National award for Excellence in Energy Management ... · Godrej Agrovet Limited (GAVL), is a diversified , Research &Development backed agribusiness company , dedicated to improving

National award for Excellence in Energy

Management & Efficiency

August, 2018

MSMS KUMAR - General Manager

Abhinav Kumar - Sr. Executive

PALM OIL MILL - CHINTAMPALLI

2 I Godrej Agrovet I GAVL – OPP August 2018

PRESENTATION OUTLINE

➢ Plant Profile

➢ Good and Green

➢ Plant performance for last three years

➢ Overview

➢ Energy conservation projects

➢ Innovative projects at Godrej Agrovet Limited–OPP

➢ Green supply Chain

➢ Energy Management system


Plant Profile

70TPH Fresh Fruit Bunch (FFB) Processing Plant. 100TPD Palm Kernel Processing Plant.

2.5MW Bio-mass based Cogeneration Plant


25TPD Briquette plant

10TPD Feed Additive plant


Godrej Agrovet Limited (GAVL), is a diversified , Research &Development

backed agribusiness company , dedicated to improving the productivity

of Indian farmers by innovating products and services. GAVL has

developed Gross area of 64,700 hectares of Oil Palm plantations across

Andhra Pradesh, Orissa, Gujarat, Telangana , Tamil Nadu, Goa and

Mizoram. We are highest Crude Palm Oil and Crude Palm Kernel Oil

producer in the country.


Major Equipment in Processing of Fresh Fruit Bunches

Crude Palm Oil Mill

❖ Sterilizers - 50ton capacity – 3Nos

❖ Screw Presses - 15ton capacity - 5Nos

❖ Clarifier section - 90ton capacity – 2Nos

❖ Decanter - 20Ton capacity -3Nos

❖ Purifiers - 10Ton Capacity-3Nos

CRUDE PALM KERNEL OIL Mill

Expellers-10TPD – 10 Nos

BIOMASS BASED CAPTIVE COGENERATION PLANT

❖ Boiler – 35TPH

❖ Turbo-Generator – 2.5Mw

❖ RO cum DM Plant – 50M3/Hr.


Process Flow Diagram

PALM OIL PROCESS FLOW CHART Fresh Fruit Bunches

EMPTY BUNCHES OIL TO CLARIFIER

FRUITS

SHREDDED FIBRE- SALE & BOILER FUEL

NUT+FIBRE

OIL+WATER

+NOS FIBRE TO BOILER SHELL- BOILER

FUEL

OIL

OIL SLUDGEWATER KERNEL

TO ETP

OIL CAKE - SALE

KERNEL CAKE

SALE SALE

CRUDE P PALM OIL PALM KERNEL OIL

BUNCH RECEPTION

BUNCH STERILIZATION

THRESHING

FRUITS DIGESTION

PULP PRESSING

CLARIFICATION

OIL PURIFICATION

VACUUM DRYING

OIL STORAGE

EFB PRESS

NUT SEPARATION

NUT CRACKING

KERNEL DRYING

KERNEL CRUSHING

PKO STORAGE

3 PHASE

DECANTER


Products

Crude Palm Oil

Crude Palm Kernel Oil

Palm Kernel Cake

Biomass Briquette

Feed Additive Powder

Co-Generation


GOOD & GREEN

OVERVIEW


Specific Energy consumption Trend

1489

1350

1400

1450

1500

1550

1600

1650

1700

1750

1800

FY-13 FY-14 FY-15 FY-16 FY-17 FY-18

Specific Energy - MJ/Ton

1753

1618 1620 1678 1578

1489

1. Capacity utilisation

2. Addition of Steriliser

Avoids steam vent loss

3. Implementation of

Energy saving projects


Our journey

We aspire to create a more

employable Indian

workforce, build a greener

India, and innovate for

'good' and 'green'

products

We are furthering this

commitment through

'shared value' initiatives

that create both social

and business benefits

We articulated our

commitment towards

building a more

inclusive and greener

India –

Godrej Good & Green

2011 2018 2020


Our goals

Achieve zero waste to landfill,

carbon neutrality and a

positive water balance, while

reducing specific energy

consumption by 30% and

increasing the use of

renewable energy by 30%

Train 1 million youth in skills

that will enhance their

earning potential

Generate a third of our

portfolio revenues from

'good' and/or 'green'

products

Ensuring

Employability

Greener

India

Product

Innovation


GridElectricity[Mwh]

HSD[Mwh]

Electricity fromBiomass[Mwh]

8235

Energy Distribution

0

20000

40000

60000

80000

100000

120000

Electrical energy

Thermal Energy

8627

Total Energy Distribution[MJ]

106947

246 147

Electrical Energy Distribution-[MW]


CHINTAMPALLI PALM OIL MILL

PERFORMANCE


Specific Green house gas emissions Scope1+2 (Kg

CO2/T)

0

1

2

3

4

5

6

7

8

9

10

FY13 FY14 FY15 FY16 FY17 FY18

2.098.74 1.541.651.43 0.94


Green house gas emissions Scope1and 2 (tCO2)

Chintampalli Absolute Emissions

Scope 1 Scope 2 Total

FY14 105 204 309

FY15 77.0 273 350

FY16 117 371 488

FY17 111 300 411

FY18 63.4 200 263


Renewable Energy share in Total Energy

RENEWABLE ENERGY

Total

Energy

Non Renewable

Energy

Renewable

Energy

Percentage

Renewable

FY14 3,49,849 2,320 3,47,530 99.3

FY15 3,43,771 2,248 3,41,523 99.3

FY16 3,92,569 3,219 3,89,350 99.2

FY17 4,21,956 2,821 4,19,134 99.3

FY18 4,16,067 1,739 4,14,328 99.6


Greener India impact

Goal

15% reduction in specific

energy consumption

Reduce specific energy

consumption by 30%

Achievement

Increase renewable

energy sources by 30%

Become carbon

neutral

Have a positive water

balance consumption

99.6% of total energy consumption

from renewable sources


greenhouse gas emissions


water consumption


waste to landfill

Send zero waste

to landfill


Specific Energy Reduction Target

TARGET (MJ/MT) 2018-19 2019-20

Total 1489 1350

SHORT TERM TARGET

TARGET (MJ/MT) BASELINE,

2013-14

2020

Specific Energy

Consumption (Total)

1753 1227

LONG TERM TARGET


Energy conservation/efficiency projects FY16-18

Name of the projectsInvestment

- [lakh]Savings Annually – [Lakh]

Biogas from ETP –

Utilization in Boiler &

Hot Air Generator37.0

8.4lac Cubic Meter/Year -

[Rs.67lac]

Replacing MH Lamp

With LED Lights6.5 24046Kwh – [Rs.1.56Lac]

VFDs 4.0 193600Kwh - [Rs.1.9Lac]


CO- Generation Plant : Waste to Wealth

Godrej Agrovet Limited has Modern

Palm Oil Mill at Chintampalli Village,

W.G.Dist , Andhra Pradesh which is

the largest Palm oil mill in India and

generates Biomass to the extent of

450Mt/day. Captive Co generation

plant of 2.5MW capacity consumes

around 220 Mt. of biomass.

Benefits:

1. 99.6% Renewable energy

2. Almost negligible GHG footprint


Bio-Gas from ETP : Waste to Wealth

Palm Oil mills generates huge volumes of Effluent with High COD levels. Anaerobic

digestion is one of the most widely employed biotechnologies for effluent treatment

because it not only digests the high organic contents of wastewater but also generates

huge quantity of renewable energy in the form of biogas

Using Up-flow Anaerobic

Sludge Blanket reactor

(UASBR) technology, capture

the methane and burn it inside

Hot Air Generator.

Benefits:

1. Reduction in GHG

emissions

2. Cost savings as reduction

in fuel helps to produce more

biomass briquettes

Biogas Pumping station


Green Supply Chain – Palm oil Value Chain


Green Supply Chain – Our Action

1. An extension team supports farmers

with cultivation, harvest and

transport of FBBs to mill; through

trainings and SOPs

2. Previously agricultural land used for

palm oil cultivation.

3. Farmer participation voluntary,

respecting free and informed prior

consent of indigenous communities.

4. No cultivation on peat / HCV / HCS

areas or any biodiversity hotspot


Green Supply Chain – Sustainable Palm Oil Mapping

Principle Mill

No. of

Indicators

No. of

Applicable

Indicators

Compliant Partially

Compliant

Non

Compliant

Complian

ce level

PRINCIPLE 1: COMMITMENT TO TRANSPARENCY 4 4 1 1 2 25%

PRINCIPLE 2: COMPLIANCE WITH APPLICABLE LAWS AND

REGULATIONS

14 4 4 0 0 100%

PRINCIPLE 3: COMMITMENT TO LONG-TERM ECONOMIC AND

FINANCIAL VIABILITY

2 1 1 0 0 100%

PRINCIPLE 4: USE OF APPROPRIATE BEST PRACTICES BY

GROWERS AND MILLERS

41 17 9 5 3 53%

PRINCIPLE 5: ENVIRONMENTAL RESPONSIBILITY AND

CONSERVATION OF NATURAL RESOURCES AND BIODIVERSITY

17 10 4 3 3 40%

PRINCIPLE 6: RESPONSIBLE CONSIDERATION OF EMPLOYEES AND

OF INDIVIDUALS

AND COMMUNITIES AFFECTED BY GROWERS AND MILLERS

36 32 23 3 6 72%

PRINCIPLE 7: RESPONSIBLE DEVELOPMENT OF NEW PLANTINGS 23 3 1 0 2 33%

PRINCIPLE 8: COMMITMENT TO CONTINUAL IMPROVEMENT IN KEY

AREAS OF ACTIVITY

1 1 0 1 0 0%

Total 138 72 43 13 16

Overall Compliance level 60%


Way forward

• Reduce specific

energy by 30%

• Carbon Neutrality

• Renewable energy

by 100%

Process Reengineering and Process Innovation

Investing in clean technologies

Incorporating sustainability in Value Chain

Integrating energy conservation education

and enhancing supplier performance


TRAINING & AWARENESS

OVERVIEW

22 suggestions

9 Implemented


Energy management cell

FACTORY HEADCORPORATE GROUP

ENERGY TEAM

(CORDINATORS)ENERGY MANAGER

SMALL GROUPS

(TEAM MEMBERS)

• Strategic Planning

• Quarterly Review

• Project facilitation

• Strategic Planning

• Monthly Review

• Daily Monitoring

• Monthly Review

• Daily Monitoring

• Identification and

execution of projects• Daily Monitoring

• Annual Activity Plan

• Initiate activity to improve

monitoring

• Equipment performance Analysis

• Conduct Internal Workshop

• Daily Monitoring of

Specific Energy

• Assisting in execution of

projects


Energy monitoring and review

SoFi Enterprise Sustainability Performance Software for

Sustainability Management and Data analysis and reporting

Review

Monthly

Review

Quarterly

Review

Plant Level &

Corporate Level

GILAC Level chaired by

Mr. N B Godrej

Governing Council at

Group Level chaired by

Mr. J N Godrej and Mr. N

B Godrej

Half yearly

ReviewDaily

Review

Plant Level

Daily reports


CONTACT US

www.godrejgoodandgreen.com

THANK YOU


Godrej Agrovet wins the award

for Highest Crude Palm Oil Producer in the Country

Mile Stones

❑ 6.0Mt. Established in 1999

❑ 1Lac Mt. FFB crushed in FY-08

❑ Unit-2 Established in FY-13

❑ 2.5Lac Mt. FFB Processed in FY-17 in single unit [unit-2]


THANK YOU FOR YOUR TIME AND CONSIDERATION

Documents

National award for Excellence in Energy Management ... · Godrej Agrovet Limited (GAVL), is a diversified , Research &Development backed agribusiness company , dedicated to improving