Team Members : Mr. Sandesh Borwankar DGM-Engg Services … · FAT SPLITTING(INPUT) 325 463 1,52,790 FATTY ACID DISTILLATION(INPUT) 325 445 1,46,850 SWEET WATER EVAPORATION(INPUT)

1Consumer Products Limited

Unit: Malanpur

“19th National Award for Excellence in Energy Management-

2018”

29- Aug 2018 to 31-August 2018 , Hyderabad.

Team Members :

Mr. Sandesh Borwankar

DGM-Engg Services

Mr. Mukesh Agrawal

Asst. Manager-Engg Serv.

Mr. S N Mathur

Asst. Manager-Operation


Plant profile

Plant area – 70 acres

Commencement of plant operations – 1990

Unit is certified with ISO 9002 , ISO 14001 ,

TPM excellence award – 2007

Green co award – Gold category in year 2017 in its first attempt.

Godrej group established in 1897; current turnover Rs. 9000 crores,18,000 strong workforce.

Manufacturer of locks to launchers and store wells to soaps.

GCPL Malanpur unit is located in dist. Bhind MP , 30 km away fromGwalior MP.

Malanpur plant manufactures toilet soaps and soap noodles producing150000 MT of soap noodles and 70000 MT of toilet soaps .

Total Capex – 230 crore

Turnover – 1000 crore


MILESTONES

Apr 1995

Mar1997

Jun 1999

May 2006

Apr

2008

Mar1991Establishment of

plants

GreenCo Gold Award

ISO 9002

Expansion

Expansion of

chemical plants

and toilet soap

plant

ISO 14001TPM Award from

JIPM

TPM award

Expansion of

chemical plants

and soap

noodles

Apr

2012Expansion of

toilet soap plant

Expansion

Expansion Jan 2017


Process Flow Diagram for manufacturing Soap

Noodles/finished

Oil Tanker

Soap Bar


PLANT CAPACITY DETAILS

PLANTINSTALLED

CAPACITY (MT / DAY)

CURRENT CAPACITY (MT /

DAY)

CURRENT CAPACITY (MT / ANNUM) @ 330

WORKDAYS

FAT SPLITTING(INPUT) 325 463 1,52,790

FATTY ACID

DISTILLATION(INPUT)325 445 1,46,850

SWEET WATER EVAPORATION(INPUT)

240 280 92,000

HYDROGENATION

(Stearic Acids)48 48 -

TOILET SOAP 200 200 66,000

SOAP NOODLES 325 425 1,50,000


2

o Achieve zero waste to landfill

o Carbon neutrality

o A positive water balance

o Reduce specific energy

consumption by 30%

o Increase renewable energy

utilization by 30%

1

Train 1 million youth in

skills that will enhance their

earning potential

ENSURING

EMPLOYABILITYGREENER

INDIA3

Generate a third of our

portfolio revenues

from ‘good’ and/or ‘green’

products

GOOD & GREEN

PRODUCTS

OUR 2020 GOALS- “GOOD & GREEN”

DRIVING FORCE

TPM and IMS policies key points Waste elimination

Optimization of resources

Continual improvements


• Target setting mechanism:

-Long term target : 30% reduction in SEC by 2020 as per Good & Green goals

-Annual targets are proposed based on the achievement during annual Greener

India council review meeting

-Greener India Council is overseen by our directors .

-All the business heads and manufacturing heads are members of the council

-The proposed targets are conveyed to all the businesses and manufacturing units

-The unit head of Malanpur discusses with the team and sets the annual target

and conveys back to the Good & Green team

-The targets are cascaded down to various sections in the plant and KPIs are set

for team members

Objectives and Targets


TARGETS

4190

2850

1000

1500

2000

2500

3000

3500

4000

4500

KWH/MT

Specific Energy Consumption (Total) MJ /MT of product

Base line 10-11 2020


Specific energy consumption MJ/MT

35

%

4190

34723192 3105

2894 2915 2957 29442689

2000

2500

3000

3500

4000

4500

10-11 11-12 12-13 13-14 14-15 15-16 16-17 17-18 18-19-YTD

Total Specific Energy Consumption- MJ/MT

Reasons for Deviations• Increased in energy in year 15-16 due to Biomass Boiler installation and

consumption of high power consumption in solid fuel boilers.• Bio-Mass Boiler is less efficient wrt Gas / liquid fuel fired boilers• FY 18-19 YTD performance results of initiatives in last year


Specific energy consumption MJ/MT

23

%

37

%

3722

30372814 2731

2530 2559 2587 2581

2329

2000

2500

3000

3500

4000Specific Thermal Energy Consumption- MJ/MT

130121

105 104 101 99 103 101 100

708090

100110120130140

Specific Power Consumption- kWH/MT

Biomass Boiler

installed

High power consumption

in Biomass Boiler


Information on Competitors, National & Global benchmark

• National/ International Benchmarking is not available

• Setting Internal Benchmarking

21.93

40.58

28.43

19.6

31.5

26.58

10

15

20

25

30

35

40

45

FSP FADP SWEP

Specific Energy Consumption wrt Vendor commitment- Fuel consumption in Kg/MT


S.No. Projects Total Annual

Savings

Investment

in Lacs

Payback in

Months

Energy saving

(GJ)

1. Installation of Energy efficient water

jet vacuum system in FSP315.0 13

10 1625

2 Installed Micro steam turbine37 127

36 1903

3. Installation of energy efficient LED

lights in place of conventional lights4.5 4

12 231

4 Installed pneumatic based control

valve system in chemical plants in

order to reduce the steam

consumption

8.9 2

3 964

5. Installed heating coil system in Raw

oil tankers in order to reduce steam

consumption

6.9 20

36 748

6. Installed Energy efficient water

chilling unit compressor in soap

finishing line

4.7 5

12 242

Total80.1 171

5713

Energy Saving projects implemented in FY 2015-16


S.No

.

Projects Total Annual

Savings

Investment

in Lacs

Payback

in

Months

Energy

Saving (GJ)

1. Installed pre-concentrator in FSP2

for conserving energy and

improving SW concentration

54 170

36 7020

2. Installed a water based vacuum

system in FADP2 to eliminate

usage of saturated steam

9 24

12 1170

3. Installation of Magnetic flux in

Burners of Boilers-10 3

3 1300

4. Installation of heat exchanger in

FSP215 10

9 1950

5. Installed a water based vacuum

system in Dryer 4 to eliminate

usage of saturated steam

8.4 14.7

18 1092

6. Installed energy efficient water

chilling compressor4.7 6.0

14 250

Total 101.1 227.7 12782



S.No

.

Projects Total Annual

Savings

Investment

in Lacs

Payback in

Months

Energy

Saving (GJ)

1. Installed & commissioned CFA vs DFA heat

exchanger in FADP-3-15 25

20 2229

2. Installed a IOT system in RO unloading

section to reduce the steam consumption –

steam saving of 30 kg/MT of oil

30 80

30 4457

3. Modified the banding machine from 50

bundles to 100 bundles /min to reduce the

power consumption

8 27

42 423

4. Reduction in steam pressure of FADP2 10

kg/cm2 steam used for booster by 8 kg/cm28.4 2.5

3 1248

5. TIC installation in Soap Making 2 & FADP2

for maintaining of steam pressure at desired

value

3.4 2.2

9 327

6 Installed energy efficient brine chilling

compressor4.7 6.0

14 249

7 Interlocking of metal detector conveyor belt

with wrapping to reduce power consumption0.1 0

Immediate 5.3

8 Enhancement of SWEP 3 cooling tower 3.0 5.5

24 446

Total75.5 148.2

9384



S. No. Year of Implementation Saving –Rs lacs

Investment –Rs in lacs

1 2010-11 28.5 35.93

2 2011-12 123.21 75.8

3 2012-13 31.29 20.72

4 2013-14 42 19.52

5 2014-15 100.71 136.22

6 2015-16 80.1 171

7 2016-17 101.1 227.7

8 2017-18 72.52 148.2

Summary of Energy saving Initiatives ( FY 2010 to 2017)


Investment Vs. Savings

171

227

148

77101

75

171

398

546

77

178253

10

110

210

310

410

510

610

15-16 16-17 17-18

Cummulative Savings vs. Investment – Rs. In Lacs


REDUCTION IN ENERGY CONSUMPTION ACHIEVED THROUGH…….

• De-Bottlenecking process

• Process Improvement

• Better planning

• Involvement of operations & maintenance teams

• Breakthrough technology- Up-gradation of technology has resulted in

improvement in reduction of energy cost. To achieve business excellence in

competitive environment, up gradation of technology is critical for existence

• Optimal running of Boilers & plants

• Reuse of waste process energy

• Cost reflecting the actual usage as per oil/FA, thereby selection of raw

material as per proper weightage of energy cost

In the last five years we have implemented more than 60 no's of energy conservation projects resulting into major cost reduction in our variable

cost



335370

382

420444 446

463 472.7477.6

300

350

400

450

500

Feed

-M

T/d

ay

Years

Improvement in plant feed through de-bottlenecking

42.5%

Some measure taken for de-bottlenecking

▪ Enhancement of plunger pump capacity

▪ Modification in instrumentations

▪ Increase in line sizes

▪ Installation of pre concentrator

▪ Installation of 10 kg heat exchanger

FSP

335 362

399415

436 438445 452 452

300

350

400

450

500

Feed

-M

T/d

ay

Years



▪ Enhancement of heat exchanger

▪ Modification in instrumentations

▪ Increase in line sizes

▪ Water jet vacuum system

▪ Installation of CFA/DFA heat exchanger

FADP

35%



200 205 211

230244

257 255244 248

180

220

260

300

Feed

-M

T/d

ay

Years


24%


▪ Utilization waste heat to preheat SW

▪ Timely cleaning of calendria

▪ Vacuum through water jet vacuum system

▪ By reducing water consumption in FSP

feed; over all sweet water generation is

reduced

294

379

414 409 421 424 425 427 431

275

315

355

395

435

Soap

No

od

le-

MT/

day

Years



▪ Enhancement of soap heat exchangers

▪ Provision of water based vacuum system

▪ Timely cleaning of recupurator

▪ Periodic maint of equipment's

SWEP SOAP NOODLES

44%


90

63.1262.44

52.1047.6445.27 43.60

43.06 39.16

30405060708090

100

% w

ater

ad

dit

ion

fo

r sp

litti

ng

Years

Reduction of water addition with oil for splitting

Some measure taken for reduction of water

▪ Optimization of critical process parameters

▪ Fine tuning of control system to achieve desired

temp.

▪ Study of oils chemistry w.r.t fatty acid present.

▪ Synchronization of oil-water ratio & temperature.

56%

Steps taken for better planning

▪ Maximum utilization of energy

efficient plants

▪ Loading of plants for AOP volume is

prioritized based on energy

REDUCTION IN ENERGY CONSUMPTION ACHIEVED THROUGH

▪ These are high return and low

investment project driven out of

system thinking.


REDUCTION IN ENERGY CONSUMPTION ACHIEVED THROUGH

Steps taken for better planning in order to utilized the plants running wrt

low consumption of energy

▪ Reduction of load in FSP 1 from 26% to 0.5%▪ Increase in FSP3 utilization from 50 to 60%

▪ Reduction of load in FADP 1 from 24% to 5%▪ Increase in FADP3 utilization from 53 to 66%

25.6 25.3

15.8 15.6

8.9 9.4

0.5

23.8 23.6

32.8

22.4

38.336.3

39.3

50.6 51.0 51.5

62.1

52.8 54.3

60.1

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

% U

tiliz

atio

n

Year

% Utilization as per Volume

24.622.6

18.5 18.8

10.112.8

4.6

22.018.1

22.4

15.5

27.2 26.529.2

53.4

59.3 59.1

65.762.7

60.8

66.3

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

% U

tiliz

atio

n

Year

% Utilization as per Volume


Innovative Projects implemented in 17-18


Reduction of steam consumption in oil unloading activity in tank farm using IOT ( Internet of things )

• Raw oils ( non edible vegetable) are transported through oil tankers which are non insulated , the total transit time is 6-7 days hence oil used to get solidify at ambient temperatures . We need to heat tankers upto 55 deg to make it fluid so that it can be unloaded through a transfer pump

• The practice used was use of open steam through steam pipe to melt the oil , which was a manual activity.

Entire operation was based on lot of manual intervention and

human judgment leading to wasteful excessive heating .

No control since tank farm is at a remote location from main

plant

No alarm system for timely action

Steam Consumption -140 Kg/MT

ISSUES

Before


STEAM FLOWMETER

SOLENOID ON/OFF VALVE

TEMP. SENSOR(RTD) 4

2 3 1

After

• Provided individual sensors for compartment temperature monitoring . A warning alarm also provided for timely actions from operators .

• Individual steam meters and solenoid shutoff valve provided for each unloading station .• Entire system of 7 such stations connected to a SCADA system for monitoring and controlling of steam

consumption on real time data basis . The online information made available to all operators , officers ,plant in charge .

All of the above benefits have resulted in timely efficient unloading of oils .Savings – 40 kg /MT of oil unloading amounting to 35 lac per annum

Reduction of steam consumption in oil unloading activity in tank farm using IOT ( Internet of things )


To install a micro steam turbine to generate

electricity from steam pressure reduction

Background: For process heating, 3 kg of LP steam is

required & pressure reducing stations were used at

various locations to reduce steam pressure from 15 bar to 3 bar for process applications.

Idea: To utilize the reduction of steam pressure from 15 to

3 bar in generating power .we came across two alternate to generate electricity

Steam Expander – Forbes MarshalMajority of installation out of India – Not provenMicro turbine – M/s Turtle Pune previously known as Biogreen energy – There were more than 20 installations inIndia , one of the installation at near by Kota (Rajasthan)we could see the actual operation and decided go for this .

Implementation: Installed a micro steam turbine of 150 kwh

in the main steam line of 15 bar which in turns gives a LP

steam of 3 bar.

Before

Steam

pressure

15 kg/cm2

Steam pressure 3

kg/cm2 to

plant

After

Saving of Rs. 37 lac/annum Investment: 127 lac


Water based vacuum system

Background:

• Our vacuum system consist of a dry ejector, a wet ejector , two boosters and a conventional barometric condenser to generate a vacuumof 2- 5 mm in our distillation plant

• For running vacuum system we required a medium pressure steam (10kg/cm2) in a tune 1000 kg per hour.

• Any fluctuation in steam pressure gives impact on vacuum & thereby on process efficiency.

• Steam boilers needs fuel & are costlier.

Idea generation : A new improved design barometric condensers we were using in our soap driers where the vacuum requirement was tothe tune of 60 mm absolute and there was no requirement of steam . Taking this into our notice , we consulted our condenser suppler to tryout our distillation process so that we can have a hybrid vacuum system without using two of the steam ejectors out of four .

Action taken:

Installed new barometric condenser with a suitable design in our distillation plant vacuum system . Now with new barometric condenser theoperations of its dry and wet ejectors is eliminated .

Benefits : 500 kg/hr steam saved amounting to Rs 72 lac per annum

After Before


0.00 1.20 1.20 0.82 1.854.00

19.20

27.4

0.00

5.00

10.00

15.00

20.00

25.00

30.00

Increased in renewable energy by 27%

Utilisation of renewable energy sources

Actions

▪ Installed a Biomass Boiler

▪ Usage of Solar power in day time

Installed in 2015-16


Utilisation of waste material as fuel

• Biomass Briquette:

Briquette is made from Bio waste reduces the use of fossil fuels and help in increasing Renewable energy foot prints

• Pitch:

Pitch is a waste material from the process –using as a fuel in boilers.

606 111 196321

5529

8546

0

2000

4000

6000

8000

10000

15-16 16-17 17-18

Utilization of waste material as Fuel- MT

Pitch Briquette


Projects identified for energy conservation for year 18-19

(under implementation)

S.No. Projects Total Annual

Savings

Investmen

t in Lacs

Payback in

Months

Energy

Saving (GJ)

1. Installation of water based vacuum system in

FADP3

23 55 30 2990

2. Installation of static mixer in place of

conventional agitator to reduce power

consumption in soap kettles

28 41 18 3640

3. Installation of energy efficient LED lights in

place of conventional lights

3.5 10.2 36 185

4. Installation of energy efficient air conditioners 2.2 7 36 371

5. Installation of water based low head vacuum

system in soap finishing

2 3 15 260

6. Installation of Heat Pump in SM2 9 21 30 477

7. Installation of energy efficient water chilling

compressor

5.5 10 24 291

8. Installation of Mechanical Vapor Compressor

for reducing energy consumption in SWEP2

110 300 36 6895

Total 183.2 447.2 15109


Roadmap for achieving Benchmark for further reduction of energy consumption

S.No. Energy Conservation Projects Expected reduction

1 Installation of mechanical vapor

compressor in SWEP2

2%

2 Removal of one roll mill from soap

lines

0.05%

3 Installation of VFD in Mixers of

soap finishing lines

0.05%

4 Installation of IOT based system

in RO unloading

1%

5 Replacement of air conditioners 0.02%

6 Use of natural lights in place -

7 Reduction in steam pressure from

12 to 10 kg/cm2

0.05%


ENERGY MANAGEMENT SYSTEM DISTRIBUTION – YEAR 2017-18

12%

88%

Electrical Thermal

56.7

1.941.4

2.9

Electrical Energy Distribution

Grid

Captive

Solar (Open access)

Micro turbine

68.9

6.4 1.4

23.3

Thermal Energy Distribution

RLNG FO PITCH Briquette

RLNG gas - 427000 mm BTU/annum

Using fossil fuel like Furnace Oil etc

Using pitch (renewable) which is a byproduct generated from our process-

Biomass fuel- Briquette for steam generation

THERMAL POWER SOURCE

Maximum Demand Contract with MPEB –3320 KVA

Captive Power Plants- 5250 KVA having 5 DG sets

•Captive is used in case of MPEB fails

•Power factor maintaining unity for the last 10 years

ELECTRICAL POWER SOURCE

Total energy in MW -


Reduction in GHG emission by 50% wrt base year

314

272

251243

233 238

179

158

100

150

200

250

300

350

10-11 11-12 12-13 13-14 14-15 15-16 16-17 17-18

GHG - CO2 emission Kg/MT of production • Biomass briquette boiler:

-Commissioned in December 2015

-Replaces approximately 25% of fossil fuel (natural gas)

-Reduces GHG emissions by 7500 tCO2e per annum

GHG Inventorisation


47397

3245531350

20000

25000

30000

35000

40000

45000

50000

15-16 16-17 17-18

GHG emission in MT

GHG Inventorisation

22281

9075

GHG Emissions tCO2e – 17-18

Scope 1 Scope 2


Green Supply Chain

• We have developed a Sustainable Procurement Policy to deep dive into the value chain and handhold our suppliers to begin/continue their sustainability journey.

• Green Practices are a key pillar in our Sustainable Procurement Policy.

• Baselining of our suppliers have been conducted.

• An emailer group has been established in which we roll out best practices communication in energy efficiency/water management and so on to our suppliers.


Green Supply Chain

S.No. Vendor Suggestions and Training

1 Sweet Industries, Baddi Suggested usage of LED lights and VFDs in

their manufacturing equipment.

2 Siddhomal, Ghaziabad On-site visit, identified opportunities of

energy reduction through interlocking of

conveyors and reducing idle running time


REDUCTION IN SUPPLIER RESOURCES• Some of the major initiatives taken during the last 3 years:

Green Supply Chain

S.No. Initiative Material Saving –MT/annum

1 Optimisation of laminate thickness

for soap wrappers from 10 mic to 8

mic

130 MT of PET

2 Optimisation of Hot Melt Adhesive

(HMA) consumption

Optimisation of Hot

Melt Adhesive (HMA)

consumption

3 Procurement of reduced GSM

cartons

353 MT of Paper


51.345

3.59 0.00 0.25 0.040.0

10.020.030.040.050.060.0

Acidification Potential (AP) [% contribution]

1.2 0 0.06

98.27

0.03 0.000.0

20.040.060.080.0

100.0120.0

OilCultivation,Processingand Import

Productionat

Malanpur

OutboundTransport

Use phaseof Toilet

Soap

Paperwaste on

landfill

Plasticwaste on

landfill

Eutrophication Potential (EP) [% contribution]

1.20 0.07 0.00

98.77

0.00 0.000.00

20.0040.0060.0080.00

100.00120.00

Blue Water Consumption (% contribution)

-65.6

29.62.2 0.0 2.6 0.0

-80.0

-60.0

-40.0

-20.0

0.0

20.0

40.0

OilCultivation,Processingand Import

Productionat

Malanpur

OutboundTransport

Use phaseof Toilet

Soap

Paperwaste on

landfill

Plasticwaste on

landfill

Global Warming Potential (GWP 100 years) [%

contribution]

Life Cycle Assessment of Godrej No.1 Soap


Team Work Employee Involvement & Monitoring


Main utilities

Boilers – 11 nos – Ranging from 17.5 barto 75 bar steam pressure

Thermic fluid heaters – 45 lac Kcal /hr heat output , Temperature upto 315 deg

Air compressors – 7 nos

Cooling towers – 16 nos

Transformers – 5 nos Ranging from 1250 KVA to 2500 KVA

DG sets – Ranging from 1000 KVA to 1000 KVA

Chilling plants – 11 nos of water and brine chilling

Energy bill of approx. 70 crore accounts for 10%of the total product cost and 92 % of the Totalvariable cost


ENERGY CELL

FACTORY HEADCORPORATE

GROUP

ENERGY TEAM (CROSS

FUNCTIONAL MEMBERS)

ENERGY CELL

HEAD

Mr. Durgesh Tripathi

• Strategic Planning

• Quarterly Review

• Project facilitation

• Strategic Planning

• Monthly Review

• Monthly Review

• Daily Monitoring

• Identification and execution of

projects

MEMBER

Mr. C B Sahu ( Sr.

Officer)- Chemical

plant

MEMBER

Mr. Dinesh Verma

( Executive) -

Utility

MEMBER

Mr. S N Mathur ( Sr.

Executive) Chemical plant

MEMBER

M. Saxena

( Ass. Manager)

Soap Plant

MEMBER

Mr. Alok Gupta (

Executive) Engg

Services

MEMBER

Mr. Mukesh Agrawal

(Astt Manager) –

Engg Services

CROSS FUNCTIONAL TEAM MEMBERS


Energy Monitoring & Management System

➢Energy meters and steam flow meters have been installed at all sections

➢Daily performance reviews and corrective actions

➢Monthly energy data is compiled based on daily reports and updated into ‘Sustainability

Performance Monitoring Tool’ (SOFI) .

➢Monitoring of consumption on major equipment to identify the potential area of improvements or

technological up gradation

➢Constantly taking help from experts by means of various audits like Process energy , Harmonics ,

pumps and compressed air network

➢Sharing of knowledge at various platform within organization and other industries

➢Started implementing concept of IOT (Internet of things ) for on time information and analytics for

consumption pattern and subsequent corrective actions .

OpportunityIdentification

• Energy Mapping

• Benchmarking

• OEE

Suggestion

• Idea Generation

• Idea Screening

• Feasibility Study

Teamformation

&

Allocation ofproject

team

Projectexecution

&

Review ofProgress

ResultsAchieved

Rewards &

Recognition


RO 1 3KG

BLENDING

CP-1 PLANT

SM-1 ,3KG STEAM

SM-1 10 KG STEAM

CP-2 PLANT MAIN

FSP 10 kg

EVP 10 kg

FADP 10 kg

FADP 3 KG STEAM

RO 3KG STEAM

TANK FARM

CP-1

CP-2

SM-1

SM-2, 3KG STEAM

SM-2, 10 KG STEAM

RO 3 KG

EVP 10 KG

FSP 10 KG HEAT EXCHANGERFADP 10 KG DISTILLER

FADP 10 KG PRECUTPLANT 3KG STEAM

SM-2

CP-3

FSP 10KG VACCUM SYSTEM STEAM

RO3

VORTEX FLOWMETER

DIFFERENTIAL PRESSURE TYPE FLOW METER

3 KG STEAM

10 KG STEAM3 KG STEAM FROM TURBINE

STEAM DISTRIBUTION NETWORK

LPB 1

LPB 2

LPB 3

TURBINE

GAS LINE

TP-25 CP-3TP-15CP-3

TP-25CP-2

TP-10CP-1

LP-1LP-2

MAIN GAS

GAIL PLANT METER

Gas Distribution Network


CP

3

MCC204

MCC213

MCC102

MCC7

MCC301

MCC302

MCC401

MCC402

WC

BEEDS MCC

MCC 109

MCC 101

MCC 303

MCC PNEUMETIC

MCC 108

MCC 9

MCC305

MCC 206

MCC 6

MCC 304

MCC 5

MCC 10

MCC MLDB

MCC3

MCC MPDB

SOA

P F

INIS

HIN

G

SOA

P M

AK

ING

-1

MCC2

MCC 8

MCC 107 ETP

MCC 205

CP

-1

MCC 4 UTI

LITY

MCC ETP 2

MCC RECTFIER 1

MCC 1

MCC 206

MCC RECTFIER 12

25

00

KV

A M

AIN

M

ETER

MCC 207

MCC MLDB

MCC CP2

MCC LP3

MCC UGP

MCC UTILITY

MCC TANKFORM

MCC FSP

MCC LP2

MCC FADP

MCC MPDB

MCC UTILITY

MCC MIL GF

MCC MIL FF

MCC PDB +LDB

MCC GCPL 1

MAIN METER MPEB

MCC ETP 3

SOA

P M

AK

ING

-2

TXR-3 1250 KVA TXR-1 1250 KVATXR-2 1250 KVATXR-4 2500 KVATXR-5 1600 KVA

LAY OUT DIAGRAM OF POWER DISTRIBUTION

• NOTE -• MCC- MAIN CONTROL CUBICAL• ETP- EFULENT TREATMENT PLANT• WC- WATER CHILLING• MLDB- MAIN LIGHT DISTRIBUTION BOARD• MPDB- MAIN POWER DISTRIBUTION BOARD


28.6

20.84

20.2917.45

7.52

3.25

0.87

0.52

0.51

0.16

Total Energy (Electrical + Thermal) in % loading

CP#3 RMD Soap Noodles

CP#2 CP#1 Soap Finishing

Boilers Others Compressors

30.36

23.27

19.4218.86

8.09

Total Thermal Energy in % loading

CP#3 RMD

Soap Noodles CP#2

27.75

26.87

15.227.43

6.84

4.43

4.4

2.49

1.35

Total Electrical Energy in % loading

Soap Finishing Soap Noodles CP#3

Boilers CP2 Others

Air Compressor

Distribution of energy at various cost centers


Monitoring of Energy consumption

POWER STATEMENT STEAM STATEMENT


Monitoring of Energy parameters in SCADA and alerts


• Awareness through Display of the Posters across the plant.

• Suggestion Schemes – INSAAN platform

• Celebration of World Environment Day on 5th June of every year.

• Celebrated Energy Conservation Week from 11th Dec to 16th Dec.

• Spot award recognition for workers at shop floow

AWARENESS CREATION


Involvement of Employees Involvement

▪Creating awareness by celebrating Energy conservation

Week

▪ External training programme being conducted regularly

▪ In-house training conducting to all employees

▪Awareness through various competitions to Staff, Workmen


TRAINING PLAN FOR 17-18

Sr. No. Topic of training programme Plan/Actual Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 Feb-18 Trainer

1 Energy conservation Plan 20 20 20 Mukesh Agrawal /

Actual 19 19 17 Durgesh Tripathi

2 Enviroment Plan 20 20 20 20 Pramod Sengar /

Actual 21 13 25 13 Amit Bahal

3 GMP Plan 20 10 40 10 40 10 Ajay Batham /

Actual 16 5 38 5 38 5 S.N.Mathur

4 ISO Plan 20 25 10 50 25 10 50 Ajay Batham /

Actual 16 10 45 10 45 Manoj Saxena

5 Material Management Plan 20 80 70 80 70 80 SS Gupta /

Actual 13 77 72 77 72 77 Surendra Singh

6 Quality circle Plan 40 20 40 20 40 40 Thomas Mathew /

Actual 38 22 38 22 38 38 Santosh Mishra

7 safety Plan 25 25 25 25 Pramod Sengar /

Actual 22 20 28 26 Sandeep Khedkar

8 health Plan 20 20 20 Pramod Sengar /

Actual 18 22 21 Santosh Mishra

9 TPM Plan 75 75 75 75 75 Pradeep Tripathi /

Actual 60 77 72 70 78 Mukesh Agrawal

10 Waste Reduction Plan 10 10 10 Manoj Saxena /

Actual 8 9 6 Sunil Sharma

11 Water conservation Plan 20 20 20 Dinesh Verma /

Actual 19 23 20 AlokGupta

12 Behaviour Training Plan 50 50 60 Amit Bahal

Actual 50 49 55 Thomas Mathew /

13 Printing machine Plan 60 60 60 Rajeev Chauhan /

Actual 62 56 56 P.Tripathi

14 Briquette fire boiler Plan 10 10 10 Sanjay Agrawal /

Actual 8 12 11 Dinesh Verma


ThemeSaving Mode

Team members Amount

Earlier 22 KW motor was running to provide cooling water for steam turbine. Our team check the requirement and arrange a pump from some other section with 7.5 KW motor for the same. Now it is working with 7.5 KW. Our team saved 14.5 KW energy every hour.

Power

Sanjay Agrawal,Sandeep Khedkar,D. K. Tripathi,D. K. Verma

6 Lacs

Installed a control valve in place of 10 kg PRV to reduce the steam losses in chemical plant.

steam Sanjay Agrawal, Rajeev Chauhan,Amol Singh

5 Lacs

We started to increase the feed water temperature of LP3 with the help of waste steam of CP2 steam drumvapors.

Fuel D. K. Verma, SanjayAgrawal, JP Yadav

4 Lacs

There are 04 no. cooling fans fitted in a cooling tower which were running continuously for 24 hrs. If any problem comes in any fan, water temperature raised, blade angle of cooling fins and set it to maximum side according to the capacity of fan motor.

Power

Abhay Gautam, Sunny Batra, Ram Milan, Sanjay Singh

2.10Lac

Projects implemented through Kaizens (Workers and Supervisor level)


Reduce, Reuse & Recycle approach

Recycle

• Water used for cooling in process pumps recycled thru cooling tower and avoided to drain in ETP. Annual saving is 3500 KL

Reuse

• Started using condensate water from oil storage tanks after settling & collected in separate tanks. This condensate water is reused for further process in plants. Annual saving of water # 5500 KL

Reduce

•

Water Consumption – KL/MT of production

43% Reduction from 2011

2.85

2.142.04

1.75 1.72 1.71 1.731.62

1.5

2

2.5

3

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18

Annual Fresh Water Consumption KL/MT of Production

Provided automatic level control system in sum of the cooling towers to prevent overflowAnnual saving is 340kL

Water Conservation Approach

More Actions

Installation of aquatron water recycling system at ETP discharge –saving of 150 KLD

Recharge

Increased the under ground water level by installing Kedia based farm technology in 25 locations


AWARDS & ACCOLADES

GCPL Malanpur has been awarded the “ Green Co” -

Gold Certification by Confederation of Indian

Industry in accordance with the Green Company

rating system. This award recognize the significant

contribution of GCPL in the area of energy reduction,

environment and sustainability performance.

Energy efficiency

Water conservation

GHG emissions

Material conservatio

n

Recycling and recyclability

Green supply chain

Renewable energy

Product stewardship

Life cycle assessment


MP state environment award 2016- First prize

CDP disclosure – Ranked 3rd in India 2016

Awards and recognitions


Awards and recognitions

Energy efficiency award in CHEMIX 2015 from FICCI

Bhamashah award 2013

CII Business Excellence award 2010

TPM excellence award JIPM Japan 2007


Thankyou

Documents

Team Members : Mr. Sandesh Borwankar DGM-Engg Services … · FAT SPLITTING(INPUT) 325 463 1,52,790 FATTY ACID DISTILLATION(INPUT) 325 445 1,46,850 SWEET WATER EVAPORATION(INPUT)