JK Tyre, Kankroli

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  • 1Lala 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 )

    2

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    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

  • 3Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    An Overview of JK Tyre & Industries Ltd.

    4

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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

  • 5Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    Manufacturing Process Flow Diagram

    6

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    Energy Policy

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

    Enhancing Equipment EfficiencyMinimizing Waste & idle runTechnology & InnovationPeriodic Reviews and Skill UpgradationPeople Involvement

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

  • 7Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    Focus areas for

    Energy conservationFuel conservation

    Resource conservation

    Reduction of green house gases

    Reduction in consumption of petroleum products

    Elimination of ozone depleting substances

    8

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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

  • 9Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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

    10

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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

  • 11

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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

    12

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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 749200809 51.725 222.53 Coal

    0.453 1.67 6.21

    LDO/LSHS 759 7.29 0.01 0

    32866 116.3 72203 766200708 55.293 243.72 Coal

    0.483 3.23 -5.69

    LDO/LSHS 731 3.04 0.01 9.1

    34670 101.12 71795 779200607 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

  • 13

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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

    14

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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

  • 15

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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.

    16

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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

  • 17

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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

    18

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

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

    JK - KTP 1.98 0.710

    Future Plans to Challenge THE

    BEST

    Reduction of fossil fuels Insulation improvement

    on hot steam linesWaste Heat recovery Reduction in flash steam

    lossesHot water recovery in

    curing pressesUsing 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

  • 19

    Lala Lakshmipat Singhania( 1910 1976 )

    A Visionary & Key ofJK Organisation

    KTP

    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