CII National Award for

“Excellence in Energy Management - 2020”

ITC Limited, PSPD, Unit - Kovai

R.Muralidaran, Energy Manager

G.Srikanth, Energy Cell Member

N Gopal Chowdary, Energy Cell Member

ITC Ltd PSPD, Unit : Kovai

MILL INTRODUCTION

ITC Ltd. , PSPD , Unit: Kovai is located 42 km North of Coimbatore, Tamil Nadu

Acquired from BIPCO in March 2004

Manufacture Duplex Board from 100 % recycled fiber

Production capacity of 1,20,000 Tons / year

Employment to 1000+ people

Certifications:

ISO 9001 : 2015; ISO 14001 : 2015; OSHAS 18001 : 2007

Certified for Forest Stewardship Council (FSC)

First Indian Manufacturing unit to gain WWF’s Global Forest Trade NetworkMembership

ITC PSPD Unit Kovai – First Company in the Pulp and Paper Sector to receiveGreenCo Platinum rating and recertified with Platinum in 2018-19

CII Excellent Energy Efficient Unit 2010, ’14, ’15, ’17, ‘19 & Energy Efficient Unit in2018.

Achieved International Water Stewardship 2019 – Platinum level by AWS (Alliancefor Water Stewardship) certification. First paper mill in the world to achieve thisaward.

PROCESS FLOW

TL wire

Coater Dryers,

MG, Calender

Board machine

ETPTreated Effluent

for Irrigation

Petax Filter

Cogen 8MW

Steam

Water from River

Condensate

Fuel

Reel & Rewinder

She

eter

s

Finishing House

Despatch

Stock Preparation

PulperWaste Paper

ScreenCentri cleanerHot disperser

FL wirePulperWaste Paper

ScreenCentricleanerHot disperser

BL wirePulperWaste Paper

ScreenCentricleanerHot disperser

Water Treatment

DM Plant

Press&

TemsecRewinder

Treated Effluent Reuse

Windmill 7.5MW

Solar 3MW

ENERGY CONSUMPTION

ENERGY DISTRIBUTION (MTOE/MT)

0.1709, 63%

0.1021, 37%

Thermal

Electricity

SPECIFIC POWER (KWH/MT)

586565

543 538 528

25.00

300

350

400

450

500

550

600

650

2015-16 2016-17 2017-18 2018-19 2019-20

Specific Power KWH/MT

5.6% reduction in last 5 years

• Refiners are added (~ consuming 25KWH/MT) in order to improve quality parameters

SPECIFIC STEAM (MT/MT)

2.39

2.32

2.19

2.06

2.16

1.50

1.60

1.70

1.80

1.90

2.00

2.10

2.20

2.30

2.40

2.50

2015-16 2016-17 2017-18 2018-19 2019-20

Specific Steam MT/MT

9.6% reduction in last 5 years

• Disperser preheater in Stock preparation and Gloss calendar are added in machine for enhancing quality parameters.

SPECIFIC ENERGY (MTOE/MT)

26% reduction

0.3677

0.3418

0.29130.2730

0.0000

0.0500

0.1000

0.1500

0.2000

0.2500

0.3000

0.3500

0.4000

2016-17 2017-18 2018-19 2019-20

• APC control

SPECIFIC POWER – SECTION WISE (KWH/MT)

DEPARATMENT 2017-18 2018-19 2019-20

Stock Preparation 223 224 236*

Board Machine 223 222 225

Utility 79 81 79

Others 16 11 13

• Refiners area added in stock preparation area to improve quality parameters.

GLOBAL BENCHMARK

NATIONAL BENCHMARKING

Kovai

553

2.16

Source: Benchmarking energy for Pulp & Paper Sector released by BEE, Sep 2018

GLOBAL BENCHMARKING – ELECTRICAL ENERGY

Source: Benchmarking Paper Mill energy efficiency and GHG Emissions for major producer countries

Fisher International, February 2018

GLOBAL BENCHMARKING – FUEL

Source: Benchmarking Paper Mill energy efficiency and GHG Emissions for major producer countries

Fisher International, February 2018

ANNUAL ENERGY REDUCTION TARGETS

543538

553

515

2017 - 18Actual

2018-19Actual

2019-20Actual

2020-21Target

Unit Specific Power Consumption (Saleable)

KWH/Ton of Product

2.19

2.06

2.16

1.98

2017 - 18Actual

2018-19Actual

2019-20Actual

2020-21Target

Unit Specific Steam Consumption (Saleable)

Ton /Ton of Product

Long Term Target, 2% Minimum Reduction year on year for next 3 years

ROAD MAP TO ACHIEVE GLOBAL BEST (ELECTRICAL AND THERMAL)

13-08-2020 ITC PSPD , Unit: Kovai

Sno

Title of Energy Saving project implemented

Energy Saving Per

day in kWH

Annual Total

savings (Kwh)

Month of

Implementation

Savings in 2019-

20Units

Annual Electrical Savings

achieved

Annual thermal savings

Total Annual Savings

Invest. Made

Payback

monthsUnits

MillionRs

MillionTons of Lignite

Rs Million

Rs Million

Rs Million

1 Energy Efficient Vacuum pump - 2 977 341880 Aug'19 2278680.34 1.60 1.600

1.173 9

2 Energy Efficient Vacuum pump - 6 859 300720 Nov'19 1252710.30 1.41 1.407

2.096 18

3 Energy Efficient Vacuum pump - 3 1157 404880 Dec'19 134929 0.40 1.89 1.895 1.115 7

4 Vacuum separator pump 2 149 52080 Nov'19 21695 0.05 0.24 0.244 0.261 13

5 Vacuum separator pump 6 149 52080 Nov'19 21695 0.05 0.24 0.241 0.261 13

6 Vacuum separator pump 8 149 52080 Nov'19 21695 0.05 0.24 0.241 0.261 13

7IE3 motor replacement in across mill -59 Nos

573 200424 Jan'20 500950.20 0.93 0.926

1.16 15

8Energy Efficient Trim pulper for Sheeter, Rewinder

528 184800 Jan'20 461890.18 0.85 0.854

3.79 53

9 VFD for TL Silo makeup pump 113 39375 Dec'19 13122 0.04 0.18 0.182 0.22 14

10 VFD for BL Silo makeup pump 138 48300 Jan'20 12072 0.05 0.22 0.223 0.22 12

11 APC for Cogen boiler 800 280000 Jul'19 209952 0.28 1.29 928.3 2.6 3.918 3.52 11

Total 5590 1956619 884584 2.0 9.0 11.7 14.1 14.4

ENERGY SAVING PROJECTS

ENCON PROJECTS IMPLEMENTED (LAST 3 YEARS)

Year No. of ProjectsSum of Invest.

Made(Rs Lakhs)

Sum of Total Annual Savings

(Rs Lakhs)

Payback(Months)

2019-20 11 140.8 117.3 14

2018-19 14 78.2 67.8 14

2017-18 21 122.2 57.3 26

Total 46 341.2 242.4 17

INNOVATIVE PROJECT

Innovative Project - 1

• 5 Wind generator turbines each of 1.5MW is installed to utilize Renewable energy for Paper

board manufacturing process.

• Total Mill electrical energy demand = Energy from Wind turbine + Energy from co-generation

• The following is the monthwise trend of wind energy generation

PRESENT SCENERIO

12

25 31 34 35

20

8 2 3 3

9 9 -

10

20

30

40

Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

Wind Generation Estimate ( in Lakhs of KWH)

• Owing to the wide variation based on environmental factors like Wind, co-generation energy generation has to be dynamic for effective utilization of Wind energy.

EFFECTIVE UTILISATION OF WIND AND CO-GENERATION VIA APC (ADVANCE PROCESS CONTROLLER)

APC (i4.0 tool)

• Multi variable controller for optimizing beyond DCS control.

• APC reduces the variability of the process. This reduction in process variability

permits operating the unit closer to constraints.

EFFECTIVE WIND ENERGY UTILISATION

MP Steam

Condenser

5.5 MW

TG

LP Steam flow – 18 TPH to 24 TPH

APC

Total Demand of mill

Wind energy

APC Output – TG Control

• APC controls TG at given input thereby rest of energy will be drawn from wind leading to effective utilization of Wind energy.

• Effective utilization of wind energy through APC control. Fine control of TG load through APC lead to effective utilization of wind energy and reducing condensing load

IDEA

200

194

190

192

194

196

198

200

202

2018-19 2019-20

Condensing Power in Lac KWH

Condensing Power

Linear ( Condensing Power )

90993

88076

86500

87000

87500

88000

88500

89000

89500

90000

90500

91000

91500

2018-19 2019-20

Condensing Steam in MT

Condensing Steam Linear ( Condensing Steam )

Innovative Project - 2

VFD for Silo make up pump

Existing Scenerio:

• Silo tanks will collect the back water from Wire section. Two Silo tanks are installed in our machines

where overflow from tank-1 goes to other Tank ( Silo-2).

• Maintaining constant Water level is important criteria for achieving board properties. Conventionally

make up water for Silo 1 comes from Silo 2 by taking level controller feedback of Silo-1.

•

Silo 1

Silo 2Recirculation

• Recirculation pump is continuously running leading to higher energy consumption

Solution:

• Installed VFD for recirculation pump maintaining Silo 1

at 80% thereby reducing energy of recirculation.

•This project was implemented for all three streets (Top,

Filler and Back).

•Annualized Energy savings in this modification :

1,31,000 KWH.

VFD for Silo make up pump

UTILISATION OF RENEWABLE ENERGY

UTILIZATION OF RENEWABLE ENERGY

Sno Technology Type of EnergyOnsite / Offsite

Installed Capacity

(MW)

Generation(Million

Kwh)

% of Overall Electrical

Energy

1 Wind Mill Electrical Offsite 7.50 11.1 18.05%

Sno Technology Type of EnergyInstalled Capacity

(MW)Usage

(Million Kwh)% of Overall

Thermal Energy

1 Biomass Thermal 8.00 6.73 14.01%

Biomass Consumption reduced due to Biomass supply chain disturbance due to Kerala Floods.

UTILIZATION OF RENEWABLE – SOLAR ENERGY

• Installation in progress for 3MWpeak Solar power plant.

• Increases the utilization of renewable energy

• Reduced steam condensing load in turbine operations.

UTILISATION OF WASTE MATERIAL AS FUEL

95%

ITC KOVAI WASTE GENERATION PARETO

Out of 13 category of waste only 4 category of waste has contributed to 95%

UTILIZATION OF WASTE MATERIAL

ETP Sludge

• 100% sludge generated is reused in process

Process Plastics Waste

• 100% sent to cement plants to Co-process in kiln

Fly Ash & Bed Ash

• 100% fly ash & Bed ash generated recycled for brick making

WASTE MANAGEMENT - INVENTORISATION

* All waste is reported on dry basis

S No Type 2017-18 2018-19 2019-20

1 Plastic Waste * 5504 7150 92852 Fly Ash 11223 10592 9148

3 ETP Primary Sludge * 2627 747 1860

4 ETP Bio sludge * 701 954.7 10255 Boiler Bed Ash 3345 440.13 1706 Metal Scrap 121 79 787 Scrap wood 405 571 4278 Scrap Core pipe 209 69.6 0

9 Waste gunny bags 37 0 10

10 Waste plastic carboys 160 25.03 16

11 Waste HDPE bags 0 105.02 14712 Canteen Waste * 8 0.82 1

13 Canteen Vegetable oil waste 1 2.771 2

14 Total 24341 20737.07 2216915 Production 114109 114544 111101

16 Sp Waste generation 0.21 0.18 0.20

SPECIFIC WASTE GENERATION DECLARATION

ITC’s Sustainability Report 2020 is yet to be declared

S.No Area UOM 2017-18 2018-19 2019-20

1 Fiber Loss % 2.13 2.03 2.18

2Finishing Loss

(B/C/D)% of Net

Production 6.87 6.02 6.21

3Machine stage

Re-Pulp (A)% of gross production

1.79 1.50 1.70

4Machine stage

Broke Gen.% 2.57 2.16 2.13

PROJECTS IMPLEMENTED TO REDUCE NON HAZARDOUS WASTE MANAGEMENT AT PROCESS

GHG INVENTORISATION

GHG EMISSION INVENTORIZATION MANAGEMENT

GHG emission Inventorization management

2014-15 2015-16 2016-17 2017-18 2018-19

Direct GHG Emissions (Scope-1) 80217 63754 53173 55,720 *99331

Energy Indirect GHG Emissions (Scope-2) 165 855 440 152 1281

Other Indirect GHG Emissions (Scope-3) 11,139 12,612 15,238 30,015 28043

Total 91521 77221 68851 70629 128655

* Increase due to reduction in bio fuel consumption

Ton of Co2

CO2 Emissions from combustion of Biomass is not considered

ITC Sustainability is yet to be released for FY 2019-20

Total GHG emission, Specific Tonnes of CO2/Tonne

GHG EMISSION INVENTORIZATION

ITC Sustainability is yet to be released for FY 2019-20

GREEN SUPPLY CHAIN

• Awareness given to 100% vendors about Green supply chain

• Critical suppliers identified (based on various criteria – such as volume of business, environment impact etc) and class room training given to 90% of them.

• Audit done by visiting 50% of critical vendors.

GREEN SUPPLY CHAIN - HIGHLIGHTS

Attendance Sheet Training Program on GreenCo

One day training program at our factory on Greening supplyITC PSPD , Unit: Kovai

TRAINING PROGRAM FOR VENDORS

Focus Improvement Project on Load ability of Inter unit Waste Paper trucks

RESOURCE CONSERVATION THROUGH SUPPLY CHAIN MANAGEMENT SYSTEM

DescriptionFY 2015-16

FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20(Baseline)

% Loadability of Inter Unit material

61% 75% 74% 77% 77%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

FY 2015-16 FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20

Series2 Linear (Series2)

RESOURCE CONSERVATION THROUGH SUPPLY CHAIN MANAGEMENT SYSTEM

Increase in Sourcing of used packaging containers

ITC PSPD , Unit: Kovai

FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20

DescriptionTotal Qty receipt

(MT)Avg per month

receipt (MT)Total Qty

receipt (MT)

Avg per month receipt (MT)

Total Qty receipt (MT)

Avg per month receipt (MT)

Total Qty receipt (MT)

Avg per month

receipt (MT)

USED PACKAGING CONTAINERS

1226 102 2612 218 3933 328 1477 123

WOW CONRIBUTION TOWARDS GSC

• Wow Collection increased YoY

1201

16101736

0

200

400

600

800

1000

1200

1400

1600

1800

2000

FY 17-18 FY 18-19 FY 19-20

Wow material receipt- Avg per month

TEAM WORK, EMPLOYEE INVOLVEMENT & MONITORING

Strategy for Capacity Building

Trainings

Internal by E&T Pillar External

Trainings

ITC Corporate, CII, BEE, NPC, LRQI, ISI.

Seminars

CII, IPMA, IPPTA, BEE, PAPEREX.

Competitions/Awards

CII, ISI, NPC, TN Govt.

Awareness Sessions and Campaigns

Posters and Signage

Campaigns by Lean Cell

Awareness creation, Training & Capacity building

EMPLOYEE INVOLVEMENT & CAPACITY BUILDING

EMPLOYEE ENGAGEMENT

ENERGY CONSERVATION WEEK CAMPAIGN AND CELEBRATIONS

Energy related statistics for Employees Awareness

KAIZEN INDEX

262

366427

22

434513 489

0.92

1.32

1.52

0.08

1.53

1.811.65

5

55

105

155

205

255

305

355

405

455

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

No

of

Kai

zen

Kai

zen

Ind

ex

Axis Title

Kaizen Index

No of Kaizens Kaizen Index

REWARD & RECOGNISATION

FINANCIAL RESOURCE ALLOCATION: CRITERIA & PROCESS

SpecifiedPlanned Schemes

> 300 Lacs

ClubbedPlanned Schemes

< 300 Lacs

FlexibleUnplanned Schemes

< 50 Lacs

▪ Planned Initiatives → Planned Schemes.

▪ Kaizen/FIPs → Unplanned Schemes.

• Kaizen/FIPs

• Energy Cell

• Unit Head

• DMC Member (Manufacturing)

• Budget Allocation by Finance

Revenue Fund allocation & utilization

• Kaizens related to non capital asset will be implemented through revenue budget

• One time budget is reserved for Kaizens / FIPs

Eg: Pump efficiency coating, automation, line modification etc.

MONTHLY REVIEWS PERTAINING TO ENERGY EFFICIENCY

Monthly review at OGM meetings by the USB

Cross functional Energy Management Cell holds weekly meetings to review the energy consumption and initiates Energy Conservation

Projects

Daily area wise Energy consumptions monitored, reviewed in AET meetings and updated in AET Boards

SNo Name Specialization Energy Cell Role

1 N AlagiriEnergy Manager & Environment

Head - Engineering

2 R. MuralidaranEnergy Auditor

& ElectricalDesignated Unit Energy Manager

3 Iswara PrasadEnergy Manager

& ElectricalBoard Machine representative

4 S.RajaramEnergy Manager

& OperationUtility representative

5 P JayasankarEnergy Manager

& MechanicalMechanical representative

6 PhaneendhraEnergy Manager

& MechanicalUtility representative

7 G Srikanth Electrical Electrical representive

8 V.Abinesh E&I Stock representative

9 P.Saranraj Mechanical Stock representative

10 S Vignesh Mechanical Utility representative

11 N Gopal Chowdary Process Board Machine representative

ENERGY MANAGEMENT CELL & ENERGY MANAGER

ENERGY MANAGEMENT SYSTEMS

TRAINING CALENDAR AND RECORDS

IMPLEMENTATION OF ISO 50001/GREEN CO/IGBC RATING

AWS & ISO 50001• Unit Kovai is the First Paper Mill in the world to achieve platinum rating – the highest rating

– under the Alliance for Water Stewardship standards..

• ITC Kovai is the first site in India and only the second in the world to be awarded thiscertification based on international benchmarks in water stewardship. The fact that the ITCKovai was awarded the prestigious AWS Platinum level certification - only awarded to thosesites that meet the very highest standards - is testament to the extensive actions directedbeyond the site's own water use to supporting communities, vulnerable groups and localagencies to build a sustainable future.

ISO50001 preliminary audit completed, Stage 1 audit is planned in Aug 2020.

THANK YOU