JK Tyre & Industries Ltd · 2018-09-13 · Ranked as the 22nd largest tyre manufacturing company globally Annual capacity of 32mn Tyres with 12 manufacturing plants globally 1st Indian

© Confederation of Indian Industry

JK Tyre & Industries LtdChennai Tyre Plant

Team Members:K.A. Unni Nayar – Vice President WorksB Ramesh Kumar – DGM (EEI) - Energy ManagerM Pandiarajan – Chief Manager Utilities

1

CII – NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT 2018


JK Tyre – Business Overview

Late Lala

Juggilal Singhania

Late Lala

Kamlapat Singhania

Established tyre business in 1977, JK Tyre is amongst the leading tyre manufacturer in India

Presence across product verticals starting from 2.1 kg to 3.5 ton

Ranked as the 22nd largest tyre manufacturing company globally

Annual capacity of 32mn Tyres with 12 manufacturing plants globally

1st Indian tyre company to have verified Carbon Footprint as per IS-14064

Among the Energy efficient tyre companies in the world (10.1Gj/Ton)

Participant in the climate initiative ‘CO2 neutral websites’ with the vision to become a

Green Company2


JK Tyre – Chennai Tyre Plant Profile

Salient Features of Chennai Tyre Plant

❖ Location Selection – Automobile Hub

❖ Most technologically advanced plant

❖ Equipment Selection for high Energy Efficiency

❖ Environment friendly technology considered during Plant Inception itself

❖ Zero Liquid Discharge Plant

❖ Usage of Maximum Day lights

❖ Highly optimized WIP material flow

❖ Modular designs for seamless expansion

❖ Young Workforce

Chennai Tyre Plant in Tamil Nadu is the 6th manufacturing plant of JK Tyre whichwent on stream on 05th February 2012 presently produces 45 Lakhs Passenger CarRadial (PCR) tyres and 12 Lakhs Truck / Bus Radial (TBR) tyres per annum.

Major Products – Chennai Tyre Plant

3


Manufacturing Process Flow

Raw Materials

Mixing & Calendering

Tyre Components Building & Inspection

Rubber Bales Rubber Chemicals

Textiles Steels

Banbury Mixer

Tyre Building

Tyre Curing

Visual Inspection

Uniformity ,X Ray ,

Balancing & QA Inspection

Finished Tyre

Tread & Sidewall Extruder

Inner Liner Calendering

Body Ply Cutter

Belt CutterCalendering

Bead Preparation

4


0.947 0.945 0.941

0.906

0.88

0.9

0.92

0.94

0.96

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

KW

H /

KG

Specific Power Consumption - Electrical

23802343

2237

2129

2000

2100

2200

2300

2400

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

Kca

l / K

g

Specific Energy Consumption – Electrical & Thermal

1. Sp. Energy Consumption in last 3 years

5

10.5% SEC reduction

0.4140.366 0.342 0.331

0

0.1

0.2

0.3

0.4

0.5

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

KG

/ K

G

Specific coal consumption - Thermal


1. Factors influences SEC Variation

0.9

83

0.9

54

0.9

18

0.8

89

0.8

64

0.8

45

0.8

30

0.8

0.9

1

1.1

180 200 220 240 260 280 300

KW

H /

KG

Production (MT)

Specific power Target - ElectricalFactors influence SEC Variation

▪ Capacity utilization because of market changes

▪ Tyre technology development trials▪ More No of SKU’s in market▪ Climatic condition▪ Product scrap and rework▪ Machine breakdowns

2.1

9

2.0

9

1.9

6

1.8

1

1.7

2

1.6

4

1.5

5

1.5

1.8

2.1

2.4

180 200 220 240 260 280 300

KG

/ K

G

Production (MT)

Specific Steam Target – Thermal

26

27

25

20

23

84

22

37

21

42

20

61

19

74

1750

2250

2750

180 200 220 240 260 280 300

Kca

l/ K

G

Production (MT)

Specific Energy Target – Electrical & Thermal

6


2. Information on Competitors, National & Global benchmark

0.87

0.99 1.00

1.10

0.91

0.60

0.80

1.00

1.20

A B C G JK

KW

H /

KG

COMPETITOR

Electrical Specific Power Consumption Benchmark

1.28

1.87

2.30

1.28

1.70

0.00

0.50

1.00

1.50

2.00

2.50

3.00

A B C G JK

KG

/ K

GCOMPETITOR

Thermal Specific Steam Consumption Benchmark

A – Competitor A (National) B – Competitor B (National)

C – Competitor C (National) G – Competitor Global

7


2.1 Target for next 3 years

8

1.6

50

1.5

67

1.4

89

1.5

00

1.4

25

1.3

50

0.8

30

0.8

15

0.8

00

0.3

05

0.2

89

0.2

75

0.000

0.200

0.400

0.600

0.800

1.000

1.200

1.400

1.600

2018-19 2019-20 2020-21

Spe

cifi

c p

er

kg o

f p

rod

uct

ion

SPC/SSC Targets for Water, Steam, Power and Coal

Water

Steam

Power

Coal


2. Road map to achieve benchmark

▪ Area / Equipment / Auxiliary Component wise target fixing and control(Targets for 0.1% Energy level)

▪ Air distribution loss study and re design▪ Innovative project implementation at Ventilation system and by

reducing energy about 1.8% from total plant consumption▪ Passenger Car Radial Tires 100% Nitrogen curing in place of High

Pressure steam curing▪ 20% Biomass fuel mix-up with coal @ boilers

2018-19

▪ Increasing Renewable energy substitution from 49% to60%

▪ Innovation project at Hydraulic ejector system for efficientuse of energy

▪ Solar Thermal for boiler feed water Heating▪ Solar Thermal for ETP Evaporator

2019- 20

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3a. Energy Saving projects implemented in Last 3 Years

2015 - 16

2016 - 17

2017 - 18

DESCRIPTION ZERO INVESTMENT WITH INVESTMENT TOTAL

Projects in (Nos) 7 9 16Total savings in (Million Kcal) 776 3373 4149Total Savings in (Million Rs) 33.83Total Investment in (Million Rs) 7.92Payback in (Months) 3





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3a. Energy Saving projects implemented in FY 2015-16

S.No. Title of Project

Annual Electrical Saving, Million

kWh

Annual Thermal Saving, Million

kcal

Total Annual Savings,

Million Rs

Investment Made

(Rs million)

Payback months

1 FRP Fan replaced at Process Cooling tower 0.07 0.00 0.50 0.18 4

23 Nos HWS pumps rated 90KW, are converted to VFD conversion from Star/Delta starter.

0.20 0.00 1.43 0.95 8

35 Nos Hydraulic pumps rated 75KW, are converted to VFD conversion from Star/Delta starter.

0.68 0.00 4.88 1.57 4

4Solar light pipe installation at Air conditioned areas of the plant

0.02 0.00 0.17 0.28 20

5Day light usage at machine floors by Installing Poly carbonate transparent UV protected roof sheet, in place of complete iso foil thermal insulated roof

0.21 0.00 1.51 2.00 16

6 Timer for Street light 0.02 0.00 0.13 0.10 9

7Energy saving by taking control of Carbon compressor with Mesnac Auto carbon loading PLC

0.07 0.00 0.52 0.00 0

11


3a. Energy Saving projects implemented in FY 2015-16

8Energy saving by replacing normal 250W high bay lights with 120W induction lamp - 425 Nos

0.32 0.00 2.30 4.89 25

9Stopping of Carbon house Compressor during idle running by auto reduced from 64 /bag to 34/bag

0.44 0.00 3.15 0.00 0

10Control room volume reduction there by reducing cooling energy requirement

0.03 0.00 0.18 0.10 7

11Stopping of one out of two Vacuum generator running in all the three SAV machines 4kw each

0.08 0.00 0.58 0.00 0

12 Installation of Variable Frequency Drives for CHP Crusher motors 0.01 0.00 0.10 0.16 19

13 282 Nos of 125W MV lamps are replaced by 45W LED bulbs at curing area 0.10 0.00 0.70 0.42 7

14 Reducing rework generations from 8% to 5.0% 0.66 0.00 4.73 0.00 0

151012 Nos of 18W tube bulbs (4X18W tube fitting) are replaced by 8W LED bulbs (4X8W LED tube fitting)

0.05 0.00 0.37 0.69 23

16190 Nos of 28W single and twin tube fittings bulbs are replaced by 14W LED bulbs inside the plant

0.01 0.00 0.10 0.14 17

17295 Nos of 36W single and twin tube fittings bulbs are replaced by 20W LED bulbs inside the plant

0.02 0.00 0.17 0.22 15

18Intoduction of HP sweep in TBR Hot water curing to reduce the specific steam consumption in HWG

0.00 2.08 2.55 0.50 2

19 Excess steam flash recovery to Boiler deaerator. 0.00 88.75 0.61 1.20 24TOTAL 3.00 90.83 24.67 13.39 7

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3b. Energy Saving projects implemented in FY 2016-17

S.No Title of Project


kWh


kcal


Million Rs

Investment Made

(Rs million)

Payback months

1Two nos. VAM Cooling towers of capacity 650 M3/Hr each, interconnection and process optimization

0.497 0.00 3.39 0.18 1

2LP and HP compressors energy performance improvement by intelligent flow controller

0.388 0.00 2.64 1.55 7

3Mixer dust collector interlock with respect to receipe sequence @ 430-1 and 430-2 machines

0.043 0.00 0.29 0.00 0

4Plant street light conversion to 70W LED inplace of 250W metal halide - 201 Nos.

0.171 0.00 1.20 1.47 15

5Energy improvement in the budde conveyor system by optimise the running hours

0.021 0.00 0.15 0.00 0

66Nos Mixers fume extraction energy performance improvement by installing VFDs

0.413 0.00 2.81 1.20 5

7Triplex Extruder machine blower replacement (22KW) by High efficiency blower

0.085 0.00 0.58 0.90 19

13


3b. Energy Saving projects implemented in FY 2016-17

8Optimizing of number entrances availability for vehicle movements @ air conditioned shop floor areas, and its sizes

0.124 0.00 0.84 0.00 0

920 Nos street lights are made OFF at inner periphery after shift timings where there is no people movement

0.004 0.00 0.02 0.00 0

10 TBR curing converted from HWS to N2 curing 2.308 0.00 15.71 1.42 1

11250W MH focus light converted to 80W LED focus light -80 Nos

0.060 0.00 0.41 0.41 12

12Mixer main motor speed reduced during idle timing from 1000rpm to 250rpm three Mixers

0.532 0.00 3.62 0.00 0

13Mixer 430-1 TSS calendar nip gap pressure setting optimization done, hence by energy saving

0.178 0.00 1.21 0.00 0

14 Curing Trench vent flash steam recovery 0.00 0.03 0.12 0.10 10

15Reduce Coal carpet loss by introduction of Coal palletizer for recycling

0.000.30

0.36 0.70 23

16Heat recovery from excess main drain water to boiler make up water

0.000.41

0.48 0.00 0

TOTAL 4.82 0.74 33.83 7.92 3

14


3c. Energy Saving projects implemented in FY 2017-18

S.No Title of Project


kWh


kcal


Million Rs

Investment Made

(Rs million)

Payback months

1Nitrogen conversion of Curing Pressess from Hot Water System

0.00 7332.53 8.66 2.24 3

2Air handling unit performance improvement, High efficiency fans with VFD control

0.064 0.00 0.415 0.65 19

3

Plant lighting complete LED conversion (250W Hibay - 855 Nos / MH focus lamps - 268 Nos / 120W MV lamps - 100 Nos / 36W tube bulbs -2360 Nos)

0.963 0.00 6.262 6.81 13

4Frequently failed pneumatic hoses replaced with rubber hoses at entire carbon transfer system

0.255 0.00 1.052 0.26 3

5Auto cutoff air valve and air pressure reduction station provided to optimize the air pressure requirement for the carbon transfer process.

0.142 0.00 0.923 0.10 1

6PU hoses with copper tubing Modification work in LTM 45 presses - AUTO PCI - 15 Nos

0.073 0.00 0.462 0.45 12

15


3c. Energy Saving projects implemented in FY 2017-18

7Movement sensors for man coolers and spot coolers inside the plant (Trail project)

0.004 0.00 0.024 0.04 20

8Process cooling tower (PCT) operation optimized and stopped one number of 75KW pump during winter season

0.384 0.00 2.496 0.00 0

9Power pack cooling tower pump 1no. 75KW rating stopped, by optimized the operation and flow requirement.

0.568 0.00 3.692 0.00 0

10Hydraulic & ejector system 5.5KW transfer pump turned Off by line modification

0.075 0.00 0.487 0.00 0

11Energy saving by implementing VFD drive for dust collector motor in 440 & 270 Master mixers

0.053 0.00 0.346 0.42 15

12Energy saving by providing VFD on new VAM Cooling tower pump(2X90 KW)

0.937 0.00 6.092 0.00 0

TOTAL 3.518 7333 30.91 10.98 4

16


4. Innovative Projects implemented

17

0

10

20

30

40

50

60

70

Coal Electricity

66

34

Pe

rce

nta

ge (

%)

Plant- Energy Sources

Fixed21.6%

Semi Fixed20.1 %

Variable58.3%

Power Consumption

Fixed Semi Fixed Variable


4.1- Innovative Projects implemented

Reduce Fixed Power ConsumptionPlant fixed power consumption is 21.6 % from the Overall plant power consumption.

IDEA: High Power consuming Centrifugal Fan can be replaced with High Efficiency Axial Fan

2050010500

7800 63003600

42%

64%

80%

93%100%

0%10%20%30%40%50%60%70%80%90%100%

2500

12500

22500

32500

42500

Ventilation VAM & AUX

Lighting MHECanteen &…

ETP/STP

KW

H/D

ay

21.6 % Split up of Fixed

Energy

18



Innovation Details: Replacing Traditional Centrifugal ventilation fan system with latest technology axial fans those should develop higher pressure air flow outlet with lesser power inputs.

Result: 68% of Energy Saving (i.e. Power Consumption reduced to 4.5kWh from 14.4 kWh. Cost Savings of 5.54 Lacs /Annum ( for POC Unit)

Horizontal Deployment: Being deployed to all other 93 Ventilation Units and there is a replication potential for all other JK Units and for Similar Industries(Allocated Budget : 1 Crore for Horizontal Deployment for the Year 2018-19

19



Reduce Semi Fixed Power ConsumptionPlant Semi fixed power consumption is 20.1 % from the Overall plant power consumption.

IDEA: Compressor Loading Hours to be optimized by elimination of Energy Loss due to Air Leak in Carbon Conveying System

19298 7866 7291 5516 4564

43.3%

61.0%

77.4%89.8%

100.0%

0.0%

20.0%

40.0%

60.0%

80.0%

100.0%

2500

12500

22500

32500

42500

Compressor Final finishing Process CT HYD BOILER

KW

H/D

ay

20.1% Split up of Fixed

Energy

20



Innovation Details: Carbon Conveying system redesigned ▪ Cut off Valve provided near the Air Reservoir Outlet▪ PRV provided in the Conveying Line to regulate the required pressure ▪ PU hose replaced with High Pressure Metallic Braided Hoses (Extended Life of 10 yrs)

Result: 8.6% saving of Compressor Energy (i.e. Power Consumption reduced to 1650 kWh/day. Cost Savings of 38 Lacs /Annum

Horizontal Deployment: Can be deployed and there is a replication potential for all other JK Units and for Similar Industries

PRESSURE CONTROL VALVECUT OFF VALVE METALLIC BRAIDED RUBBER HOSES

21



Reduce Steam Consumption in TBR Curing ProcessHot Water System consumes 39% of Steam from the Overall Truck Bus Radial TyreSteam consumption.

IDEA: Conversion of Hot Water Curing to Nitrogen Curing during Tyre Curing Process

39% Steam Consumption for Hot Water

System

56%

5%

39%

TBR Steam Consumption (MT/Day)

MPS

LPS

HWS

22



Innovation Details: Traditional Internal Hot Water Cure Media has been replaced with Nitrogen Cure

Result: ▪ 10% of Steam reduction in TBR Curing (i.e. Coal Consumption - 4 MT/day. Cost Savings of

70 Lacs /Annum)▪ 2.7% of Power Saving from Overall Plant consumption(i.e. Power saving- 6500 kWh/day.

Cost Savings of 150 Lacs /AnnumHorizontal Deployment : Can be deployed and there is a replication potential for all other JK Units and for Similar Industries

23



Reduce Steam Consumption in PCR Curing Process ( PCR - Passenger car radial )PCR curing consumes 37% of Steam from the Overall Plant Steam generation. And PCR curing process Specific is Higher than overall plant Specific.

IDEA: Steam distribution through three individual headers (HPS, MPS & LPS) in PCR Tyre Curing Process. Individual steam headers causing more header trap losses. Header merging can be done to reduce the header trap losses

PCR curing Specific

consumption is higher than

Overall specific

0.95

1.63

0.35

1.5

0

0.5

1

1.5

2

TBR PCR VAM Over all

Area wise specific steam Target (Kg. / Kg)

TBR PCR VAM Over all

24



Innovation Details: One header (MPS) isolated and HPS & MPS steam supplied from HPS header.

Result: ▪ 9 MT / day of Steam reduction in PCR Curing (i.e. Coal Consumption – 1.7 MT/day. Cost

Savings of 29.7 Lacs /Annum)Horizontal Deployment : Can be deployed and there is a replication potential for all other JK Units and for Similar Industries

25

HP Steam Header

MP Steam Header

HP & MP Steam Header

Curing Press Curing Press


5. Utilisation of renewable energy sources

Total On-site Renewable Energy Generation = 10 %

Total Off-site Renewable Energy Generation = 39 % Day light utilization (savings of 18000 units/month)

1560 Nos Turbo Vents (savings of 3 Lacs units/month)

15.2 MW Installation Capacity

6 MW Installation Capacity

26


5. Utilisation of renewable energy sources

2015-16 2016-17 2017-18

WIND 1 13.26 38.77

SOLAR 0 2.48 5.35

1

13.26

38.77

02.48

5.35

0

5

10

15

20

25

30

35

40

45

Co

nsu

mp

tio

n in

(%

)

Renewable energy utilization

TNEB36%

IEX20%

WIND39%

SOLAR5%

GREEN44%

Plant Energy Mix 2017-18

27

Currently solar is at 10% and the total capacity is 6MWp


6. Utilisation of waste material as fuel

USAGE OF SPILLEAGE & WASTE COAL FINES :Palletizing of Coal Fines from Coal Handling

Plant & Coal Yard by using Palletizer Machine andPalletized Coal fines used in Boiler( 0.5 Ton / Day Coal Fine Palletized and used)ASH RECYCLING FOR UNBURNT REDUCTION

Bed Ashes are collected from the Boiler BankZone, Economizer & APH Hopers where Un burntcontent is high. Collected Ashes are recycled in theBoiler for further combustion.

PLANT WOOD WASTE USED AS FUEL FOR BOILER:Plant Wooden Waste has been sent to

Recycler and then Crushed into Wooden Dust. Then Wooden dust mixed with Coal in 20% ratio and used in Boiler

28


7. GHG Inventorisation

• All Plant (decentralized level) GHG Inventorisation

• Rolling up the inventory to Corporate Level

Identification of GHG Sources and Sinks

Selection of Quantification Methodology

Selection and collection of GHG Activity Data

Selection of GHG Emission Factor

Calculation of GHG Emission and Removal

Emission Sources Scope of Emission

Diesel for internal material transport

Direct Emission (scope 1)

Diesel for generators

Boiler coal

HSD (High speed diesel)

Company vehicle‐Diesel

Company vehicle‐Petrol

LPG consumption ( GH)

Release of refrigerant

Use of Acetylene

Weight of CO2 released from fire extinguishers

Overall purchase of Electricity Energy

Indirect Emission (scope 2)

29


7. GHG Emission Intensity and Verification

1.73

1.39 1.431.27

1.01

2013-14 2014-15 2015-16 2016-17 2017-18

Emission Intensity Co2e Ton/Ton of Tyre

GHG Emission Intensity reduced to42 % from the base Year 2013-14

30


8. Green Supply Chain

❑ Transport route optimization: Raw material supply truck used to carry our finished goods to various customers and depots.

❑ We minimise the transit distance by selecting the vendor which is near to our plant.

❑ We are avoiding Transportation distance of material approx. 13 lacs Kms per year.

❑ Silica was received in 25 Kg bags which has been changed to jumbo bags of capacity 400 Kg

Silica

Jumbo Bag

Annual Energy Conference is organized to share the Energy Projects, Improvements & Best practices within JK organization, Supplier and Vendors. Horizontal deployment done across the verticals based on the Applicability of the Projects.

SUPPLIER VISITS: TO SHARE THE GREEN PRACTICES

31


9. Team work, Employee Involvement & Monitoring

Daily Monitoring System

• Advance EMS System - EMS plus Breaker controlling system for online monitoring and Control. Auto SMS, Email, Android mobile application facility and web access

• Plant ,Area wise ,Equipment wise SPC and Analysis report shared to the Process Owner for Improvements

• Daily Review Meeting chaired by Plant Head

• Monthly Energy Review meeting chaired by Director Manufacturing

• Monthly Business Review Meeting chaired by President – India Operations

• EnMS Management Review Meeting chaired by Plant Head – Half Yearly

32



Annual Separate Energy

CAPEX Budget 38

80 76

163

-20

30

80

130

180

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

In L

acs

ENERGY CAPEX BUDGET

654914

1087

723

0

500

1000

1500

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

In N

os

KAIZEN TREND

Kaizens Implemented

33



1. Class room training –All Employees were trained with Green Initiatives like plant Energy consumption & Energy efficiency methodology in planned intervals

2. Visual aids – Training has been taken with different visual aids for better understanding on Green Initiatives.

3. Displaying posters – On shop floor stickers/posters were pasted to create awareness in every individual.

4. Cross Functional Team /Kaizens – In shop floor, CFT Approach followed to understand the Energy consumption & process of their equipment/machine.

5. Motivation by Awards & Recognition – Awards & recognition has been given to employee upon their performance which can be indicated as KAIZEN’s etc.,

34


10. Implementation of ISO 50001/Green Co/IGBC rating

ISO 50001 : 2011 Certified on July 2013

35


Awards and Accolades

Golden Peacock Energy Efficiency Award 2017

SEEM National Energy Management Award 2016 & 2017

CII – National Award for Excellence in Energy Management -2016 & 2017

BEE – National Energy Conservation Award 2014 & 2015

CII - Green Factory Certification 2016 CII - Green Co Certification 2014

36


Thank you

37

Documents

JK Tyre & Industries Ltd · 2018-09-13 · Ranked as the 22nd largest tyre manufacturing company globally Annual capacity of 32mn Tyres with 12 manufacturing plants globally 1st Indian