CII National Award on Excellence in Energy Management ITC SAHARANPUR. Excellence in Energy Management ITC Limited Saharanpur

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1 CII National Award on Excellence in Energy Management ITC Limited Saharanpur ITC SAHARANPUR Excellence in Energy Management

2 ITC Limited Saharanpur Excellence in Energy Management ITC: An Exemplar in Triple Bottom Line Performance Environment Water Positive : 14 years in a row Carbon Positive : 11 consecutive years Solid waste recycling positive : 9 consecutive years Soil & moisture conservation over 2,70,000 hectares 47% renewable energy ITC s bio-diversity program now covers 4,000hectares Economic Market Capitalization Over $ 44 billion Turnover: Nearly $ 8 billion Powered by the vitality of worldclass brands Social Over 50,000 sustainable livelihoods for rural women Primary Education Initiative: Benefitting 4,70,000 children Empowering 4 million farmers Approx. 100 million person-days of employment generated through afforestation programme

3 Company Profile: ITC Limited Saharanpur Year of establishment: 1926 Product: Cigarettes & Cut Tobacco Capacity of Production: 35 BNC, 3 shift operation Manpower: 822 employees & 250 ESPs SEC: 9% reduction (YoY) RE Portfolio:9% Water: Benchmark in Specific Consumption ITC Limited Saharanpur Excellence in Energy Management

4 Process Flow in ITC Saharanpur Primary Manufacturing Process Lamina /Stem DCCC Cutters KLD Secondary Manufacturing Process Cigarette Packing Cigarette Making Cut Tobacco Flavoring & Mixing Finished Goods Storage Shipping Automated Manufacturing Facility: Energy Efficient Process & Machinery ITC Limited Saharanpur Excellence in Energy Management

5 Energy Management

6 Energy Management Philosophy at ITC Saharanpur Energy Management Systems Awareness Excellence in Energy Design Process... Sustainability beyond boundary ITC Limited Saharanpur Excellence in Energy Management

7 ITC Saharanpur Energy Management Organization Production Manager I/C SMD Staff & Workmen I/C PMD Staff & Workmen Branch Manager IDEATE EHS Manager EHS Team Branch Engineer Utility Manager - Electrical Staff & Workmen Utility Manger- Mechanical ALL ROUND MANAGEMENT COMMITMENT Staff & Workmen Central Energy Team Departmental Energy Team Design Validation Team Sankalp Task Force UNiS Task Force Plant level Audits Peer Audits Divisional Audits SUSTAIN Corporate Audits Third Party /TERI Audits Steam & Air Audit (OEM)

8 Energy Management - Close Monitoring Electrical Energy Monitoring Online monitoring of electrical loading of all sources by energy management system Thermal Energy Monitoring On receipt Fuel quality monitoring Real time monitoring of power consumption of major equipment by energy management system Daily boiler performance monitoring-evr Real time monitoring of power factor for all major load Daily monitoring of Grid utilization Daily Steam consumption monitoring Daily analysis of Exceptions AMC for 33KV supply line for Preventive maintenance and faster repair Daily performance monitoring of DG and Solar plant Monthly Steam trap monitoring Condensate recovery monitoring and analysis Excellence in Energy Management

9 Consolidated Reporting and Management Reviews Daily Exception Reporting Weekly Review by Department Head Energy Performance Review by Unit Head Quarterly Sustainability Data Reporting to Corporate Yearly Energy Performance Review by Divisional Management Detailed Energy Audit by External Certified Auditors every Three Years Audit Recommendation implementation validation by Corporate Auditors

10 EnCon Projects

11 Snapshot of Energy Conservation at ITC Saharanpur Investments 33 kv & SUPS for Grid Utilization Improvement Just-do-its Half-bins for Stem Conditioning Innovations CONTINUOUS IMPROVEMENT FOR SUSTAINABLE DEVELOPMENT Celdak Pads in AHU High Bay LED in Shop floor (initially Metal Halides) Condensate & Waste Heat Recovery from PMD Investment lacs Screw Compressors instead of Vertical Reciprocating Energy Efficient cyclone fan induction in PMD Idle run arresting at Packaging-unit Heaters Dust Removal System Optimization in SMD Annual Saving Power Factor improvement to 0.99 Steam Consumption optimization at PMD STS Polycarbonate Sheet in Shop floor for Natural Lighting Energy cost Rs./1000 cigarette 1 Motion sensor enabled fans 7 % 8.54 Heat Recovery Compressor % 7.36 Liquid Off-take system for Canteen LPG consumption

12 Improving Grid Utilization & GHG Inventorization SUPS 1650 KVA 33KV line commissioning 15-16: 1650 KVA SUPS Commissioned 16-17: Line installed Charging & Industrial Status 1500 KVA DG Upgradation from 11 kv to 33 kv 100% 90% 80% 81% Grid Utilization 94% 97% DG Running Hrs Cr/annum (Saving) Cr (Invest) 70%

13 Recovering Waste Heat from Process LAMINA PROCESSING SLICING CONDITIONING CUTTING EXPANSION & DRYING LAMINA BALES MIXING & FLAVOURING STEM PROCESSING DRY STEMS FINAL CUT TOBACCO CONDITIONING CUTTING EXPANSION & DRYING 100% Condensate Recovery from all indirect heating process 100% Flash Steam Recovery from Recovered Condensate Waste Heat Recovery from Stem Expansion Exhaust (Direct Heating) Plan: Waste Heat Recovery from Lamina Expansion Exhaust 9.6 L/annum (Saving) 18.2 L (Invest)

14 Energy Efficient Lighting Across Shop Floor Metal Halide (MWh) LED (MWh) SMD PMD WMS Other Before Lighting load/annum 5 8 % 279 After 75 L (Invest) 30.5L/annum (Saving)

15 Just-Do-It Projects Half-bins for Stem Conditioning Employee-driven Ideation Core Committee Validation Idle run arresting at Packagingunit Heaters Dust Removal System Optimization in SMD Power Factor improvement to 0.99 Steam Consumption optimization at PMD STS Implementation & Sustenance 15 L/annum (Saving) व च र स आक र तक 2 L (Invest) Management Review

16 Innovations

17 Innovation: Celdak Pads in AHU UNiS Conservation of Water & Energy Event Employee suggestions received on Celdak pads ITC Utility Team conducted initial feasibility study Third party verification of the idea Implementation plan of project Reduction in Steam consumption Recycling of water Product quality improvement Reduction in Power Steam consumption (Tons) L/annum (Saving) 8 L (Invest) ITC Limited Saharanpur Excellence in Energy Management

18 Innovation: Polycarbonate Sheets for Natural Lighting Shop floor lighting load (MWh) Before PC Sheet SMD PMD WMS + Shipping After PC Sheet Other Replaced existing North Light Glass Panels with transparent & durable Polycarbonate Sheets Commissioned in entire manufacturing block 32 L (Invest) 5.8 L/annum (Saving)

19 Other Innovations in the Factory LDR and Occupancy sensor based lighting Heat Recovery Compressor Light pipe in DRF for natural lighting Remote operated lighting Occupancy based Air circulator Automatic tube cleaning for chiller 102 L (Invest) Energy Efficient fan Solar Street lights 22 L/annum (Saving)

20 Energy Conservation through People Engagement व च र स आक र तक OATH FOR ENCON ENCON EXHIBITION Commit Introduction to Unit s Policy towards Sustainability Oath towards all-round energy conservation Involve 4 EnCon Agencies: Awareness towards Sustainability Participation: 700+ employees & 300+ ESPs AD MAD: ENCON WATER SAVING ACTIVITY Ideate UNiS Team: Committed towards continuous ideation UNiS Event: 90+ EnCon Projects ideated by Employees ARRESTING LEAKAGES REWARDS & RECOGNITION

21 Renewable Energy

22 Rooftop Solar Power Plant at ITC Saharanpur Phase 1: 630 kwp (October 15) Phase 2: 140 kwp (April 16) Phase 3: 82 kwp (plan) Plan 100% utilization of roof area Central Power Evacuation: 11kms cable Utilization of parking area through PEB Erection 143kWp installation Standing Seam Clamping solution at FGS Structural Strengthening of Godown U Type Clamp Additional Members Sustenance: Cleaning setup, Lifelines Ladder Lifeline Extension

23 Rooftop Solar Power Plant at ITC Saharanpur Real time monitoring performance Daily monitoring of Generation Monthly A3 Reporting to HO Weekly Cleaning Schedule High pressure jet cleaning system Maintenance By OEM

24 Renewable Energy Portfolio of ITC Saharanpur Rooftop Solar Power Plant 770 kwp 8% RE Polycarbonate Sheets in Shop Floor (+1% RE) Offsite Solar Power Plant 10 MWp 79% Representations: Chief Sec., Principle Sec, UPERC & UPNEDA Petitions Filed to UPERC Inter-state Wind Energy Wheeling 3 MW 100% Representation made to NRLDC Acceptance from UPPTCL NOC awaited from UPPVNL

25 Indices

26 Energy Indices ITC Saharanpur 100% 95% 90% 85% 80% 75% 70% Grid Utilization 16% Improvement kg steam/kg fuel ---Boiler Efficiency 9% Improvement 97% 94% 81% FY LED Light across factory 809 Compressor air leakage audit Energy KWh Unit/Mnc 806 Celdek pad for SMD and CTH AHU 802 Shutdown related initiatives Switch machines Idle load Energy Efficient Cyclone Fans 5% Reduction over FY CTS shaker feeder to gravity feeding

27 Energy Indices ITC Saharanpur CO2 Emission (T) Electrical SEC GJ/MNC % Reduction Over FY Thermal SEC GJ/MNC % Reduction Over FY SEC Benchmarking GJ/Mnc % % % Reduction YOY Benchmark CO2 Emission % Reduction Over FY

28 Beyond Boundaries

29 Encon-Beyond Boundaries Solar Streetlights in local communities Investment: Rs. 16 lakhs Total Solar street light installed: 50 Title of Project 117 Nos. 70W Street lights replaced with 45W LED Street lights Energy Efficient lights and fans installation Turbo ventilators fixing in Godown Year Name of the Vendor ITC Residential Colony ITC Marketing office M/S V.K Associates Name of service provided M/S Kumar Electric work M/S Kumar Electric work M/S V.K Associates Energy Saved kwh/year 8250 kwh/year kwh/year Knowledge Sharing with Government officials EnCon awareness session in nearby school Awareness EnCon session to contract workmen EnCon awareness in nearby villagers

30 Thank You