Best Practices in Textile Plant

Transcription

1 BIRLA GROUP OF COMPANIES B. K. B. K. BIRLA GROUP OF COMPANIES Best Practices in Textile Plant PRESENTATION BY RAJDEEP HEGDE DGM (Boiler House )

2 Shri B. K. Birla (Chairman) In the corporate world, managers are compelled by circumstances to make their enterprises increasingly efficient, entrepreneurial, equitable, and ethical in strategic pursuits. Efficiency and effectiveness have become the salient driving forces of this strategic change. Competition is getting fiercer. Globalization pits our firms against multinationals, who have already made their presence in our country with seemingly unlimited resources. Our managers have therefore to compete and creatively so for market positions and sizable shares regionally and nationally. In this climate inefficient and uneconomic units risk getting wiped out. Only fittest will survive and we have to be amongst them and as leaders B. K. Birla Chairman

3 Company Profile Division of Century Textile & Industries Ltd. Belonging to B. K. Birla Group of Companies India s largest producer of Viscose Filament Yarn Highly Labour & Energy Intensive

4 CENTURY RAYON (A Division of Century Textiles & Industries Ltd) Products Viscose Filament Yarn High Tenacity Viscose Tyre Yarn Continuous Spun Viscose Filament Yarn Caustic Soda Carbon disulphide Sulphuric Acid Power Generation 45 TPD 18 TPD 7 TPD 55 TPD 50 TPD 200 TPD 18 MW Employees No. of Workers 4300 No. of Staff 700

5 Energy Policy Energy saved is energy produced. So, no effort will be spared to achieve highest levels of efficiency in managing and conserving the energy resources. Both financial and human resources coupled with technological up-gradation will be provided for the purpose.

6 % Share of Total Cost (Rs. 800 Crores) Others 14% Stores 9% Raw Material 38% Sal Wages 19% Power & Fuel 20% Energy is the second largest contributor to the cost Energy cost = Rs. 160 Crores 1% saving = Rs. 1.6 Crores

7 ELIMINATING UNNECESSARY ENERGY USE IMPROVING THE EFFICIENCY OF NEEDED ENERGY USE BUYING ENERGY AT LOWER NET PRICES ADJUSTING OPERATIONS TO ALLOW PURCHASING ENERGY AT LOWER PRICES 7

8 ENERGY TARGET % Saving Realized Rs.158 Lacs 1.00% Saving Realized Rs.197 Lacs % Saving Realized Rs.145 Lacs % Target 1.3% Saving Realized Rs.196 Lacs

9 Quarterly Review Apex Energy committee Chaired by Sr.President Energy Target, Suggestion scheme, Red Tag Identification, Energy Audit Central Energy committee Chaired by Exe. President Bi-Monthly Review Energy Team Rayon Energy Team TC & CSY Energy Team Chemical Energy Team Auxiliary Energy Team BH-PH Monthly Review

10 BEST PRACTICES ADOPTED IN CENTURY RAYON REAL TIME MONITORING & MANAGEMENT

11 Real Time Energy Management POWER CONSUMPTION STEAM CONSUMPTION

12 MSEDCL Tariff Incentive Avail Year 2014 Month P. F. P.F.Incentive Incentive (Rs. Lacs) L.F.% L.F.Incentive Incentive (Rs.Lacs) Total Month wise (Rs.Lacs) Jan Feb Mar Apr May Jun July Aug Sept Oct Nov Dec Total

13 Before : Simultaneous Operation of Pulpers Optimization of peak load After : Staggered Operation of Pulpers Two Pulper -running simultaneously Two Pulpers - running separately

14 Optimization of peak load Savings from Optimized Operation of Pulper :: Energy Monitoring Grid Load Before After 18.2 MW 18.2 MW Peak Load Impact 734 kw 220 kw Loss in Caustic production/ day 2 Ton Nil Per Day Loss Rs Nil Per Year Loss (in Rs. Lakhs) Nil Saving Realized Rs Lacks

15 ZERO BREAKDOWN APPROACH Thermography. Vibration Analysis. Scientific Alignment of Rotating Equipments Bearing Installation through Induction Heating.

16 Predictive Maintenance : Thermovision Save Energy Cost Prevention of more costly repairs Reducing the risk of fire hazards Replacing only needed parts Minimize production loss Predictive scheduling of repair Inspection can be done under full load Faster inspection time Increased productivity Fast, accurate and cost effective ENERGY CONSERVATION BY NEW MODERN TECHNOLOGIES

17 PREDECTIVE MAINTENANCE THERMOGRAPHY PHOTOGRAPH

18 Steam Trap Audit - Thermography

19 HT INSULATION TAPPING IN MAIN SUB-STATION HT Insulation Tapping to minimize crow fault in Main Substation

20 Present Alignment Practice Laser Alignment LIMITATIONS Human Error More Time Consuming Space Constraint Advantages Highly Accurate & Eliminates Human Error Less Time Consuming User Friendly

21 Predictive Maintenance : Vibration Analysis Machine out of balance Machine out of alignment Resonance Bent shafts Gear mesh disturbances Blade pass disturbances Vane pass disturbances Recirculation & Cavitation's Motor faults (rotor & stator) Bearing failures Mechanical looseness Critical machine speeds

22 Present Bearing Installation Practice BEARING INSTALLATION INDUCTION HEATING LIMITATIONS Prevents Damage of Bearing during Installation HUMAN ERROR TIME CONSUMING POSSIBLITY OF BEARING DAMAGE

23 BEST PRACTICES ADOPTED IN CENTURY RAYON TECHNOLOGY UP GRADATION

24 Old PSY M/c. New CSY M/c.

25 ENERGY CONSERVATION BY NEW MODERN TECHNOLOGIES EXISTING NEW MACHINE Existing machine having Gear boxes & New Machine upgraded with AC drives in place of Gearboxes for Energy saving & Reduce the maintenance problems.

26 Replacement of Screw chiller with Centrifugal Chiller BEFORE AFTER Sp. Power consumption 0.75 kw/tr Sp. Power consumption 0.65 kw/tr

27 Replacement of Water ring vacuum pump with Mist Condenser BEFORE AFTER Annual Power Saving 1.51 Lacs KWH

28 Replacement Of Water Ring Vacuum Pump With Mist Condenser BEFORE AFTER Degaser 0.6 Kg/cm2 and 225 M3/Hr (ETP Water) 22 KW/960 RPM motor Investment Power Savings Savings Rs Lacs 1.51 Lacs KWH Rs Lacs

29 CRYSTALLISER. CONDENSER CONDENSER CRYSTALLISER. CONDENSER SPIN BATH VAPOUR STEAM VAPOUR ABSORBER STEAM Steam Jet Crystalliser L.P. STEAM Acid Absorption Crystalliser BOOSTER C/T C/T SPIN BATH PHE ST.TANK (70% ACID) SALT PROD. SALT PROD. HOT WELL HOT WELL

30 Acid Absorbtion Crystallizer 1 2 Steam consumption by Crystallizer system Steam consumption by Acid Absorption Crystallizer system 85 TPD 30 TPD 3 Net Steam Savings per day 55 TPD Investment Actual Saving per year 1.Steam 55 TPD 2. Power 600 kwh/day Pay back period Rs. 450 Lacs Rs Lacs 4 Years

31 BEST PRACTICES ADOPTED IN CENTURY RAYON IDENTIFICATION & IMPLEMENTATION OF EnCON PROJECTS

32 Nos. of Projects Amount ( in Lacs) Amount ( in Lacs) Century Rayon ENCON Projects ENCON Projects Undertaken Investment Realization Year Year Year

33 Installation of 70KW LP Steam Turbine to avoid PRV in Deareator Investment = Rs Lacs Annual Savings = Rs Lacs Pay back = 20 Months

34 MSEB POWER FACTOR IMPROVEMENT 16.5 MW 16.8 MVA 16.6 MVA 1.4 Mvar After 2 Mvar Capacitor Added Reactive Power Kvar = 3.4 Before Investment Rs.36 Lacs Benefits 1. Rs.91 Lacs / Annum 2. Extra 200 Kva i.e.198 kw Power Available

35 MISSION : Condensate recovery in CS2 plant STATUS : 50 MTD Condensate of 80 deg. feed to Boiler SAVING : Rs.5.22 Lacs/Annum BEFORE AFTER Coal Saving 645Kg x Rs.6.3 /kg Water Saving 50 M3 X Rs. 14/m Less Power generation loss & interest on investment Total Saving Rs.Lacs 5.22

36 Boiler No kg /cm2 45 kg /cm2 CENTURY RAYON - SHAHAD OPTIMUM PIPE SIZING & LAYOUT Boiler No. 5 & 6 ORIGINAL Length -341 mtr REVISED Length- 205 mtr New Header 43.5 kg /cm kg /cm2 TURBINE DETAILS PRESSURE DROP TEMPERATURE DROP ORIGINAL 2.5 Kg/Cm² 15 º C Old IJT Header SAVING REALISED : Rs. 40 Lacs/Annum REVISED 1.5 Kg/Cm² 7 º C

37 Modification in Steam Supply Line from Acid Plant 100 NB TO T/C VAM 100 NB TO T/C VAM STEAM PR kg/cm STEAM PR kg/cm 100NB LINE TO CS2 150 NB LINE TO RAYON VAM 100NB LINE TO CS2 150 NB LINE TO RAYON VAM 100 NB TO T/C VAM 100 NB TO T/C VAM STEAM PR kg/cm STEAM PR kg/cm 150 NB LINE TO RAYON VAM 150 NB TO CS2 150 NB LINE TO RAYON VAM 150 NB TO CS2 STEAM HEADER IN CS2 PLANT STEAM HEADER IN CS2 PLANT STEAM PR kg/cm BEFORE BEFORE STEAM PR kg/cm MAIN STEAM HEADER IN ACID PLANT MAIN STEAM HEADER IN ACID PLANT AFTER STEAM PR kg/cm STEAM PR kg/cm MAIN STEAM HEADER IN ACID PLANT MAIN STEAM HEADER IN ACID PLANT Benefit 1. Steam pressure drop is reduced from 2.5 to 0.4 Kg/cm2 2. The steam supply route to T/C VAM has reduced up to 150 Meters 3. Smooth supply of steam to all the users of up to 8 Kg/ cm2. 4. Additional 450 TR VAM able to run i.e. saving of 250 kw

38 Reduction in Compressed Air Discharge Pressure Boiler Instrument Air Compressor: Capacity 100 CFM No. of Bends reduced = 07 Nos Pipeline Length reduced by rerouting = 30 mts Air Pressure Reduced = 6.0 to 5.0 Kg/cm2 Power Savings Savings = kwh/annum = Rs 1.58 Lacs/Annum Ash Conveying Air Compressor: Capacity 220 CFM Optimized Ash Conveying system operation Conveying Air Pressure Reduced = 5 to 3.3 Kg/cm2 Power Savings Savings = kwh/annum = Rs 1.98 Lacs/Annum

39 Efficiency improvement in Lighting system Replacement of T8 (36W,2450 Lumens) to T5 (28W,2700 Lumen) BEFORE 116 Lux Level AFTER 182 Lux Level 16 fittings / Line (45 Lines) 10 fittings / Line (45 Lines) Electricity Saving Total Saving Investment 1.15 Lakhs kwh / yr. Rs 5.75 lakhs/ yr. Rs 4.55 lakhs

40 SELF DRIVEN ROOF VENTILLATORS ON TURBINE ROOF Solar Street Light Solar Heater for Hot water in Coal Plant

41 Unwanted lights kept OFF in the plant :: NATURAL LIGHT Electricity Saving Total Saving Investment kwh / yr. Rs 1.0 lakhs/ yr. Rs 0.50 lakhs

42 Solar Daylighting System for Warehouse Installed in ware house before installation with transparent sheets 150 Lux and after 400 Lux

43 LED Lighting Photo Sensor Heat Recovery VFD Mist Condenser

44 BEST PRACTICES ADOPTED IN CENTURY RAYON AWARENESS & TRAINING

45 Energy Week Celebration * Release Of Energy Bulletin * Quiz Competition for Staff & Workmen * External Faculties presentation for Staff * Poster Competition * Energy quantifiable Waste Identification * Internal Faculties Presentation On Energy Conservation for Workmen * Drawing Competition & Energy Awareness Programme for School Children

46 Release Of Energy Bulletin 2013 Awareness Creation in the employees & Their involvement

47 Quiz Competition for Staff (Plant-wise) Five Teams with 2 members each

48 Awareness Training (Employees, School & College Students)

49 Energy Loss Red Tag Identification during Energy week Plant EC Week 2012 No.of Red Tags Identified & Implemented EC Week 2013 No.of Red Tags Identified & Implemented EC Week 2014 No.of Red Tags Identified & Implemented TC & CSY Rayon Chemical Auxiliary Total

50 Awareness Creation in the employees & Their involvement

51 Energy Conservation Awareness In Kalyan City Through Energy Walk

52 Rayon waste used for cleaning Scrap Pot use for plantation ETP Water recycled used for Garden

53 Name of the Agency Month/Year Area Synergy Consultants Pvt Ltd, Mumbai November 2001 Electrical and Thermal Energy Forbes Marshall Ltd., Pune January 2003 Steam supply and distribution network. Ingersoll-Rand Ltd., Ahmedabad February 2003 Compressed air system KSB Pumps Ltd., Pune March 2003 Pumps Reitz India Ltd, Hyderabad April 2003 Air Washers and Exhaust Fans. Green Audit by CII, Hyderabad January 2004 To Focus on Root cause of inefficiency Central fuel Research Institute, Nagpur March 2005 Boiler House & Coal Plant Madura Compressor, Kalyan 2006 Rebalancing of airline to reduce pressure drop & losses. Marco Blower, Kolkata List Of Energy Audits December 2007 Study of exhaust fan & exhaust system. Pack Plast, Kota January 2008 Study of air washer system CII January 2009 Complete Plant Bapat Energy Consultant April 2011 Engine Room Rayon Plant Schneider Electric India Pvt. Limited May 2011 Complete Plant Forbes Marshal pvt.ltd. May 2012 Complete TC-CSY Plant Ecube March 2014 Plant Electrical motors TUV India Pvt Ltd March 2015 Complete Plant (Electrical & Thermal)

54 AWARDS.. Sr. No Details of Awards Year Organization National Award for Excellent Energy Efficient Unit in Energy Management ICC Award for Excellence in Energy conservation & Management 9th State Level Award in Excellence in Energy Conservation and Management 1st Prize in Textile Sector 8th State Level Award in Excellence in Energy Conservation and Management 1st Prize in Textile Sector 7th State Level Award in Excellence in Energy Conservation and Management 1st Prize in Textile Sector 2015 Confederation of Indian Industry (CII) 2013 ICC Maharashtra Energy Development Agency (MEDA) Maharashtra Energy Development Agency (MEDA) Maharashtra Energy Development Agency (MEDA)

55 AWARDS.. Sr. No. 6 7 Details of Awards Year Organization 6th State Level Award in Excellence in Energy Conservation and Management 1st Prize in Textile Sector 5th State Level Award in Excellence in Energy Conservation and Management Award for Continuous Excellence Maharashtra Energy Development Agency (MEDA) Maharashtra Energy Development Agency (MEDA) 8 State Level Award in Excellence in Energy Conservation and Management 1st Prize in Textile Sector 2006 Maharashtra Energy Development Agency (MEDA) 9 National Award for Energy Efficient Unit in Energy Conservation Confederation of Indian Industry.

56 AWARDS.. Sr. No. Details of Awards Year Organization 1 Winner of Platinum Award at 14th Annual Greentech Safety Award th Annual Greentech Safety Award Green Tech Environment Award th Green Tech Environment Award 3 Water resources management in chemical industry 2005 Indian Chemical Manufacturers Association, Mumbai.

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