creating sustainable livelihoods and a positive...
TRANSCRIPT
ITC LIMITED, AGRI BUSINESS DIVISION – ILTD
KGLT, MYSURU
30th, 31st Aug 2017Hyderabad
18TH NATIONAL AWARD FOR EXCELLENCE IN ENEGY MANAGEMENT 2017
Creating Sustainable livelihoods
and
a positive environmental footprint
ITC: Putting India First
Agri Business Division
ITC's Agri Business Division is the country's second largest exporter of Agri-products.
• Grains
• Marine Products
• Processed Fruits
• Coffee
Spices:
• ITC Spices Business, is one of India's leading producers and exporters of
Backward Integrated Food Safe Spices.
Leaf Tobacco:
• Largest Buyer, Processor & Exporter of Leaf Tobaccos in India
• Serving customers over 50 countries & 70 destinations
• GLTs @ Strategic Locations – Anaparti, Chirala & Mysore
Karnataka Green Leaf Threshing Plant [ KGLT]
5
KGLT is the only Green Leaf Threshing Unit in Karnataka
Green Field Project commissioned – 2011
Commercial Production – 2012
Spread across: 79.6 Acres
Green Cover: 28.7 Acres (36%)
Green Leaf Threshing- Unit Operations
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Tobacco processing is done for following value addition.
Separation of Stem and lamina.
Improve the Shelf life of the product from 2 Months to 3 Years.
Segregate Non Tobacco Related Matter to ensure clean product.
Energy Conservation Projects – Journey So Far (Cumulative)…
2016-17
Energy Saving– 1308 GJ
Right Sizing of Critical drives –22811 kWH
Improve power factor to 0.99 –9100 kWH
Process modification +
Cylinder Automation
28387 kWH
2014-15
Energy Saving– 744 GJ
VFD Installation in Boiler FD Fan– 88206 kWH
Six-Sigma project on Energy Reduction in KGLT – 74449 kWH
Optimization of Compressed Air Network
– 43920 kWH
2015-16
Energy Saving– 1091 GJ
Tobacco Dust as Green Fuel in Boiler – 441 kWH
Improve Evap Ratio in Boiler from 3.65 T/T to 3.83 T/T
Boiler Feed pump right sizing+ Other Improvement Projects–
95859 kWH
Energy Conservation - Road map
2014-15
2016-17
2015-16
2017-18
2018-20
• Compressed Air Network optimization • LED Lighting – Phase 1 –Under Progress
• LED Lighting – Phase 2• Conserve Energy by Process improvement Initiatives• Encon through Idea Generation• Energy Efficient Drives
3.5%
13.8%
18.8 %
23 %
27%
Reference year 2013-14
523 582 (-1%)
474 (10%)451 (14%)
2013-14 2014-15 2015-16 2016-17
Net Thermal Energy Consumption (GJ /Day)
Specific Energy Consumption -Trend
SEC is high in 2014-15 due to
• New Product Development trials to meet customer’s requirement
• Variation in Leaf Characteristics- Inherent variability in Agri- Products
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113 (5%)
108 (9%)
102 (14%)
2013-14 2014-15 2015-16 2016-17
Continual improvement in Energy Efficiency forms a critical part of the performance matrix
Net Electrical Energy Consumption( GJ / day)
Specific Energy Consumption -Trend
Global Benchmark – Electrical Energy
• Energy Efficiency built into the design and layout
• Contemporary Plant layout and process flow to reduce energy footprint by minimize losses
• Continual improvement in the organizational DNA
244236
230220 221
213
186
Mexico Indonesia Pakistan Brazil AGLT CGLT KGLT
SEC (kWH/ToT) (Elec)
We are the “GLOBAL BENCHMARK”
Global Benchmark – Thermal Energy
Thermal Energy (Steam) requirementdependent on Leaf Characteristics and variesacross the growing region
161 160
117
AGLT CGLT KGLT
SSC (kG/ToT) (Coal)
Performance benchmarked against the factories processing similar leaf with similar characteristics
KGLT is the National Benchmark for Specific Energy- Thermal
Global Benchmark
ITC- KGLT is the most energy efficient unit in its line of business
So, how do we fair against the national benchmark of Overall Energy Efficiency??
3.63.5
3.23.1
2.9
Alliance Deccan AGLT CGLT KGLT
Overall SEC (GJ/ToT)
Renewable Energy Footprint (%)
72.3
94.1 94.8 98.3
2013-14 2014-15 2015-16 2016-17
Captive Wind Turbines-Karnataka
Renewable Energy Footprint %
98.3% of our Electricity requirement is met through Wind Energy
The Captive Wind Farm generates three times the energy requirement. Surplus Energy is wheeled to
other Units and Businesses
10470 10230
7768
3973
2013-14 2014-15 2015-16 2016-17
1544
371275
53
2013-14 2014-15 2015-16 2016-17
439
58 5827
2013-14 2014-15 2015-16 2016-17
Use of Tobacco Dust as fuel in Boiler
Improvement of Evap Ratio in Boiler
98.3% of Wind Power Utilization
Improved Grid Availability
Lower Operation of DG Sets
Overall SEC (GJ/ToT)
Scope2 (CO2e MT)
Scope3 (CO2e MT)
GHG Inventorizations
0.270.26
0.21
CGLT AGLT KGLT
ITC-KGLT is the national benchmark across other Green Leaf Processing Units
Scope1 (CO2e MT)
0.3
0.240.22
0.21
2013-14 2014-15 2015-16 2016-17
12453
10659
8101
4053
2013-14 2014-15 2015-16 2016-17
GHG Inventorizations
GHG Emissions (CO2e MT)GHG Emissions Reductions:
Wind Energy Utilization of upto 98.7%
Dedicated 66kV Line, so that Generation from DG is reduced
Use of Tobacco dust in Boiler
Energy Audits
LED Lightings
Energy Efficient Drives
GHG Emissions (CO2e ToT)
Water Conservation
Reuse of Back wash water of Pressure sand filter and
Activated Sand filter
Re use of RO reject water to plate wash in canteen for
reduce of fresh water usage.
Reuse of ETP treated water to Ash wetting and coal wetting for
reduce of fresh water usage .
Comprehensive Rain Water Harvesting system
Treated water for Gardening & Green Belt
ETP treated water for Ash & Coal Wetting
1.15
0.91
0.77
2014-15 2015-16 2016-17
Specific Water Consumption (KL/ToT) Water Conservation Initiatives
Innovation @ ITC
Business Need
I4iInnovation to Implementation to Imitation to Integration
Approach Organizational Benefits
Implementation
Our Unit actively participated in such event involving all employees and participated in Divisional level competition.
Brief Statistical note on I4i competition:
100% ParticipationNo. of Teams formed: 4No. of Ideas Generated: 36No. of Ideas Implemented: 32
ITC organizes Organization level competition on Innovation projects across all its branches & awards the best innovation projects based on above said criteria.
Tobacco Dust as Green Fuel in Boiler
Innovation Project - 1 (Tobacco Dust as Green Fuel in Boiler)
Business Need
Innovation Component
SustainabilityCost Optimization
Use of available Tobacco dust as Green Fuel in Boiler
Project Outcome
Organization Benefit
Investment – Rs. 35 LakhsSaving – Rs. 7 Lakhs
Lower Operational CostWealth out of Waste
Steam
Condensate line
Steam line from boiler
Condensate line
Scrap dryer
Condensate line from LRD, TIPS & BUTTS conditioning cylinder
Tobacco out Avg.50’CTobacco in
shell
Innovation Project - 2 (Utilization of Flash Steam in Dryer)
Business Need
Innovation Component
High Operation CostUse of Flash steam in Drying
Operation
Project Outcome
Organization Benefit
Investment – Rs. 0.05 Lakhs Saving – Rs. 8 Lakhs
Lower Operational CostLesser CO2 emission to
environment
Innovation Project - 3 (Tip Line Modification)
Layout Modification:
Business Need
Innovation Component
High Operating Cost [Energy Cost] Layout Optimization
Project Outcome
Organization Benefit
Investment – Rs. 0.2 Lakhs Saving – Rs. 1.05 Lakhs
Lesser Energy CostLower R&M Cost
First amongst Any other Tobacco Processing Industries
Tobacco as fuel in Boiler
Design- Co-firing System
Proportionate ratio of mix
Flue Gas
No changes in Emissions
CFE Approved by KSPCB
Replication of Concept across other GLT’s
Tobacco Dust as Green Fuel in Boiler
Utilization of Waste for replacing of Conventional Energy
Boiler
Screw conveyor
SurgeHopper
Under Bed Feeding
MotorisedGate
DRF Unit
Airlock150 Kg/Hr
LevelController
Pneumatic Vibration
pads
Dust Bagging and Truck Loading
Dust from Threshing plant
DRF Unit
Tobacco Dust as Green Fuel in Boiler
Utilization of Waste for replacing of Conventional Energy
Impact of the Project:
• Utilization of Green Fuel & Reduction in Scope-1 Emissions
• Reduction in average coal consumption by 0.7 tons/day
• Reduction in waste disposal by 2.5 tons/day
• Net Savings of 4.3 Lakhs/annum
Tobacco Dust Impact 2015-16 2016-17 UOMGCV of Coal Average of Dom:Imp 4648.3 5273.4 Kcal
Coal saved due to usage of Tobacco Dust 81.7 45.18 Tons
Thermal Energy saved due to utilization of dust
379684.8 238276.8 Kcal/yr
Savings 4.3 2.4 Lakhs
Tobacco Dust as Green Fuel in Boiler
Utilization of Waste for replacing of Conventional Energy
Unit - Energy Management Organogram & % investment on Turnover
% Investment
o Unit Turn over (16-17): ` 3343 Million
o investment : ` 20 Lakhs
o % investment: 0.06%
BEE Certified:
Energy Manager – 1
Energy Manager * - 3 (Applied)
Energy Monitoring Format
KGLT Daily Energy Dashboard
o A dashboard with details of MCC wise consumption isanalyzed daily
o Also Specific Energy is monitored
o Process & Utility units are monitored.
o Dashboard is mailed daily to all the stake holders
29000
29500
30000
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31000
31500
32000
32500
33000
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Monthly Energy Dashboard
o Divisional level dashboard datareview on monthly basis
o All GLTS energy performance will becompiled and reviewed for both forprocessing & Non-Processing days
Quarterly Energy Dashboard
o Energy consumption & generationdata is monitored on Quarterly basisat Corporate level
o All energy consumption data isuploaded in a portal and analyzed
Annual Energy Review Mechanism
o Full year energy performance will bepresented to DMCmembers.
o In the same forum, Target for nextyear will be presented.
KGLT Energy Processing Days Lac Units 1.4031 - - -
KGLT Energy Non Processing Days Lac Units 1.0233 1.0359 0.8622 0.6924
KGLT Energy Additions Lac KWH Processing - - - -
KGLT Energy Reduction Lac KWH other than Ene Con Processing- - - -
KGLT Water Consumption KL Actual Processing 0 -
KGLT Water Consumption KL Actual Non Processing3630 423
Karnataka Net Gen Actual Lac units Month 7.07 10.48 23.83 34.32
Karnataka Machine Uptime Actual 80.0% 97.3% 99.4% 99.15%
Karnataka Grid Uptime Actual 98.1% 77.3% 99.7% 99.97%
Karnataka Banked Energy Lac units Cum 0.04 7.62 19.74 41.74
Karnataka Other ITC Units 4.70 1.9 10.85 11.59
Karnataka Third party sale Lac Units Month 0.00 0.00 0.00 0.00
Karnataka Site Visits Plan 0 0.00 1.00 0.00
Karnataka Site Visits Actual 0 1.00 1.00 0.00
Karnataka Submission of Scheduling and forecasting infoNo No Yes Yes
Karnataka Wind Power Available days AGLT
Karnataka Wind Power KGLT Lac units Month 2.33 1.01 0.85 0.69
Karnataka Grid - IEX/APGPCL KGLT Lac Units month 0.11 0.03 0.00 0.00
Karnataka DG KGLT Lac Units Month 0.06 0.02 0.01 0.00
Water conservation
Karnataka Wind
Turbine
Energy
Conservation
Renewable energy consumption (generated by ITC)
Electricity from windValue Unit Comment
1st quarter 460.5 MWh Less processing days
2nd quarter 275 MWh Plant was under shut down
3rd quarter 1659 MWh Processing Re-started
4th quarter 2196 MWh Full fledged Processing
Energy Conservation – Awareness & Training Program
Unit organizes an structured Energy week Competition in order to create awareness on energy and its importance among all the employees.
Brief Statistical note about Energy Week competition:
100% ParticipationNo. of Teams formed: 25No. of Ideas Generated: 108No. of Ideas evaluated in first phase of evaluation: 37No. of Ideas awarded after final phase of evaluation: 04
KGLT ENERGY WEEK - Campaign & Awareness Program
Greening of Supply Chain
Greening of Supply Chain
Barn Efficiency Improvement Initiatives –27% reduction in fuel consumption
Soil Conservation Improvements [ 25000 Ha Soil compaction]
Solar Street Lights in selected Villages - >1000 Nos in 122 Villages , hence reducing 968 MT of CO2e
Water Harvesting Initiatives : To provide water for irrigation of 27420 Ha
Various Initiatives towards Greening at
Farm End
(Incoming Raw Material Leaf Tobacco)
Sustainability- Social Outreach
Unit has successfully planted >1 Lakh Tree Saplings during the year
Awareness training program of importance of environment at surrounding schools
Establishment & Awareness on Composting
Awareness sessions to leading schools across Mysore to promote Kitchen Garden
Awards & Accolades
OHSAS EMSQMS SA 8000 NABL “IGBC GOLD” rating
National Convention on
Quality Concepts – Excellence & Distinguished
Awards
Karnataka State Level Safety Award -
2015
Large Scale Industry category.
2nd Best Project in CII's National
Level Competition
Best Paper Finalist at Engineering
Lean Six Sigma Conference (Institute
of Industrial Engineers (Florida,
USA)).
“Prashamsa SurakshaPuraskara"
Award by National Safety Council, Karnataka Chapter
3rd Best Safe Boiler at State Level
Sustainable Tobacco Program (STP): Apex level certification for Global Tobacco Producers
KGLT achieved 92% and is the highest scorer among all GLTs across the globe.
Global Recognition
62%
89% 91% 92%
Alliance AGLT CGLT KGLT
STP Audit Score - GLTsGovernance
Facility
People
Environment
Most Energy Efficient Unit across the globe [ GJ/T]
ITC-KGLT-MYSORE
Benchmarked performance on Specific Water Consumption
GHG Inventorization- National Benchmark across other Green Leaf Processing Units
Renewable Energy Footprint at 98.3% [ Electrical Energy]
Our Motto “ Putting INDIA First”
Thank You
Saving of One Unit of Energy is equal to Generation of Two units of Energy