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UPL Limited, Unit-5, Jhagadia
Kishor Kumar - Manager (Energy Cell )
Hemant Warhekar - Sr Manager (Energy Cell )
Suresh Kalla - Sr Manager (Technical Department)
2
Business FactsUPL is positioned as a knowledge hub that innovates products for the benefit of farmers the world over.
Our portfolio of total crop solution products enhances farm profitability. This portfolio extends from seeds
to post-harvest solutions. Representing a one-stop farmer solution.
Farmer Engagement
Aquatics
Post Harvest
Bio Solutions
Crop Protection
Seeds
Global status as a post-patentcrop protection chemicals company
2nd
3
Manufacturing Sites
4
Brief Introduction to UPL Ltd. Unit-5, Jhagadia
21st National Award for Excellence in Energy Management 2019, CII
• Largest unit of UPL
• Captive Power Plant of 26 MW and 15 MW.
• We have 4 Improvement Cells : Energy Cell, Maxpro, Maxpro+, Green Cell
• Manufacturer of : Fungicides, Insecticides, Herbicides and Chemicals
Crop Protection Herbicides Fungicides Insecticides
Soil & Water Technologies
CCP, PCL3, TPPI, Acrolein, CS2
Chemicals
5
Jhagadia Industrial Estate –4200 acres or 1707 Hectares
UPL Site is spread over an area of 219 acres i.e., 89 Hectares (890000 Sq. mtrs)
Jhagadia Site – Aerial View
21st National Award for Excellence in Energy Management 2019, CII
6
2. Energy Consumption Overview
21st National Award for Excellence in Energy Management 2019, CII
102251
134974151348
186100
289797 289861
0
50000
100000
150000
200000
250000
300000
350000
0
20000
40000
60000
80000
100000
120000
140000
160000
2017-2018 2018-2019 2019-2020
MT
MTO
E
Energy Consumption & Production
Overall Energy Consumption Production
4%
96%
2019-2020
Annual Electrical Energy Consumption
Annual Thermal Energy Consumption
7
2. Energy Consumption Overview
21st National Award for Excellence in Energy Management 2019, CII
889634965178
1292401
1460180
0
200000
400000
600000
800000
1000000
1200000
1400000
1600000
2016-2017 2017-2018 2018-2019 2019-2020
mill
ion
kca
l
Annual Thermal Energy Consumption
61.8
66.66 66.67
61.97
0
10
20
30
40
50
60
70
80
2016-2017 2017-2018 2018-2019 2019-2020
mill
ion
kW
h
Annual Electrical Energy Consumption
5641199
5186341
4459677
5037518
0
1000000
2000000
3000000
4000000
5000000
6000000
7000000
8000000
2016-2017 2017-2018 2018-2019 2019-2020
Kca
l/To
n o
f p
rod
uct
ion
Specific Thermal Energy Consumption
392
358
230214
0
50
100
150
200
250
300
350
400
450
2016-2017 2017-2018 2018-2019 2019-2020
kWh
/To
n o
f p
rod
uct
ion
Specific Electrical Energy Consumption
8
3. Sp. Energy Consumption in last 3 years (FY 2017-20)
21st National Award for Excellence in Energy Management 2019, CII
8% Reduction
35% Reduction
7% Reduction
8% Reduction 14%
Reduction
12% Increment
Reason for Increment in Specific Thermal Energy Consumption : Introduction of new energy intensive Products and Plants.
9
3. Sp. Energy Consumption in last 3 years (FY 2017-20)
21st National Award for Excellence in Energy Management 2019, CII
12.08 12.0011.87
11.43
12.50
11.06
11.4511.27
10.00
10.50
11.00
11.50
12.00
12.50
13.00
2016-17 2017-18 2018-19 2019-20
Norm Comparision - CCP
Total (GJ/MT) Budget Total (GJ/MT) Actual
13.58 13.48
12.77
13.45
12.7412.48
11.50
12.00
12.50
13.00
13.50
14.00
2017-18 2018-19 2019-20
Norm Comparision - MNZ
Total (GJ/MT) Budget Total (GJ/MT) Actual
335.92
304.99307.77
311.06305.94
296.42
270.00
280.00
290.00
300.00
310.00
320.00
330.00
340.00
2017-18 2018-19 2019-20
Norm Comparision - GF1
Total (GJ/MT) Budget Total (GJ/MT) Actual
45.2850.45 52.52
74.38
48.90
40.26
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
2017-18 2018-19 2019-20
Norm Comparision - UPI 12
Total (GJ/MT) Budget Total (GJ/MT) Actual
10
4. Information on Competitors, National & Global benchmark
21st National Award for Excellence in Energy Management 2019, CII
List of Major Encon project planned in FY 2020-21
392
358
230214
189
0
50
100
150
200
250
300
350
400
450
2016-2017 2017-2018 2018-2019 2019-2020 Proposed 20-21
kWh
/To
n o
f p
rod
uct
ion
Specific Electrical Energy Consumption
11% Reduction
5641199
5186341
4459677
50375184882158
0
1000000
2000000
3000000
4000000
5000000
6000000
7000000
8000000
2016-2017 2017-2018 2018-2019 2019-2020 Proposed 20-21
Kca
l/To
n o
f p
rod
uct
ion
Specific Thermal Energy Consumption
3% Reduction
11
4. Information on Competitors, National & Global benchmark
21st National Award for Excellence in Energy Management 2019, CII
List of Major Encon project planned in FY 2020-21
Sr. No. Title of ProjectAnnual Electrical
Saving (kWh)
Annual Thermal Saving Investment Made
(Rs million)Quantity Unit of Measurement Million kcal
1 Back pressure Turbine in place of Pressure reducing station for steam 923077 9
2 Steam reduction by Heat integration Methanol & Ethanol recovery column 17424242 kg of steam 14554 30
3 Reflux optimization distillation column by increasing column height by 4 Mtr 15151515 kg of steam 12656 20
4 Variable nozzle thermocompressor installation to recover flash steam 4090909 kg of steam 3417 3
5 VFD for Secondary air fan 353846 2
6 Power boiler Blowdown Flash recovery to preheat condensate to deaerator 1946488 kg of Coal 8175 10
7 Heat recovery from blowdown water and preheat DM water 695870 kg of Coal 2923 1
8 Refrigerant liquid overfeed system for reactor to optimize power consumption 3168000 10
9 Low pressure blower to reduce power in CS2 furnace 792000 1
10 Steam optimization in Distillation column by reducing vacuum 3960000 kg of steam 3308 0
11 Roof Top Solar Power 1944462 47
Total 7181385 43269025 45032.6 132
12
5. Energy Saving projects implemented in for last three years
21st National Award for Excellence in Energy Management 2019, CII
Summary of project implemented in last three years
2017-18 2018-19 2019-20
No. of Proposals 12 8 14
Payback Months 7 4 7
Invetments (Rs million) 38 30 67
Savings (Rs million) 63 96 124
0
20
40
60
80
100
120
140
0
2
4
6
8
10
12
14
16
18
20
EnCon Projects
13
5. Energy Saving projects implemented in for last three years
21st National Award for Excellence in Energy Management 2019, CII
EnCon Projects for Year 2017-18
Sr. No. Title of Project
Annual Electrical
Saving (kWh)
Annual Electrical
Cost Saving(Rs million)
Annual Thermal Saving Annual Thermal
Cost Saving(Rs million)
Total Annual Savings(Rs million)
Investment Made
(Rs million)
Payback (Months)Quantity
Unit of Measurement
1Power consumption reduction by replacing to correct duty pump for utility
2774194 17.2 17.2 9.1 6
2Steam consumption reduction in Multiple effect evaporator by VFBD Air Pre-heating using waste heat
2347418 kg of steam 3.5 3.5 2.1 7.2
3 Replacement of HPMV lights to LED lights 866452 5.4 5.4 4.1 9
4Power Plant DM water Pre heating using waste heat of condensate
1572917 kg of coal 7.6 7.6 2.4 4
5Power consumption reduction at power plant by avoiding buffer tank for condensate
602742 3.7 3.7 3.8 12
6 Air Compressor stopped by Load optimization 269355 1.7 1.7 0.0 0
7Power generation by Installing Back Pressure Turbine in place of Pressure reducing Valve
950400 6.3 6.3 6.6 12
8 DM water Pre heating using waste heat from process condenser 3960000 kg of steam 5.1 5.1 2.0 5
9Power consumption reduction by replacing Reciprocating Air compressor to Screw air compressor
532258 3.3 3.3 1.6 6
10 Flash Steam Recovery by closed loop flash jet pump 1911469 kg of steam 2.9 2.9 1.7 7
11Pulley Change and Evaporative condenser in place of shell and tube condenser for reciprocation compressor & chiller
391452 2.4 2.4 1.8 9
12 Flash Jet Pump to Recover Heat from Flash Steam 2608987 kg of steam 3.9 3.9 2.4 7
Total 6386852 40 12400791 23 63 38
14
5. Energy Saving projects implemented in for last three years
21st National Award for Excellence in Energy Management 2019, CII
EnCon Projects for Year 2018-19
Sr. No. Title of Project
Annual Electrical
Saving (kWh)
Annual Electrical
Cost Saving(Rs million)
Annual Thermal Saving Annual Thermal
Cost Saving(Rs million)
Total Annual Savings(Rs million)
Investment Made
(Rs million)
Payback (Months)
QuantityUnit of
Measurement
1Elimination primary pumping for Chilled water and brine & evaporative condenser in chiller for new projects
2352941 15.6 15.6 6.7 5
2Replacing Shell and tube condenser with Evaporative Condenser for Brine Chiller
1297134 8.6 8.6 6.0 8
3 Flash steam recovery using Variable Nozzle thermocompressor 3383459 kg of steam 4.5 4.5 2.8 7
4Natural Gas consumption reduction in Spray Dryer by Air Pre-heating with flash steam
247029 SM3 of NG 7.9 7.9 5.7 9
5Eliminating use of primary pump by utilizing gravitational head for Chiller in existing plants
780692 5.2 5.2 0.5 1
6Steam consumption reduction by Heat Integration for pre heating column feed by column outlet vapour and flash steam.
2635338 kg of steam 3.5 3.5 4.1 14
7NG norm reduction by incinerator Air pre-heating by flash steam
159475 SM3 of NG 5.1 5.1 2.7 6
8Online Condenser cleaning system at power plant for turbine condenser
6850800 45.4 45.4 1.2 0.3
Total11281567 75 6425301 21 95.8
29.7
15
5. Energy Saving projects implemented in for last three years
21st National Award for Excellence in Energy Management 2019, CII
EnCon Projects for Year 2019-20
Sr. No. Title of Project
Annual Electrical
Saving (kWh)
Annual Electrical
Cost Saving(Rs million)
Annual Thermal Saving Annual Thermal
Cost Saving(Rs million)
Total Annual Savings(Rs million)
Investment Made
(Rs million)
Payback (Months)Quantity
Unit of Measurement
1Power Generation trough Back Pressure turbine in place of steam pressure reducing station
3523077 22.90 22.90 17.8 9
2 Use of gravity flow and eliminated chilled water primary pumps 792000 5.15 5.15 1.0 2
3 Steam Reduction in evaporator by heat integration 2803030 kg of steam 3.70 3.70 4.0 13
4 Incinerator Air pre-heating by using flash steam 145714 SM3 of NG 5.10 5.10 2.4 6
5Brine chiller power optimization by using evaporative Condenser
153846 1.00 1.00 3.7 44
6 VFBD Air Pre-heating by waste Condensate heat 2651515 Kg of Steam 3.50 3.50 2.8 10
7Heat Recovery from process reactor vapor to preheat DM water for boiler
15227273 kg of steam 20.10 20.10 11.1 7
8Condensate recovery 50 KL/Hr by installing condensate polishing unit
6448210 kg of coal 34.78 34.78 16.0 6
9Variable nozzle thermocompressor installation to recover flash steam
3409091 kg of steam 4.50 4.50 2.8 7
10 NG Reduction by Pre-heating SPD air by Steam 225714 SM3 of NG 7.90 7.90 5.7 9
11Auxiliary cooling water pump stopped using EPANET simulation of water distribution
453846 2.95 2.95 0.0 0
12 Chilled water pump optimization 396000 2.57 2.57 0.0 0
13 CFBC Boiler Blowdown Flash recovery 889823 kg of coal 4.80 4.80 0.0 0
14 Process CW Pump Optimization with impeller trimming 810277 5.27 5.27 0.0 0
Total 6129046 40 31800371 84 124 67
16
6. Innovative Projects implemented
21st National Award for Excellence in Energy Management 2019, CII
Project : PCL3 condensation heat recovery by preheating powerplant DM Water
Idea : To Recover PCL3 condensation heat i.e. 13.44 lac. kCal/h.
Before: All the generated heat was rejected in cooling tower.
After: By using HNP oil as heat exchanging medium between PCL3 and DM Water, heat was recovered to preheat DM water.
Benefits:1. Saving in terms of steam 1388 TPA2. Water evaporation reduction 15392 KLPA3. Cost Saving Rs. 201 LPA , Total investments Rs. 111.6 Lacs
After successfully implementing in one of the reactors we are planning to implement the same in other reactors with potential additional saving of Rs. 402 LPA.
17
6. Innovative Projects implemented
21st National Award for Excellence in Energy Management 2019, CII
COLD DM WATER INLET
HOT DM WATER OUTLET
PCL3 Vapour @78 Deg. C.
Trombone Cooler
Catch POT
Ref
lux
Co
lum
n
New
PC
L3 C
on
den
ser
Catch POT
HNPStorage
Tank
PHE
COLD HNP IN
HOT HNP OUT
COOLING TOWER
18
7. Utilization of Renewable Energy sources
21st National Award for Excellence in Energy Management 2019, CII
Technology Type of Energy Onsite/ OffsitePurchase / Own
GenerationInstalled
Capacity (MW)
Generation (Million kWh)
for 2019-20
% of overall electrical energy
Solar PV Cell Solar Energy OffsitePurchase through
Agreement7 6 9%
Wind Turbine Wind Energy OffsitePurchase through
Agreement3.6 9 15%
Unit PartySolar / Wind
Capacity (MW)
Lacs. kwh for 2019-20
Savings(Rs. Lacs)
PL00 Party A Solar 2.2 28 79
PL01Party A Wind 2.1 49 136
Party A Solar 1.8 23 64
PL02 Party A Solar 2.5 12 35
PL05
Party B Wind 2.1 59 177
Party C Wind 1.5 34 95
Party A Solar 7 56 160
Total
Solar 4 13.5 120 338
Wind 3 5.7 141 408
Total 7 19.2 261 746
Renewable power purchase through “Long term Agreement”
Group Capacity : 19.2 MWUnit Capacity : 10.6 MW
19
7. Utilization of Renewable Energy sources
21st National Award for Excellence in Energy Management 2019, CII
Renewable Power Purchase 2017-18 2018-19 2019-20
No of Project Implemented - 1 2
Capacity Addition (MW) - 2.1 8.5
Power Generation(Million kWh - 3.4 14.9
Group total capacity(MW) - 4.2 19.2
Unit total capacity(MW) - 2.1 8.5
20
8. Waste utilization and management
21st National Award for Excellence in Energy Management 2019, CII
2017-2018 2018-2019 2019-2020
Type of waste generated
Quantity of waste generated (MT/year)
Disposal methodType of waste
generatedQuantity of waste
generated (MT/year)Disposal method
Type of waste generated
Quantity of waste generated (MT/year)
Disposal method
Solid 31332 Landfill Solid 45514 Landfill Solid 69844 Landfill
Liquid 3818 Incineration Liquid 5463 Incineration Liquid 6753 Incineration
• We have common hazardous waste treatment facility called as BEIL, Bharuch . BEIL promoted by Industries in Bharuch District with major shareholding by Tatva Global Environment Private Limited (known as ‘Tatva’ group), the Company promoted by the Directors of UPL Limited.
• In 2019-2020, Incinerable liquid 1280 MT/year (19% of total liquid) send to cement industries out of total 6753 MT/Year as a alternative fuel.
21
9. GHG Inventorisation
21st National Award for Excellence in Energy Management 2019, CII
2015-2016
2016-2017
2017-2018
2018-2019
2019-2020
2020-2021
Target
kgCO2 / Ton of Final Product 2800 2400 2200 1900 2135 1964
0
500
1000
1500
2000
2500
3000
Carbon Emission
0
500
1000
1500
2000
2500
3000
2015-2016 2016-2017 2017-2018 2018-2019 2019-2020
kgC
O2
/ T
on
of
Fin
al P
rod
uct
Carbon Emission
Sp.CO2 Generation Scope 1 Sp.CO2 Generation Scope 2
22
11. Teamwork, Employee Involvement & Monitoring
21st National Award for Excellence in Energy Management 2019, CII
1. Daily Monitoring system: Utility Report, Power distribution report, Energy Tracker (monthly).2. Review Meeting chaired by :
• Monthly Review meeting: Energy Cell, group production head, maintenance head, Unit Head & Director .
3. Separate Capex is allotted to energy conservation projects
This Tracker is formed every month from the data from monthly reports.
Also for major products tracking is done for energy.
We receive this report daily, which includes Power import and distribution
23
11. Teamwork, Employee Involvement & Monitoring
21st National Award for Excellence in Energy Management 2019, CII
24
11. Teamwork, Employee Involvement & Monitoring
21st National Award for Excellence in Energy Management 2019, CII
4. Energy efficiency / awareness training programAll staff, contract workers and workmen are aware on energy performance. On joining of new employee during induction
energy philosophy being discussed. Every Friday ‘Energy-Talk’ happens across all cross functional department to aware about energy efficiency. Approximately 70% staff aware about energy conservation.
Energy Management Policy
Water Conservation Policy
Revised Energy Conservation Book for Weekly/Daily Talk
25
11. Teamwork, Employee Involvement & Monitoring
21st National Award for Excellence in Energy Management 2019, CII
Energy Quiz duringEnergy
Conservation Week
Revised Energy Booklet
Unveiling at Energy
Conservation Week
Weekly Energy talk on Shop Floor
26
12. Implementation of ISO 50001/Green Co/IGBC rating
21st National Award for Excellence in Energy Management 2019, CII
1. Implemented ISO 50001 at Unit -2, in process for Unit-1. In Unit-5 new project is coming up and under stabilization.2. Investment over turnover % (Excluding Plant Expansion Investment)
1. 2016-17 : 0.80 %2. 2017-18 : 0.93%3. 2018-19 : 0.85%4. 2019-20 : 0.42%
UPL Unit-5 Canteen and Meeting building is certified by IGBC
27
13. Other Innovative technologies implemented
21st National Award for Excellence in Energy Management 2019, CII
Installed online monitoring system for Chillers, with the help of IOT and Automation.Advantages : Data can monitor from anywhere in company WAN, Trend/Data can be downloaded for analysis and study.By this we have optimized the chiller operation.
28
14. Long Term Vision on EE
21st National Award for Excellence in Energy Management 2019, CII
1. Long term target of energy efficiency
a) Integrate Energy management with business objective
b) Ensure energy efficiency while procuring significant energy consuming products and services
c) Organize periodic training to all personnel
d) ISO 50001 certification for all units
e) Implementation of advanced technologies
f) 100% condensate recovery of recoverable condensate
g) 20% renewable energy of total consumption
2. What support you require to achieve those target
a) Collaboration with institution, forums and organization to explore new technology
b) Knowledge sharing with cross functional team
c) Special budget for new technology
2921st National Award for Excellence in Energy Management 2019, CII
Milestones & Achievements
2018
2016
2015
2014
2010
2011
2012
2013
2017
21.ISO 50001:2011, Energy Management System - First Unit in Agrochemical Sector to be certified
13. UPL Excellence Award14. Steam Tech Award –PL02* F&S Mfg. Excellence –15. PL01 (Challengers)16. PL02 (Challengers)IGMC Silver Award 2015 by IRIM
10. UPL Mfg. Excellence Award - PPA* F&S Mfg. Excellence for 11. PL01 (Challengers)12. PL02 (Challengers)
5. UPL Mfg. Excellence Award – PPA* F&S Mfg. Excellence for 6. PL017. PL028. PL059. FICCI Award – PL02
17. FICCI award for energyefficiency PL02
18. QCFI award for PL0519. BEE First prize for PL02 20. BEE COM for PL01
3. UPL Mfg. Excellence Award –Savings4. ICC Award – PL02
2. UPL Mfg. Excellence Award -Savings
1. National Energy conservation award – PL00
2009
EC cell formed 2009
2020
2019
22. Future of Energy management submit & award - 201823. ISO 50001 surveillance audit Completion at PL02
24. CII 20th National Award for Excellence in Energy Management 2019 • Excellent Energy Efficient Unit• Innovative Project
3021st National Award for Excellence in Energy Management 2019, CII
Milestones & Achievements
3121st National Award for Excellence in Energy Management 2019, CII
Milestones & Achievements
32
Thank You
Hemant Warhekar - warhekarhs@upl-ltd.com - +91 9099034428Suresh Kalla - suresh.kalla@upl-ltd.com - +91 8238022352Kishor Kumar- kishor.kumar@upl-ltd.com - +91 9512177585
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