 7 years with Government subsidies. Mandatory requirement of usage of Solar power either necessitates huge investment or procurement at a very high cost.. RECmarket prices are low at the moment due to market forces. REC s are becoming state specific.shift from earlier policies. 11