UNILEVER INDIA EXPORTS LIMITED INSTANT TEA FACTORY ETAH ANJAN MAJI FACTORY MANAGER BALAKRISHAN ENGG MANAGER. Confederation of Indian Industry

Transcription

1 UNILEVER INDIA EXPORTS LIMITED INSTANT TEA FACTORY ETAH ANJAN MAJI FACTORY MANAGER BALAKRISHAN ENGG MANAGER

2 Brief introduction on Unit Location Year of establishment : 1996 Built in capacity Product Variants Key Technology : Etah, India (UP) : 1100 Tons : Instant tea powder for Lipton Ice tea premix : CWS (Cold water soluble) Green Tea, Evian Brite and Saint Brite HWS (Hot water soluble) HIT : 3 stage extraction process with spray dryer : SCADA application for Process automation& control One of the 3 Unilever sites of Instant Tea across the world contributing to 27% of Unilever s tea powder supply in 2017

3 Brief introduction Instant Tea Process Tea Waste Indirect Steam Water 3 Stage Extraction Tea spent Tea Liquor COLD LIQUOR INSOLUBLES SEPARATION TEA SPENT TROLLEY HOT LIQUOR INSOLUBLES SEPARATION 1 st EVAPORATOR GLYCOL PHE For cooling SPRAY DRYER PUMP PACKING 2nd EVAPORATOR

4 Sp. Power Consumption Trend Specific Energy Cons.KWH/Ton Energy Efficient Motor (IE3) & Pump installation Pump capacity optimization based on requirement Replacement with Planetary gearbox VFD for compressor & 11KVA Express feeder ATB in Chiller, Combined Cooling tower and Diffused Aerator Productivity improvement through yield increase in process

5 Sp. Thermal Energy Consumption trend Specific Thermal Energy (KJ/Kgs) Evaporation ratio improvement in Boiler Auto Steam cutoff valves in all process equipment In Boiler O2 Analyzer, Sonic soot blower, Auto blow down & 3D Element controller Servo Based Burner for HAG HAG Flue gas Heat recovery

6 Bench Mark with Ceytea plant Power (Sri Lanka) Plant Location Built in capacity Product Variants Key Technology Spec. Power per Ton Spec. Steam per Ton : Ceytea Instant Tea Plant Sri Lanka : Sri Lanka : 3500 Tons : Instant tea powder for Lipton Ice tea premix : CWS (Cold water soluble)-saint Brite and Dark : 3 stage extraction process with spray dryer : SCADA application for Process automation& control : 2076 KW/Ton : tons of steam/ton

7 Spec. Power - Gap & Road Map Electrical Energy Bench Mark Etah vs Ceytea Etah KWH/Ton CEYTEA KWH/Ton CEYTEA KWH/Ton Etah KWH/Ton Spec. Power Reduction water Map KWH/Ton

8 Spec. Thermal Energy - Gap & Road Map Thermal Energy Bench Mark Etah vs Ceytea Etah Tons of steam/ton CEYTEA Ton of steam/ton CEYTEA Ton of steam/ton Etah Tons of steam/ton Spec.Steam Reduction water flow chart Tons/Ton

9 Energy Saving projects implemented in FY Title of the project ele cost (Rs Mn) thermal cost (Rs Mn) Total Investme nt made Payback in Months Boiler Evaporation ratio improvement SABD Project ( Planetary gearbox, VFD for air compressor & Cooling tower, DE system, auto steam cutoff valve) 11KVA Express Feeder

10 Energy Saving projects implemented in FY Title of the project ele cost (Rs Mn) thermal cost (Rs Mn) Total Investme nt made Payback in Months Energy Efficient Motor in Plant Energy Efficient Pumps in plant SABD Projects - Thermal Energy Reduction - Online Flue gas Analyzer and synchronizing with FD & PA fan & Fuel feeder, Steam optimization throught the plant by installaling Flow meter, Traps & Moistire separator in header, D Element controller in Boiler Yield Improvement - Back pressure plate, Tea water Ratio, Online flushing of screw, MF meter

11 Energy Saving projects implemented in FY Title of the project Pump Optimization to reduce Power ele cost (Rs Mn) thermal cost (Rs Mn) Total Investme nt made Payback in Months Boiler Efficiency Improvement Combined Cooling tower SABD projects - Servo based Burner, Steam control valves, ATB system in Chiller etc HAG Flue Gas heat recovery system Diffused Aerator in ETP

12 Energy Savings Projects IMPROVED THE POWER FACTOR FROM 0.97 TO.984 OPTIMIZED THE UTILITY LOAD BY RUNNING OPTIMIZED CAPACITY EQUIPMENT S, CHILLER, AIR COMPRESSOR INSTALLED PREMIUM LEVEL EFFICIENCY MOTORS

13 Energy Savings Projects 3D ELEMENT Oxygen Analyzer SC Feeder TPH ON/OFF level control gives sudden volumes of sub-cooled water in the boilers steaming capacity, which results in large excursions in the boiler water temperature, drum level and pressure. These excursions reduce boiler steam efficiency by sub-cooling the boiler feed water for the sudden mass/heat upset 110% Excess air % of O2 level 3-4% Combustion efficiency improvement Black smoke reduction Boiler was tunes at 3.3 TPH. Screw feeder and FD fan tuned at 4.2 TPH. Combustion efficiency improvement.

14 Energy Savings Projects FEED WATER TEMP INCREASE TEMPERATURE CONTROL SYSTEM AT APV ABD SYSTEM INSTALLATION Increased feed water temperature up to 96 deg. Automatic temperature control system installation at APV tank. Excess heated water went out. Was maintaining the TDS 2500 PPM Maintain cosinsistly 11 bar pressure by maint 3500 TDS.

15 Energy Savings Projects Pump Optimization Rs 15 Lakhs ized started from Mar 2017 HAG Flue Gas Heat recovery system to preheat Spray drier Supply Air Rs 8 Lakhs ized started from Mar 2018 Sonic Soot Blower & Steam Fuel ratio improvement projects in Boiler Rs 15 Lakhs ized started from Mar 2018

16 Energy Savings Projects Induced Cooling tower for Process Evaporation system which will improve plant Efficiency through Better Heat Transfer. ized 10Lakhs started from April 2018 Automatic Tube Brushing system for Chiller - Rs 6 Lakhs ized started from Mar 2018 Servo based air & fuel control HSD burner for Spray Drier Rs 7 Lakhs ized started from Mar 2018

17 Energy Savings Projects Temperature Based steam control valve for Soft water Preheating in Extraction Process. 10L ized Savings started from Mar 2018 Temperature Based steam control valve for Leaf Heater (3Nos) operation in Extraction Process. 6L ized Savings started from Mar 2018 Solar street lights. 7lights are installed across the plant.

18 Innovative Projects implemented Name of the Project Flue Gas Heat recovery from Indirect Fired HAG Brief description on why innovative Indirect Fired HAG flue gas was venting to atmosphere which was have with 300 deg C and flow of 750m3/hour. we have taken a call to utilize that heat to preheat the supply air to spray drier before heating diesel fired burner Trigger for implementing the project To reduce HSD consumption in Diesel burner and utilize the flue gas heat which was venting to atmosphere Year Re of plic Imple abil menta ity tion Savings ( Rs. In lakhs) Invest ment ( Rs. In lakhs YES

19 Innovative Projects implemented Name of the Project Combined Cooling tower Brief description on why innovative Trigger for implementing the project It was a practice to use two different cooling tower for process. and we were consuming energy Huge power for fans as well pumps in consumption by both the cooling tower. running both the we have taken a call to go cooling tower for for single cooling tower to process use for entire process and requirement made with double fan which can be stopped any one during winter season Year Re of plic Imple abil menta ity tion Savings ( Rs. In lakhs) Invest ment ( Rs. In lakhs YES

20 Innovative Projects implemented Name of the Project ATB system in Chiller Brief description on why innovative Auto Tube brushing system in Chiller for descaling the tubes in fixed intervals which will increase the heat transfer and give better chilling at low power generation Trigger for implementing the project We observed that huge scaling in the tubes during annual cleaning periods. we found that it was impacting the heat transfer and consuming huge power. we have taken a call to install auto tube cleaning system Year Re of plic Imple abil menta ity tion Savings ( Rs. In lakhs) Invest ment ( Rs. In lakhs YES

21 Innovative Projects 40KL HSD Equal to 10 Lakhs /annu m

22 Innovative Projects Induced Cooling tower for Process Evaporation system which will improve plant Efficiency through Better Heat Transfer. ized 11Lakhs started from April 2018 Automatic Tube Brushing system for Chiller - Rs 8 Lakhs ized started from Mar 2018

23 tilisation of Renewable energy sources & Future Plan 81% of overall Energy is generating from Renewable Energy Biomass Boiler Fuel is Mixture of Rice Husk & Tea Waste Sl.N o Year Project Proposed Savings Electrical (KWH) Thermal Energy Savings (HSD in KL) Roof Top Solar panel installation Biofuel in place of Fossil fuel (Diesel) 240 Usage of BMB Steam to Eliminate Electrical heater 66000

24 Utilisation of waste material as fuel TEA WASTE in MT (Biomass Fuel) % of Tea Waste used in Boiler as Biomass fuel which is generated from the Instant Tea Process. We are installing In-House Tea spent drier to maximize the Tea waste usage upto 55%

25 GHG disclosure Tons of CO2 from Power & HSD CO2 generation from Electricity and HSD. And 184kgs of R134 refrigerant in the site.

26 Green Supply Chain Green Purchase Policy 100% RA Certified Raw Material used for Instant Tea Process Unilever Responsible Sourcing Policy Business should be conducted in a manner which embraces Sustainability and reduces Environmental Impact

27 Green Supply Chain Projects & Benefits Title of the project Boiler Evaporation ratio improvement Electric al Savings (KWH) ele cost (Rs Mn) Thermal with units therma l cost (Rs Mn) Total Invest ment made Paybac k in Months Kcal SABD Project KVA Express Feeder 0 0 Energy Efficient Motor in Plant Energy Efficient Pumps in plant SABD Projects D Element controller in Boiler 255 Klof HSD tons of steam 172 tons of fuel

28 Green Supply Chain Projects and Benefits Title of the project Electric al Savings (KWH) ele cost (Rs Mn) Yield Improvement Pump Optimization to reduce Power Boiler Efficiency Improvement Thermal with units 164 tons of Steam therma l cost (Rs Mn) Total Invest ment made Paybac k in Months tons of fuel Combined Cooling tower SABD projects HAG Flue Gas heat recovery system tons of steam 1550 tons of steam Diffused Aerator in ETP Confederation of Indian Industry

29 Green Supply Chain Evaluation Process Evaluation on Energy reduction, Savings & IRR verification and Approval through capex portal Confederation by Central of Indian Industry team

30 Daily performance Monitoring Environment performance Monitoring and reporting system Daily monitoring system for Energy and Efficiency. Daily performance is getting reviewed by Factory Head

31 Capex allocation for Energy saving projects Dedicated Capex is available for Energy and Sustainable projects and it is being allocated centrally from Unilever HO. No limit on Energy capex

32 eam work & Employee Involvement Energy Savings projects are identified through Kaizens and Implemented by Factory Team. Factory team members are trained for Energy reduction activities

33 Encon projects investment % Encon Projects Investment - Year Turnover of the company INR Mn 16.5 Invested in Encon Projects INR Mn Investment 3% on overall Turnover

34 Sustainability Award at NFEST Sustainability Award at NFEST 2018 at its 1st International conference at New Delhi 34

35 Thank you