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Garware Polyester Ltd. Aurangabad 1. Company Profile 2.

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Presentation on theme: "Garware Polyester Ltd. Aurangabad 1. Company Profile 2."— Presentation transcript:

1 Garware Polyester Ltd. Aurangabad 1

2 Company Profile 2

3 Garware Polyester Limited is the pioneer in the field of polyester film. The Company has developed various types of films and is exporting to 57 countries in World. The company has excellent infrastructure and strong commitment to Safety, Quality, Energy Conservation, Environment preservation and R&D. Winner of Highest Export Award-Plex council (Govt. of India, Ministry of Commerce) since last 20 years. Winner of Energy Efficient Unit by CII. Winner of 1 st award in 2009 in Plastic Category on National Level (NECA) Winner of 2 nd award for excellence in Energy Conservation and Management in 5th Maharashtra State Level Award competition in year 2008 in category Other Industries. The company has set up cross functional Energy Conservation Cell, which focuses on energy management and improvement. The company recognizes the importance of energy conservation, not only to improve the bottom line but also to help the environment and society at large for sustainable growth. Unit Profile 3

4 Process Flow Diagram 4

5 5

6 6

7 ENCON 7

8 Garware Polyester Limited plays vital role for producing variety of products with high level of quality standard and prioritizes energy value for the final product. Our mission is : To produce products with minimum use of energy. Use of cleaner technologies wherever possible and ensuring efficient and uninterrupted supply of utilities to plants. This, we plan by following ways. Efficient energy generation, utilization and distribution. Continuous evaluation of performance of plant equipments and processes to achieve most efficient, high standard quality products. Targeting the under-performance equipments and processes for improvement. Monitoring and targeting the specific energy consumption to achieve best possible as compared to past performance. Use of internal and external expertise to achieve targeted performance. Train employees and implement ideas of energy conservation thorough small ENCON teams. M S Adsul Director-Technical Energy Management Policy 8

9 ENCON Team Structure DIRECTOR - TECHNICAL ENGINEERING HEAD DY. GENERAL MANAGER CENTRAL UTILITY ENCON TEAM FILM PLANT ENCON TEAM POLYMERISATION PLANT ENCON TEAM CENTRAL UTILITY ENCON TEAM CHIKALTHANA PLANT 9

10 Energy Monitoring 1.Daily Energy report is generated by Central Utility on daily basis and circulated to all concerned. 2.Monthly Based on daily energy report, monthly energy report is prepared and circulated to all concerned. Comparison & analysis of energy consumption is done with previous months and deviations are studied for reduction in Energy Bills. 3.Yearly Yearly reports generated from data collected as above. Specific energy consumptions are calculated and targets are set for future. Major ENCON projects are listed in annual report. 10

11 ENCON Methodology 1.Identification of high energy consuming equipments/processes through internal & external audits. 2.Elimination of inefficient equipment & substitution with new & efficient technologies. 3.Continuous energy performance monitoring through statistical analysis. 4.Brainstorming in small group activities for innovative ideas. 5.Reduction in Carbon foot print & implementation of green projects. 6.Benchmarking with other competitors. 7.Involvements of employees through suggestion schemes & competitions. 11

12 12

13 ENCON IMPLEMENTED PROJECTS 13

14 ENCON PROJECTS

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16 ENCON PROJECTS Year of Commissionin g of the projects S. No.Project descriptionAchievement of energy savings per year basis Investment incurred on the project (Rs. Lakhs) ElectricityF.OilOthersTotal savings in (Rs. Lakhs) (Lakhs (kWh) (MT) EIL heater efficiency optimization. Central Utility, Waluj Polyplant cutter cooling tower Direct transfer of condensate from Glycol Recovery to De-aerator Stopping of MDO chilled water system and hook up from Central Utility Commissioning of Biomass fired Boiler p.f. incentive at Waluj p.f.incentive at Chikalthana Use of emulsified F.O. for Thermic fluid heater in CHK plant Provision of VFD to TDO oven blower.in CHK plant Secondary hot oil pump impeller trimming in CHK plant Sub Total

17 ENCON PROJECTS Year of Commissio ning of the projects S. No. Project descriptionAchievement of energy savings per year basisInvestment incurred on the project (Rs. Lakhs) ElectricityF.OilOthersTotal savings in (Rs. Lakhs) (Lakhs (kWh) (KL) Thermal Fluid Heater (EIL) efficiency optimization. Central Utility, (Waluj) Waste heat recovery from boiler flue gases.(Waluj) Direct transfer of condensate from Glycol recovery to de- aerator, Waluj Conversion of Aluminum blade to FRP blade for cooling tower fan (Waluj) Provision of booster compressor for instrument air system (Waluj) p.f. Incentive at waluj p.f. Incentive at Chikalthana Commissioning of 110 TR chiller & reducing VAHP load (Waluj) Operation of separate 13TR chiller for Kappa cooler stopped by transferring load to primary chilled water system. (Chikalthana) Pneumatic booster installed & stopped operation of portable compressor. (Chikalthana) Return water pump for twin screw vacuum system operation stopped by using gravity flow system. (Chikalthana) Energy Efficient lighting used in L#2 TDO & slitter area. Total – 45 Nos (Chikalthana) Rotary feeder installed at L#1 instead ventury system. (Chikalthana) Replacement of 125W HPMV lamps by 23W CFL-60 nos. (Waluj) Sub Total

18 ENCON PROJECTS Year of Commission ing of the projects S.NO.Project description Achievement of Annual energy savings in Investm ent incurred on the project Rs. (Lakhs) Electrici ty Fuels* Total savings in (Rs. Lakhs) (Lakhs kWh) Coal (tonnes) F.Oil Gas (lakh Nm 3 ) Total (fuel) in (MTOE) (kL) Optimisation of Cooling tower pumps (at waluj) Optimisation of chilled water pumps. (At waluj) Optimisation of Therminol pumps. (at waluj) Power factor incentive (at waluj) Replacement of Cooling tower fan blades with FRP blades (at waluj) Complete stoppage of FO Boiler (at waluj) Replacement of Condenser water pump by low head. (chikalthana) Provision of Rotary feeder for chips conveying instead of ventury system. (chikalthana) Water Emulsification of furnace oil. (chikalthana) Twin screw return water pump stopped by using gravity flow system. (chikalthana) L#2 AHU No-3 water pump replaced by energy efficient pump. (chikalthana) Power factor incentive (at chikalthana) SUB TOTAL

19 ENCON SUMMARY - LAST 5 YRS YEARNo. of Measures implemente d (i) Investment made (Rs. Lakhs) (ii Savings achieved (Rs. Lakhs / year) (iii) Energy Cost (Rs. Lakhs/ year) (iv) % Savings of Energy Cost (iii /iv x 100)

20 Energy Reduction – Chips Plant 5.61% 6.12% 10.42% 20

21 Energy Reduction – Film Plant 7.5% 0.2% 0.87% 5.46% 1.7% 18.91% 21

22 INNOVATIVE PROJECTS 22

23 ENCON Project : 1 Title : Poly Plant Cutter Cooling Tower Loss no: 15 Background of the project : To reduce chilled water load. Observation made : oChilled water is used for Poly plant cutter for cooling of chips from 280°C to 40°C. oCooling water can also be used for cutter cooling. Technical and Financial Analysis Investment : Rs. 15 Lacs Implemented : Aug st year cost Saving : Rs Lacs Impact of implementation : Reduction in chilled water load by 200 TR/Hr. On annual basis Electricity cons. (Lacs kWh) Energy consumption before : 9.81 Energy consumption after :

24 After Before 24

25 25

26 Process Flow Diagram of Chilled Water System VAHP MACHINE Film Plant Poly Plant Batch Plant Chilled water in Chilled water out Cooling water in Cooling water out Pump Chilled water return from plants 26

27 Single effect Machine Steam consumption single effect machine = 8.1 Kg/TR 27

28 Double Effect Machine CondensorHigh Temp. Generator Over flow pipe Cooling Water Absorber Evaporator Purge Pump Diluted Solution Inter Solution Concentrated LiBr Refrigerant Chilled Water Cooling Water Refrigerant Vapour Steam/ Flue Gases Low temp. generator Steam consumption Double effect machine = 4.1 Kg/TR 28

29 Single Effect Machine Double Effect Machine Steam consumption 8.1 Kg/TR4.1 Kg/TR Cost of Steam Rs. 737 Lacs /Annum373 Lacs /Annum Cost Saving (fluctuates as per FO Price) 364 Lacs / Annum Cost Saving Table 29

30 Machine Photographs Single Effect Machine - Before Double Effect Machine - After 30

31 ENCON Project : 3 Title : Commissioning of Biomass Fired Boiler Loss No- 15 Background of the project : To reduce Furnace oil consumption for Boilers. Observation made : Cost of steam on briquette is almost half that of F.O. Unused IAEC make F.O. fired boiler of 18 MT/Hr capacity is available. Can be used by installing external furnace for biomass firing. Existing underutilized go down can be used for boiler operation and briquette storage. Technical and Financial Analysis : Investment : Rs. 332 Lacs Implemented : Jan Impact of implementation :Reduction in Furnace Oil consumption. Thereby reduction in SO2 by Kg/annum and estimated reduction in CER by per annum. 31

32 Avg. Furnace oil Reduction = 200 MT/M Average Cost of Furnace Oil = Rs./MT Yearly Cost savings (Fluctuate as per Price variation in the Fuel) = 183 Lacs/Year 32

33 33

34 Briquette Fired Boiler 34

35 F.O. Fired BoilerBiomass Fired Boiler after conversion 35

36 36 Before KAIZEN Implementation After KAIZEN Implementation

37 ENCON Project : 4 Title :Optimization of Cooling water system Loss no- 15 Background of the project : To reduce power consumption for Cooling water pumping. Observation made : 1. Cooling water high head and low head requirement areas were identified. 2. It was observed that high head heat exchangers were starving due to low pressure although the flow through pumps was satisfactory. 3. The low head areas were provided with positive isolation wherever possible to reduce the unnecessary power consumption and other heat exchangers were tuned for appropriate diff temp for optimum flow. Technical and Financial Analysis : Investment : 0.5 Lacs Implemented : Dec st year cost Saving : Rs Lacs Impact of implementation : Reduction in power consumption5.04 LkWh per annum 37

38 Sample Calculation Equipment Main process cooling tower pump no 1 DG cooling tower pump no 2 DG cooling tower pump no 3 Main process cooling tower pump no 2 Time KW KVA KVAR PF VOLTS AMPS FREQUENCY Previous condition : Pumps running : PCT pump no.1 and DGCT pump no. 2 & 3 After optimisation : Pumps running : PCT pump no. 2 only For saving we have considered the difference in KW of PCT pump no.1 and 2 KW saved = 246 – 161 = 85 KWH Saving in Rs. = 85 x 24 x 30 x 5. = Rs lacs / Month = Rs Lacs / Annum 38

39 ENCON Project : 5 Title :Optimization of chilled water system Background of the project : To reduce power consumption for Chilled water pumping. Observation made : 1. Chilled water high head and low head requirement areas were identified. 2. It was observed that high head heat exchangers were starving due to low pressure although the flow through pumps was satisfactory. 3. The expansion tank of the system was raised by 8 M of height to improve the suction and discharge head. 4. The low head pumps were put into operation to reduce the power consumption. 5. All heat exchangers were tuned for required chilled water flow. Technical and Financial Analysis : Investment : 0.5 Lacs Implemented : Dec st year cost Saving : Rs Lacs Impact of implementation : Reduction in power consumption LkWh per annum. 39

40 Sample Calculation Chilled water systemPump. no.1pump no.2Totalpump no.3 KW KVA76.33, KVAR29.19, PF0.921, Lag VOLTS407.5, AMPS107.6, FREQUENCY50.09, Previous condition : Pumps running : pump no.1 and 2 After optimisation : Pump running : pump no. 3 only ( Pump replaced ) KW saved = 103 – 39 = 64 KWH Saving in Rs. = 64 x 24 x 30 x 5.85 = Rs lacs / Month = Rs Lacs / Annum (for 300Days/year) 40

41 ENCON Project : 6 Title :Optimization of Hot oil system Background of the project : To reduce power consumption for Hot oil pumping. Observation made : 1. Hot oil high head and low head requirement areas were identified. 2. It was observed that high head heat exchangers were starving due to low pressure although the flow through pumps was satisfactory. 3. Thermic fluid heater coil flow made fine tuning. 4. Before implementation one high head pump was running with full impeller, after that two pumps impeller trimmed & reduced the head & increased the flow. Technical and Financial Analysis : Investment : 0.5 Lacs Implemented : Dec st year cost Saving : Rs Lacs Impact of implementation : Reduction in power consumption Lac kWh/annum 41

42 Sample Calculation Equipment Primary santotherm pump no 1 Primary santotherm pump no 3 Total Primary santotherm pump no 2 Time Hrs KVA KW KVAR PF VOLTS AMPS FREQUENCY Previously condition : Only pump no. 2 in line After optimisation : Pump no. 1 & 3 in line. NET KW SAVED = 235 – 198 = 35 KWH SAVING IN Rs. = 35 x 24 x 30 x 6 = Rs. 1.6 Lacs / Month = Rs Lacs / Annum 42

43 Utilization of High efficiency motor for blower. Blower old motor efficiency was lower i.e 88%. Before implementation blower motor taking Kwh & with high efficiency motor Kwh. Cost Saving : Rs Lacs Impact of implementation : Reduction in power consumption---0.3Lac kWh/annum 43 Efforts on Electrical Energy reduction

44 BALDOR HIGH EFFICIENCY MOTOR TRIAL AND COMPARISION WITH NORMAL MOTOR ENERGY READINGS WITH THE HELP OF ENERGY MGR.(DATE-09/05/07,TIME TRIM SUCTION BLOWER NO - 01TRIM SUCTION BLOWER NO - 03 Make -BBL3Ph I.M. Make -BaldorFR -D160 Type - 1LAJO87- 2FR -160L Kw -18.5V -415 Hz -50Ins cl -B Amps -30RPM M/C No -K ENCL -TEFCHz -50 Duty -S1V -415 Delta Ins. Cl -FSER. F -1 Amps -33Eff. -88% Nima Eff -93%IP -55 Kw -18.5RPM Rating -45 CAMB -CONT P.F Sr No -Z Usable at 208 V Valve position on - 3 MEASUR EAVGRYB RYB V402.3RY-400.7YB BR RY-401.8YB RB-399.4,Ln A , N F Wh Vah VARh PF Sample Calculation

45 Conversion of motor connections from delta to star. Methanol recovery cooling tower fan motor connections changed from delta to star reducing power by 0.16 kwh Calculation: (1.78*24*30*12/100000)*6 Total Cost Saving : Rs Lacs Impact of implementation : Reduction in power consumption Lac kWh/annum 45 Efforts on Electrical Energy reduction

46 DELTA TO STAR CONVERSION SR NO NAME OF EQIPMENT MOTOR RATING ENERGY PARAMETER KW SAVI NG KV AR SA VIN G NET ENER GY SAVIN G PER MONT H NET DEM AND SAVI NG DELT A STAR VAHWH VARH PFAMPFREQVAHWH VARH PF AMP FREQ 1 MEOH RECOVERY COOLING TOWER FAN NO 1 11 KW, 1500 RPM MEOH RECOVERY COOLING TOWER FAN NO 2 11 KW, 1500 RPM DMT SCRUBBER PUMP 3.7KW, 3000 RPM REBOILER PUMP7.5 KW, 3000RP M Sample Calculation

47 DELTA TO STAR CONVERSION SR NO NAME OF EQIPMENTMOTO R RATIN G ENERGY PARAMETER KW SAVI NG KV AR SA VIN G NET ENER GY SAVIN G PER MONT H NET DEM AND SAVI NG DELT A STA R VAHWH VAR H PFAMP FRE Q VAHWH VAR H PFAMP FRE Q 5 SEC EI PUMP5.5 KW, 3000 RPM MEOH FEED PUMP NO CASTING COOLING TOWER FAN 9.3KW, 1500R PM PACKING AHU11KW, 1500 RPM Sample Calculation

48 List of Awards Sr. No. Awards TitleOrganized by YearWinner Category 15 th State Level For Excellence in Energy Conservation and Management MEDA2008Second Award in Other Industries. 2National Energy Conservation Award-2009 BEE2009First Award in Plastic Sector. 3CII – Energy Efficient UnitCII2010Energy Efficient Unit 4CII – National Award for Excellence in Energy Management CII2011Excellent Energy Efficient Unit 56 th State Level For Excellence in Energy Conservation and Management MEDA2012Certificate 67 th State Level For Excellence in Energy Conservation and Management MEDA2012Certificate 48

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