18th national award for excellence in energy management...

Presented By :

Harvinder Rathee (Head – Engineering)

Kushal Trivedi (Sr. Manager – Engineering)

18th National Award for Excellence in Energy Management 2017: 30, 31 August & 1 September

What Arvind ?1

Textile – Process Flow

2

Methodology toward Energy Conservation

3

Projects

4

Case studies

10

GHG Reduction

6

Certifications and Award

7

8 Renewable Energy

9

Contents

2020 Goals

Benchmarking5

Who we are?

$1.3Bn Indian conglomerate

Interests in Textiles, Retail, Advanced materials,

Environmental solutions

and Real estate

Founded in 1931 during Swadeshi

movement

Among Global top 5 organized Denim

manufactures and pioneers of Denim in India

Every 2 secondsan Arvind manged brand apparel is sold in India

Our fabric can go around the

earth

~6 times

Own or manage

30 brands (International and domestic) in India

1 lac acres of farmland under organic cultivation

22 global patents

for environmental solutions

Largest Fire Protection

Fabric Producer in India

Arvind’s leading practices to ensure environmental sustainability

Water One of the largest

Zero Liquid Discharge plant in

Asia at Gandhinagar

Use of Sewage water from nearby

communities as process water

Energy

Chemicals

100% process water from

recycled water

India’s most energy efficient textile unit, awarded three years in a row

One of the largest solar roof-top plant in Gujarat

Specific energy consumption

reduced by 20% over last four years

Robust quality check established

for incoming chemicals

In house state of the art IQC

lab

Globally first textile mill to sign a

pact towards zero discharge of hazardous

chemicals

ISO 14001 SA 8000 ISO 9001 ISO 50001 BS OHSAS 18001

Certifications

TopRank

NECA

2014 2015

2016MOST INNOVATIVE ENVIRONMENTAL PROJECT

Highest number of ECerts in

Textiles Sector – PAT 1

Recognitions

A : Organized National Level Workshop in Best practices in Energy Efficiency in Textile Sector ; BEE , State Designated Agency (GEDA) and Industries brought at same platform; 42 Industries from all over India Participated

B : 5 days Internal Capacity Building Program Organized at our campus on Energy Efficiency

Knowledge Exchange Workshop

A B

Raw Material

Spinning

Yarn Dyeing

Weaving /Knitting

Processing Finishing

Inspection

Textile – Process Flow

Continuous & Proactive Efforts

Internal Audit Team formation for Energy

Management

Assistance from External Team

– EESL

– TERI

– Thermal audit from Expert

Strong Management Will & support

Methodology

Energy Committee –Chaired by Head

(Engineering )

Energy Team -Shirting

Energy Team Bottom weight

Energy Team -Knit

Ene

rgy aud

it Te

am

Energy Conservation Organogram

Methodology toward Energy Conservation

71406659

62625626

2013 - 14 2014 - 15 2015 - 16 2016 - 17

Electrical Energy (KWHr/Tonn)

Specific energy consumption – Internal bench marking

75210 7487566627

59686

2013 - 14 2014 - 15 2015 - 16 2016 - 17

Thermal Energy (KJ/Kg)

21 % reduction in four years

Benchmarking for Year 2017-

18

No. of Projects : 31

Total Amount Invested : Rs. 196 Million

Cost Saving Achieved : Rs. 344 Million

Reduction in GHG emissions : 68756 Tons of CO2

Thermal Energy Saved : 18760 Tons of coal

Electrical Energy Saved : 263.7 Lacs kWh

Encon Projects Implemented in the years 2014-15 , 2015-16 & 2016-17

S.

No.Title of Project

Annual

Savings,

(Rs. million)

Investmen

t

(Rs

million)

1 VFDs in Auto Coner Machines 2.0 1.3

2Installed of VFD with Pressure Transducer for 28 nos. Re-

winding Machines & blow room Waste collection system 10.1 5.4

3Installed of VFD on the following Blowers in Pressure

Dryer of Dyeing Machine4.3 1.4

4 Replaced of the existing Pumps by more efficient Pumps 3.3 3.1

5 Installed of VFD on Feed water pumps in ETP 1.4 0.4

6Eliminated of Cooling Tower & pumping by installing HR

PHE in Gas engine 3.0 0.0

7Replaced of old Screw air compressors with Energy

efficient centrifugal air compressor 37.1 20.7

8Replaced of 6 nos. pump set with 2 nos. of Energy

Efficient pump set in FFP area Central ETP2.0 1.6

9Installed O2 sensor & Insulation improvement in steam

boilers16.1 4.2

10 Installed of two PHE in 4.3 MWM & 4 MWM Gas Engine 17.1 6.8

Total 96.4 44.9

Projects Year 2014 - 15

Projects Year 2015 – 16

S.

No.Title of Project

Annual

Savings,

(Rs.

million)

Investment

(Rs. million)

1Replaced of 36 Watt TFL by 18 Watt LED lamps in Loom shed,

spinning & Ware house shed 24.3 19.5

2Optimized Compressed air System i.e. reduction in pressure drop &

increase Pipe Size with close loop for entire generation & User End 40.0 7.5

3

Replaced of old air dryers with High size new Refrigerant Air dryer

(Large size SS Pre cooler) to avoid line loss & replaced Demister

pad of old ref. dryer with New SS Mess

18.2 6.4

4 Replaced of Raw water pump with right capacity & Head EE pumps 5.9 5.1

5Replaced of 6 nos. of Cooling Water Pumps & Process Water

Pumps with 2 nos. of right Size EE pumps in Shirting Pump House6.0 3.1

6Installed of PNLD in Air compressors & dryers drain & drain water

Diverted to Cooling tower make up5.7 1.3

7Installed of day light sheet/ Translucent Sheet in Bottom & Knit

Process House 0.7 1.2

8 Insulation improved in 20 & 30 TPH boilers 1.2 0.5

9 Installed of Economizer in 15 & 8 TPH boiler 21.3 6.9

10 Replaced of faulty Steam Trap in Khakhi division 7.6 4.7

11 Heat Recovery from process effluent water @ 85 C Effluent 15.4 9.9

Total 146.4 66.1

Projects Year 2016 – 17

S.

No.Title of Project

Annual

Savings,

(Rs.

million)

Investment

(Rs. million)

1Installed PNLD on Air dryer drains (Qnty -12) & reused Condensed

water to cooling tower makeup 11.7 2.5

2 Installed APH in 20 LkCal & 15 Lkcal Thermic fluid Heater 27.1 50.1

3 Installed natural Draft CT for air Compressors 18.2 6.1

4 Insulation Improvement in steams lines 5.9 5.1

5 Installed PPPU Pumps for Sizing Condensate (80 KL / day) 9.9 6.8

6Installed 450 CFM low pressure 4.5 barg air compressor for

Cleaning application 5.7 1.3

7 Conversion of negative Suction Effluent pumps to positive Suction 0.7 1.2

8Replaced of forced draft cooling tower to natural draft CT in air

compressors 1.2 0.5

9Heat recovery Unit, humidity sensors, fabric moisture sensor in

thermic Fluid stenters Exhaust air 13.5 6.9

10 Installed of 175 kW sloar panels in shirting office area 7.6 4.7

Total 101.5 85.2

Case Study - 1

STENTER Machine

Stenter ( 8 Chamber ) – Cost Analysis

Machine Cost, 16%

Labour Cost, 11%

Maintenance, 5%

Spare Parts, 3%

Electricity , 12%

Heat Energy, 48%

Others , 5%

ENERGY COST = 60 % i.e. Rs 750 / 1000 mtr of fabric

Thermal Energy = 8.00 lacs Kcal/ HrsElectrical Energy = 125 units / hrs

considerationsPower Rate Rs 7.81 / unitCNG Rate Rs 23 / SCM

Fabric Moisture sensor, Exhaust humidity, Fabric temperature sensor

Energy Cost Rs 750 / 1000 mtr

fabric


fabric

Annual saving = Rs 91 LacsInvestment = Rs 20 Lacs

Stenter Exhaust

Temp. 190 deg c / 140 deg C

Exhaust Thermal Energy is still available here

Stenter Exhaust• Heat of Exhaust gases is

used to heat the fresh air• Reduce heat demand by 15

to 20 % for finishing• For dry heat setting to 30

to 35 %

Stenter Exhaust

• Energy Saving of up to approx. 30 % with 190 deg C dryer temperature


fabric


fabric

Annual saving = Rs 44 LacsInvestment = Rs 45 Lacs

Case Study - 2

CARDING Machine

Case Study 2 - VFD in Waste Collection

Waste

- 600 Pa

Carding M/C

Waste Collection

SCHEMATIC DIA. OF WASTE COLLECTION SYSTEM


Primary Filter

Secondary filter Exhaust fan

- 600 Pa

- 600 Pa Duct loss

- 50 Pa- 75 Pa

- 300 Pa

-1625 Pa

-150 Pa-250 Pa

- 2100 Pa

-800 Pa

CLEAN CONDITION

(MINIMUM)

CHOCK CONDITION

(MAXIMUM)

Negative Pressure required

by M/C Supplier (-600Pa

Minimum M/C operating

Cond.)

-600Pa -800Pa

Duct Loss -600Pa -600Pa

Primary (Disc) Filter losses -50Pa -150Pa

Secondary(Rotary) Filter

Losses

-75Pa -250Pa

Exhaust Losses -300Pa -300Pa

TOTAL -1625Pa -2100Pa

-2250(Considered for final design including unforeseen losses; Air & Duct losses)


SCHEMATIC DIA. OF WASTE COLLECTION SYSTEM


Primary Filter

Secondary filter Exhaust fan

Pressure Transmitter

VFD

Project Duration :2016-17Annual Electrical Saving :3.45 Lakhs kWhProject Cost :Rs. 1.5 millionAnnual Saving :Rs. 2.7 million


Case Study - 3

Compressor – Moisture drain

Case Study 3 – PNLD in compressed air system &condensate make up to cooling tower

Manually Drain (Air + Water)

Air In @ 0 Barg Air Out @ 7 Barg Dry Air Out @ 6.5 Barg

Before

Compressed Air System (46,000 CFM network) All Compressors drain provided with needle ( notch) valves All Dryers’ drain provided with mechanical bucket type drain Problems with above system Lot of Air Loss in Air compressor drain even needle valves fully closed Dryer drain found frequently choked & stopped. Damaged pneumatic tools when any dryer drain chocked, line flushing require to remove moisture from lines, lot of

compressed air loss Header pressure was not maintained so, start additional compressors to meet

requirement

Manually Drain (Air + Water)

Air In @ 0 Barg Air Out @ 7 Barg Dry Air Out @ 6.7 Barg

After

Tangible benefit : Air Pressure Increased – By avoiding air Drain loss Quantity of make up water Reduced Inlet water temperature of air compressor reduced, Performance increased Intangible benefit : Better housekeeping as less leakages and oil spillages

Cooling Tower Make Up Tank


Project Duration :2016-17Annual Electrical Saving :15.3 Lakhs kWhWater saving :Avg. 0.8 KL per

day in Monsoon Project Cost :Rs. 2.50 millionAnnual Saving :Rs. 11.70 million


Installed Day Light sheets at Process Shed

Turbo ventilator to exhaust hot Air form Process Shed

200kW X 14 Nos. Wind mill @

Costal Area of Saurastra, Gujarat

Renewable Energy Front – 12 % Renewable Energy

GHG Reduction

11

11.5

12

12.5

13

13.5

14

2013-14 2014-15 2015-16 2016-17

13.7 13.6

13

12.1

Gate To Gate GHG/TON

- 11 %

2020 Goals

EMS

Energy & GHG

Water Use

Waste water / Effluent

Air Emission

Waste management

Chemical management

Sustainable RM

“ Improve, Measure & Report ”

“ To reduce specific energy consumption by 15% ”

“ To become water positive

“ Improving the quality of waste water/ effluent ”

“ To reduce overall Emissions by 10% ”

“ Zero Hazardous chemicals, turning Green , ZDHC”

“ To increase the share of sustainable raw material to 40% ”

Focus Areas

“ To reduce ETP sludge and improve in-houserecycling of waste”

Draft Future Strategy Planning

Thank You

18th national award for excellence in energy management...

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