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

Transcription

1 THE ENERGY STORY : A PRESENTATION BY Himanshu Agrawal, Milind Bhandarkar, Ajit Patil, Rajdeep Hegde

2 Products Viscose Filament Yarn Pot Spun Yarn Continuous Spun Yarn Tyre Yarn Caustic soda (& allied chemicals) Carbon disulphide Sulphuric Acid Power Utilities Water Treatment Plant Effluent Treatment Plant 46 TPD 9 TPD 17 TPD 63 TPD 54 TPD 200 TPD 24 MW M 3 /day M 3 /day Stores 9% Salary Wages 19% Others 14% Raw Material 38% Power & Fuel 20% Energy is the second largest contributor to the cost Energy cost = Rs. 180 Crores

3 SPECIFIC ENERGY CONSUMPTION Specific Thermal Energy Consumption in KJ/Kg of Equivalent Production Specific Electrical Energy Consumption in Kwh/Ton of Equivalent Production (SEC is based on PAT Data equivalent production; baseline of )

4 CENTURY RAYON :: THE BEST AMONG INDIAN COMPANIES Electrical Power Consumption in kwh/million Mtrs of Yarn CR Competitor Competitor Steam Consumption in Kgs/Million Mtrs of Yarn CR Competitor Competitor

5 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

6 ENERGY CONSERVATION MANAGEMENT SYSTEM Quarterly Review Apex Energy committee Chaired by Business Head Monthly Review Energy Team Rayon EM-01, EA-03 Energy Team TC & CSY EM-02 Energy Team Chemical EM-01 Energy Team Auxiliary EM-01 Energy Team BH-PH EM-02, EA-03 Fortnightly Review Quality Circle (Rayon) Quality Circle (T/C & CSY) Quality Circle (Chemical) Quality Circle (Auxiliary) Quality Circle (BH-PH)

7 ENERGY TARGETS : RAISING THE BAR CONTINUOUSLY Savings Purely from Energy Schemes in Rs Crores/Year Target 2.2% Target Achieved

8 Sr. No. 1 2 USE OF NEW TECHNOLOGY & INNOVATIVE APPROACH Project Description Replacement of conventional cooling Towers with Mist cooling tower Power Generation from LP Turbine utilizing pressure reduction across control valve Savings/Year Lakhs units Lakhs Rs. Investme nt Lakhs Rs Mist Condenser for CSY degasser (2Nos) Jet Type Cooling Tower in place of Induced draft Tower Higher head acid cooling PHE pump & sending the cooling water directly to cooling tower Turbine gland recovery pump by direct feeding of steam to feed water tank in Boiler House Reduction in Condensate Pump Loading by feeding Feed Water condensate to direct to Feed water tank & running of small capacity pump in Boiler House

9 MIST COOLING TOWER 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. Investment Power Saving Financial saving Pay Back Period 90 Lakhs Rs. 47 kw x 24 hrs x 350 days = 3.94 lakhs kwh/annum 3.94 x 6.5 Rs/kwh = lakhs Rs/annum 42 Months

10 JET COOLING TOWER 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. Investment Power Saving Financial saving Pay Back Period 4 Lakhs Rs. 2 x 4.5 kw x 24 hrs x 350 days = kwh/annum x 6.5 Rs/kwh = 4.9 Lakhs Rs/annum 10 Months

11 LP TURBINE Total 4 TPH Steam throttling for Boiler Feed water heating. 2.3 kg/cm2 to 0.2 kg/cm2 for 35 o C to 80 o C and 2.3 kg/cm2 to 0.25 kg/cm2 for 80 o C to 105 o C 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. Investment Power Generation Financial saving Pay Back Period 38 Lakhs Rs Kwh in year x 6.5 Rs/kwh = Lakhs Rs/annum 15 Months

12 ENCON PROJECTS IN PREVIOUS YEARS Projects Undertaken Investment (in Rs. Lakhs) Savings (in Rs. Lakhs)

13 ENCON PROJECTS IN LAST TWO YEARS Total accumulated savings/year 69 Lakhs kwh 52 MT coal 375 Lakhs Rs Total Investment : 589 lacs Rs. Transfor Humidif Cooling mer ication towers Steam Belts Lights Sulphur system Compre ssors VFDs Piping system Motors Pumps Fans Electrol yser Savings in Rs. Lakhs/yr

14 ENCON PROJECTS WITH NIL INVESTMENT (LAST 3 YEARS) Sr. No. ENCON PROJECTS Lakhs Units Savings (Rs.Lakhs) 1 Optimization of Air washer & Exh. Fan power consumption Reduction in water lifting due to arrest of leakages and old-line replacement Optimization of HF frequency on high denier & Color Spinning m/cs Segregation of high wattage pot motors Optimization of no. of circulation fan running in AT Dryer Reduction in unloading time of Air Compressor by decreasing speed Energy saving by reduction in DG set Lube oil pump running hrs Reduction in flash steam loss & Desuper heating water pumping power in Boiler House 5 MT Coal 0.32

15 REAL TIME ENERGY MONITORING Power Consumption Steam consumption

16 PERFORM, ACHIEVE & TRADE (PAT) CYCLE -1 Compliance Assessment Year : Ministry of Power (Govt. of India) PAT CYCLE -1 ENERGY REDUCTION TARGET RECOMMENDATION 598 MTOE ISSUANCE OF ESCerts By Ministry of Power PAT CYCLE -2 SEC REDUCTION TARGET TO (6%) SEC for year (w.r.t base year ) 1.78 (3.22%)

17 LIST OF ENERGY AUDITS Name of the Agency Area Period 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.

18 INVOLVEMENT OF ALL RED TAG Plant Identification of Energy Loss during Energy Week No. of Red Tags Identified TC & CSY Rayon Chemical Auxiliary Total

19 USE OF RENEWABLE ENERGY Wind ventilators on roofs Solar street light Solar heater for hot water Solar Day lighting System Total savings realised: Rs. 30 lakhs per annum

20 IMPROVED MAINTENANCE HELPING THE CAUSE Laser Alignment Thermography Vibration analysis No. of breakdowns / Year % Reduction CSY plant % PSY plant % Electrical %

21 UTILIZATION OF WASTE Industrial Waste used as Fuel (MT/Yr) Recyling of Canteen Waste Currently about 0.5% of our total coal energy requirement is being met through fuel from waste Food Waste Convertor Kg of Canteen food waste produce 60 Kg of Manure per day.

22 ENERGY CONSERVATION WEEK CELEBRATION 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.

23 REDUCTION IN CO2 EMISSION THROUGH ENCON PROJECTS Plantation of Trees in Century Rayon Recycling of Treated ETP Water (M 3 / day) Uses Lime batch preparation CS2 deashing Fly Ash quenching Degasser Vacuum System Gardening Dust suppression

24 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 Total estimated investment : Rs. 138 Lakhs : Rs 205 Lakhs

25 Sr. No. SOME ENCON PROJECTS ALREADY PLANNED FOR Project Description Savings/Year Lakhs units Lakhs Rs. Investme nt Lakhs Rs. 1 Increase the LP turbine load factor from 77% to 90% Nil 2 Energy efficient pumps Mist Condenser for CSY Degassers (2Nos) LED lights Change of V belts to flat belts VFDs on pumps Modified rewinding for CSY m/c old Rolls motors Automation of turbine back pressure control. 218 MT AFBC Boiler CBD automation 150 MT Using HP steam from Acid plant for Boiler feed water heating 907MT Rescheduling of DG set trial from 8 days to 15 days. 4.8 KL HSD 2.69 Nil

26 No. Details of Awards Year Organization 1 CII Award for Excellent Energy efficient Unit 2015 CII ICC Award for Excellence in Energy conservation & Management State Level Award in Excellence in Energy Conservation & Management 1st Prize in Textile Sector National Award for Energy Efficient Unit in Energy Conservation Winner of Platinum Award at 14th Annual Greentech Safety Award ICC Every year since 2006 till CII Green Tech Environment Award Water resources management in chemical industry AWARDS 2005 Maharashtra Energy Development Agency (MEDA) 14th Annual Greentech Safety Award th Green Tech Environment Award Indian Chemical Manufacturers Association, Mumbai.