JK Tyre & Industries Ltd. D R PAI

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Lala Lakshmipat Singhania( 1910 – 1976 )

A Visionary & Key ofJK Organisation

KTP

Presentation By

D R PAI General Manager Engineering & Project

Kankroli Tyre Plant (KTP) A unit of

JK TYRE & INDUSTRIES LIMITED( TS-16949 , ISO-9001, OHSAS & ISO-14001 Plant )

JK Tyre & Industries Ltd.Kankroli ( Rajasthan )

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KTP

Presentation By

Team Members D.R. PaiA.K. PamechaM.K. Sharma

Kankroli Tyre Plant (KTP) A unit of

JK TYRE & INDUSTRIES LIMITED( TS-16949 ,OHSAS, ISO-9001 & ISO-14001 Plant )

11th National Award

for Excellence in Energy Management-2010

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An Overview of JK Tyre & Industries Ltd.

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• Be a Customer Obsessed Company-Customer first 24x7• No.1 Tyre Brand In India• Most profitable Tyre company in India• Motivated and committed team for excellence in

performance• Be a green company• Deliver enhanced value to all stakeholders• Leverage & Enhance global presence through Acquisition /

JV

• To be amongst the most admired companies in India Committed to Excellence.

VISION

MISSION

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Manufacturing Process Flow Diagram

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Energy Policy

We at J.K.Tyres are Committed to Conserve Natural Resources & Energy by

•Enhancing Equipment Efficiency•Minimizing Waste & idle run•Technology & Innovation•Periodic Reviews and Skill Upgradation•People Involvement

We will continuously Benchmark & Improve Energy Performance in our endeavor to be the World’s Best Bias Tyre Plant By 2010.

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Focus areas for

Energy conservationFuel conservation

Resource conservation

Reduction of green house gases

Reduction in consumption of petroleum products

Elimination of ozone depleting substances

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Actions:

Optimization of Blowers and pumps

Process Optimization

Energy Efficient Lighting

Use of renewable energy

Efficient compressed air generation

Extensive use of VFDs

Energy Monitoring.

POWER

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Plant Specific Power Consumption( Kwh/Kg.)

0.712

0.748

0.776

0.795

0.816

2004-05 2005-06 2006-07 2007-09 2009-10

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Actions:Optimization of Usage Pressure

Elimination of redundant lines

Process improvements

Waste heat recovery Switching to alternate economic energy forms

Heat recovery and reuse

STEAM

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Plant Specific Steam Consumption( Kg./Kg.)

2.125

2.385

2.516

2.593

2.634

2004-05 2005-06 2006-07 2007-09 2009-10

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Saving Realization

Year

KWH * Million

Rs Million

Type of fuel

Tons/KL Rs Million

0.403 1.22 3.82

LDO/LSHS 596** 2.47 0.01 0

21696** 96.44 53711 7402009-10 39.747** 170.91 Coal

0.419 2.22 7.51

LDO/LSHS 734 5.31 0.01 0

28946 120.82 69089 7492008–09 51.725 222.53 Coal

0.453 1.67 6.21

LDO/LSHS 759 7.29 0.01 0

32866 116.3 72203 7662007–08 55.293 243.72 Coal

0.483 3.23 -5.69

LDO/LSHS 731 3.04 0.01 9.1

34670 101.12 71795 7792006–07 55.918 218.65 Coal

(April − March)

Electrical Thermal Electrical KWH / Ton or unit of

prodn

Annual Energy consumption Prodn. in tons or

any other unit of prodn.

Specific Energy Consumption

Redn. in Specific Energy consn. Over previous year **

Thermal tons or kL per ton or

unit of prodn

Electrical Thermal

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56.08

39.75

01/01/1900 02/01/1900

31824

21696

2005-06 2009-10

788

596

2005-06 2009-10

Power Consumption ( Million Kwh )Coal Consumption ( MT )

LDO/LSHS ( KL )

Savings

815 Lacs

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Plant Power Consuming Loads

Power Consumption

Utilities = 38% , Mixing = 36%.Extruders = 7%, Air Washer = 5%, Calendaring = 4%Tyre Curing = 4%, Tyre Building = 2%, Lighting = 2%.

Plant Energy Data Review

Calendaring, 4

A ir W asher, 5

E x truders , 7

Ty re Curing , 4

Ty re B uild ing , 2

L ight ing, 2

Utilit ies , 38

M ix ing , 36

Utilities & Mixing Consume Maximum Power

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Banbury # 4 Single Stage MixingINNOVATION:

Concept of conversion of three stages mixing in to two stages mixing is innovative itself. Which have an added advantage of improvement in productivity, reduction in powerconsumption, low man-hour cost.

The complete concept of conversion of three stages mixing in to two stage mixing was new and developed in-house. The design of required equipment and schemes was done locally including selection of process requirement.

Benefit:-

After implementation of this project we generate extra 150 min/day for mixing which is equivalent to 10500 KG master compound per day or equivalent to 35000 Rs/day.

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AIR WASHER Band Building Air Washer Metallic Blades replaced by FRP Blades.Horizontal Deployment to be done on All AHU

AIR FLOW DELIVERED VIS –A-VIS POWER CONSUMED

AIR FLOW (CFM) POWER (KW)

ALUMINIUM ENCON ALUMINIUM ENCON

TOTAL 140000 140000 56 44

Pump Conversion 18KW to 3.7 KW 13.7 KW

SAVING 11 KW

SAVING PER DAY Per AHU 264 KWH

SAVING PER DAY 13 AHU 7800 KWH

SAVING (Rs.)/Year (250 Days) 2.73 LACS/Annum

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ENERGY SAVER Batch Off Mill BANBURY # 2

Variable Triggered Voltage (Thyristor Control) with respect to variable load.

Approximately 300 KWH saving per day.

Energy Saver Cost 2.25 Lacs For 200 KW Motor.

Pay Back 8 Months

WORKING PRINCIPLE

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Utility Steam (Kg/ Kg ) Power (Kwh/Kg)

JK - KTP 1.98 0.710

Future Plans to Challenge “THE

BEST”

ØReduction of fossil fuelsØ Insulation improvement

on hot steam linesØWaste Heat recovery ØReduction in flash steam

lossesØHot water recovery in

curing pressesØUsing optimum solution

for process heating

q Replacement of in-efficient pumps.

q Strengthen power monitoring system.q On line Energy

managementqVFD installation on

Higher HP MillsqOptimization of Blower

on air washers

Industry Benchmark & Road Map

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•Daily capturing of energy parameters, their analysis and investigate for deviations by section and functional heads

•Comparison within similar equipment

•Daily reporting and threadbare discussions in management review meeting

•Review of energy projects by unit head for progress and employee participation

P a r t i c u l a r s U n i tP l a n A c t u a l D i f f P l a n A c t u a l D i f f

K g s 1 7 0 1 7 4 7 7 4 3 2 4 5% 0 .0 1 0 0 . 0 0 0 0 .0 1 0 0 . 0 1 0 0 .0 0 9 0 .0 0 1K g s 1 5 7 0 1 5 6 . 5 4 2 9 1 2 1 0 3 2 1 8 7 . 6% 0 .0 9 0 0 . 0 0 0 0 .0 9 0 0 . 0 9 0 0 .0 4 4 0 .0 4 6K g s 0 5 0 4% 0 . 0 0 0 0 . 0 0 0 0 .0 1 1K g s 1 5 7 0 4 2 9 1 2 6 0 7% 0 .0 9 0 0 . 0 0 0 0 . 0 9 0 0 .0 5 5K g s 4 3 4 6 - 3 1 1 2 7 1 8 2 2 - 6 9 5% 0 .0 6 0 0 . 0 6 4 - 0 . 0 0 4 0 . 0 6 0 0 .0 9 7 - 0 . 0 3 7K g s 2 9 0 3 8 2 - 9 2 7 5 1 2 1 0 0 8 2 - 2 5 7 0% 0 .4 0 0 0 . 5 2 8 - 0 . 1 2 8 0 . 4 0 0 0 .5 3 7 - 0 . 1 3 7K g s 3 3 3 4 2 8 - 9 5 8 6 3 9 1 1 9 0 4 - 3 2 6 5% 0 .4 6 0 0 . 5 9 1 - 0 . 1 3 1 0 . 4 6 0 0 .6 3 4 - 0 . 1 7 4

S q W o v e n F a b r i c K g s 1 6 1 9 - 3 5 0 9 7 2 1 - 2 1 2% 0 .7 2 0 0 . 8 4 3 - 0 . 1 2 3 0 . 7 2 0 1 .0 2 1 - 0 . 3 0 1K g s 2 8 2 1 7 7 5 9 7 7 8 - 1 9% 0 .2 7 0 0 . 2 0 5 0 .0 6 5 0 . 2 7 0 0 .2 7 7 - 0 . 0 0 7K g s 1 9 2 0 - 1 5 4 1 6 2 6 - 8 5% 0 .0 1 0 0 . 0 1 0 0 .0 0 0 0 . 0 1 0 0 .0 1 2 - 0 . 0 0 2K g s 9 8 3 7 6 1 2 6 3 2 3 4 8 0 - 8 4 8% 0 .0 5 0 0 . 0 1 9 0 .0 3 1 0 . 0 5 0 0 .0 6 6 - 0 . 0 1 6K g s 5 2 7 5 2 5 2 1 4 2 1 5 1 8 6 5 5 - 4 4 4 0% 0 .2 7 0 0 . 2 6 9 0 .0 0 1 0 . 2 7 0 0 .3 5 4 - 0 . 0 8 4V a l u e 5 6 7 7 2 5 9 8 3 0 - 3 0 5 9 1 5 3 2 7 3 5 1 9 4 8 8 4 5 - 4 1 6 1 1 0% 0 .3 3 4 0 . 3 4 7 - 0 . 0 1 3 0 . 3 3 4 0 .4 1 8 - 0 . 0 8 4K g s 1 2 4 1 3 0 - 6 3 4 5 6 2 5 7 7 8 7 9% 1 .3 6 3 1 . 4 2 4 - 0 . 0 6 1 1 . 3 6 3 1 .0 1 6 0 .3 4 7K g s 1 8 1 2 6 4 8 4 3 4 7 1 3 7% 1 .2 0 0 0 . 8 0 3 0 .3 9 7 1 . 2 0 0 0 .8 6 1 0 .3 3 9K g s 8 4 1 6 6 7 1 7 4 2 2 7 3 6 2 5 4 0 3 - 2 6 6 8% 0 .4 0 9 0 . 3 2 4 0 .0 8 5 0 . 4 0 9 0 .4 5 7 - 0 . 0 4 8V a l u e 8 5 2 4 1 7 3 8 9 8 1 1 3 4 3 2 3 0 4 2 9 1 2 5 3 8 0 9 5 - 2 3 3 8 0 4% 0 .4 9 4 0 . 4 0 4 0 .0 9 0 0 . 4 9 4 0 .5 1 3 - 0 . 0 1 9

T o d a y M T D

C o m p o u n d S c r a p

F a b r i c S c r a p - B U 1

C o m p o u n d L u m p y -B U 2

C o m p o u n d L u m p y -B U 1

C o m p o u n d L u m p y -T o t a l

F a b r i c S c r a p - B U 2

F a b r i c S c r a p - T o t a l

I n s u l a t e d B e a d

G r e e n T y r e

C u r e d T y r e

T o t a l P r o c e s s S c r a p - T y r eT o t a l P r o c e s s S c r a p - T y r e

T o t a l P r o c e s s S c r a p

T o t a l P r o c e s s S c r a p

C u r e d T u b e

C u r e d F l a p

Eq. Prodn. Power ( Kwh.)

Consumptionper Unit

Power ( Kwh.)

Consumptionper Unit

1 BANBURY # 1 Kgs. 47710 9803 0.205 9337 0.2032 BANBURY#2 Kgs. 45323 12336 0.272 11352 0.2673 BANBURY#3 Kgs. 44967 10101 0.225 11128 0.2674 BANBURY#4 Kgs. 44220 11509 0.260 11344 0.2505 TOTAL BANBURIES Kgs. 182220 43749 0.240 43161 0.2466 DIP UNIT KM 28299 2691 0.095 2911 0.0757 3 ROLL CALENDER Eq.Rolls 1549 3543 2.287 3822 2.9158 4 ROLL CALENDER KM 50292 7798 0.155 7610 0.1629 DUAL EXTRUDER Eq.Trk.Tread 5121 14299 2.792 13011 2.67010 MP EXTRUDER Eq S/W 10504 3671 0.349 3259 0.35911 TUBE EXTRUDER Eq.Trk. Tube 5270 3688 0.700 3769 0.74712 TOTAL BUILDING MT 192.42 3273 17.010 3129 16.20013 TOTAL CURING MT 205.63 11764 57.209 11282 56.82714 PCI AIR M3 64650 8979 0.139 10962 0.17015 PLANT AIR M3 58029 10011 0.173 8924 0.15416 TOTAL AIR M3 122679 18990 0.155 19886 0.16217 COOLING TOWER MT 205633 9106 0.044 9122 0.04618 BOILER MT 205633 3483 0.017 3716 0.01919 OTHER UTILITY 205633 5102 0.025 4779 0.02420 TOTAL UTILITY MT 205633 43510 0.212 45965 0.23221 LIGHTING TOTAL MT 205633 3827 0.019 3553 0.01822 AIR WASHERS TOTAL MT 205633 11827 0.058 11584 0.05823 REST METERED LOAD MT 205633 1467 0.007 2078 0.01024 TOTAL UNMETERED MT 205633 6666 0.032 6280 0.03225 NET PLANT CONSUM MT 205633 161773 0.787 161413 0.81326 RSEB MT 205633 164000 0.798 164554 0.829

Sl.No.

To-Day MTD UnitEquipment

Particulars UnitBuilding Plan Actual Diff Plan Actual DiffTyre MT 192.51 192.42 -0.09 191.56 193.17 1.61CuringTyre MT 192.51 195.01 2.50 191.56 188.03 -3.53Tube MT 8.89 9.13 0.24 8.87 9.06 0.18Flap MT 1.51 1.49 -0.01 1.51 1.44 -0.07Total MT 202.91 205.63 2.73 201.9 198.53 -3.42UtilityPower KWH/Kg 0.750 0.787 -0.04 0.750 0.813 -0.06Coal MT 86.366 77.30 9.07 83.382 92.03 -8.65

Kg/Kg 0.420 0.376 0.04 0.420 0.464 -0.04Kg/MT 153.0 162.05 -9.05 153.0 183.60 -30.60

Steam(G) MT 534.646 477.00 57.65 516.176 501.24 14.94Kg/Kg 2.600 2.32 0.28 2.600 2.52 0.08

Steam(S) Kg/Kg 2.450 2.31 0.14 2.450 2.41 0.04Air M3/Kg 0.675 0.597 0.08 0.675 0.637 0.04Water-Ex Ltr/Kg 5.750 3.676 2.074 5.750 4.162 1.588Water-Inc Ltr/Kg 6.550 4.678 1.872 6.550 5.170 1.380Naphtha Ltr/MT 12.00 14.97 -2.97 12.00 12.73 -0.73

Today MTD

Daily Monitoring Key Parameters

Daily Review of utility Parameters Daily Review of equipment power

Daily Review of Process ScrapeParametersReview Mechanisms

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Energy Conservation Structure

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Contd ….

Proposed Project for Energy and Fuel Conservation

Location Key Projects Plan Project Cost Saving Remarks

Township Street light to be replaced with LEDlamp. 30 Nos.

Halogen lights of 250W to be replaced with LED lights

20000 per piece

Rs. 7000 PA

Rs. 70000 per annum saving per uint

BU#1 MP F/mill drive - race sent to H.O . Trial Taken 13 lacs 11 Lacs PA Awaited For Race approval

BU#3 G,H line lightining to be linked withpress.

Circuit modification to be done

Rs. 5000 25000 PA approx.25000 per annum saving

BU#3 curing lights to be linked with lightingtransformer.

Transformer available to be taken in line

10000.00 1.25 Lacs PA

Plant AHU pump replacement Relacement of Pump 1.5 Lacs 2.73 Lacs

Plant AHU filter replacememnt Relacement of Filter 1.2 LacsBU#1 MP cooling conveyor D.C motor

replaced with A.C motor .Conversion Of DcMotor with Ac MotorVFD

4 Lacs 3.5 Lacs Technology Upgradation

BU#1 BB#2 Reconditioning in 27 lacsinstead of 1.1 corers. (17lacs/yearto be continued for 6 years)

BB#2 Reconditioning 27 Lacs 17 lacs PA for Six years

17 lacs per year for next six years.

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Proposed Project for Energy and Fuel Conservation

Location Key Projects Plan Project Cost Saving Remarks

Utility Bio fuel to be used in boiler. Usage of biomass instead of coal

To Be evaluated.

Utility Boiler blow down control Process Optimization 0 Top Be evaluated

BU#1 Steam reduction by installation of electrical heater (4-roll calander,T.C.U ,hot can,Dil. heating)

Conversion of steam to electric heater

9 Lacs 15 Lacs

SSU#1 Rs. 24 lacs to be saved under W/shop reconditioning

In House spare development with spares.

No Cost 24 Lacs 24 lacs will be saved by development of in house spares.

SSU#1 Ecoventilater to be fixed - 200 Nos. Ecoventillaters to be provided over roof

5000/- per piece

to be evaluated

BU#1 BB V.F.D To Be Evaluated 1 Carore To Be Evaluated

Approx Rs. 60 to 70 Lacs per year saving expected

Utility power saving in ACFC +cooling tower by VFD

Common VFD to be provided or switchng On & OFF of AC motors as per temperature

2.5 Lacs 4 Lacs

BU#3 CBD pump vertical to horizontal.BU#2 slitter D.C motor replaced with A.C

motor + driveTecnology Upgradation

1 Lacs 1.5 Lacs Per Annum

To Be evaluated.

Utility Dome drain + Condensate recovery Process Optimization To Be evaluated.

SSU#1 old age A.C to be replaced by star A.C

Old Low Efficeint AC to be replaced with new efficient AC

22000 per unit

To be evaluated

Utility Air and water Pr. Drop study in drop line

Process Optimization To Be evaluated.

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Accolades- Present Glory-2009

National Energy Conservation BEE Award Rajasthan Energy Conservation Award

CII Excellent Energy Efficient Unit CII Excellent Water Efficient Unit

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Thank You

Documents

JK Tyre & Industries Ltd. D R PAI