The Mylan Story UNIT-8 - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/General/Myla… · 11 This document contains confidential and proprietary information

1 This document contains confidential and proprietary information of Mylan N.V. Unauthorized use, duplication, dissemination or disclosure to third parties is strictly prohibited. © 2016 1 This document contains proprietary information of Mylan N.V. Unauthorized use, duplication, dissemination or disclosure to third parties is strictly prohibited. © 2017

The Mylan StoryUNIT-8VIZIANAGARAM


At Mylan,We are committed to setting new standards in

healthcare.

Working together around the world to provide 7 billion

people access to high quality medicine

7B:1

Products offered in >165 countries

Ship to ~60,000 customers

>35,000 passionate Workforce

~80% volume internally produced

More Than Just Words


Operational Scale

Facilities

Doses Units Units Kiloliters

80B 500M 1.5B 4,800

Oral Solid Doses Injectables Complex Products API

24 Facilities 9 Facilities 8 Facilities 9 Facilities

A global healthcare company with an unmatched platform


Site Overview: Unit-8, Vizianagaram

Manufacturing site was established in 1993 to produce

Active Pharma Ingredients (APIs)

Plant Capacity Approvals Accreditations

Kiloliters

1,172

Built-up Area

57%Total Factory Area

2,75,992 m2

Green Belt

33% 10%Expansion


Major Equipment P R O C E S S E Q U I P M E N T

286 Reactors(GLR & SS) PROCESS TYPE:

Manufacturing of APIs

Manufacturing Blocks11

1172 KL of Reactor Volume

80 Centrifuges

56 Vacuum Tray Driers

32 Tray Driers

U T I L I T Y E Q U I P M E N T

16 +5 Chillers 1715 TR

03 -10 Chillers 186 TR

14 -20 Chillers 604 TR

05 Nitrogen Plants 800 N3/Hr

05 Dry Air Plants: 1180 CFM

14 Cooling Towers : 8250 TR


ENERGY MANAGEMENT SYSTEM


Energy Management System at Site

Energy Management System (EnMS) Policy was

established in year 2013 and developed:

Implementation, Reporting & Monitoring

Methodologies

Created extensive Awareness among Employees

via. Training, Indoor/Outdoor Posters & Contests

Equipped with In-House Energy Monitoring &

Measuring Devices

Designed Procurement strategy in tune with Asset

life cycle cost assessment

Extensively exploring Renewable Solar energy via

Solar Power Purchasing Agreement (PPA)

In-house 10 KW Rooftop Solar grid system &

also Water Heaters

Implemented various Innovative Energy saving

projects at Site

Mylan has received ISO-50001 CERTIFICATION in July-16

23 Internal auditors were nominated and trained by DNV.GL.

41 Members were elected as Energy Core Committee team


EnMS Policy IS0-50001 Certification


EnMS Implementation

Methodology

EnMS Implementation Methodology


EnMS Reporting Methodology

20

51

0 10 20 30 40 50 60

OPEN

CLOSED

ESO REPORTED FROM JULY-17

Energy Aspects Identification

➟ Energy usage Register

➟ Feed back from Inspection team/Operator

➟ ESO Format

➟ Review Meetings/Internal Audits

➟ Feed back from Other Units


EnMS Monitoring Methodology


Awareness Programs at Site

Display Posters Trainings

Energy Conservation

Day Contest

Name of Entry No of EntriesDrawing contest 70Essay contest 61Slogan contest 124Suggestion Contest 165Total 420


In-House Energy Monitoring & Measuring Devices

13

Best tool for to check the pump performance to optimize Chilling plants and

other systems

Locate, measure the Air/Nitrogen/Vacuum leakages/condition of valve and

steam traps

Generate reports that simplify our energy management tasks (Voltage,

Current, Frequency, Harmonics, Power factor, Active & Reactive power etc.,)

Measure hot & cold surfaces and bearing temperatures

Ultrasonic flowmeter – Speedy flow measurement

Ultra probe leak detector

Power analyzer

Thermal image scanner & infrared thermometer


Energy Mapping for 2016

Electricity Demand Electricity SupplyDG Power

2%

Solar Power

11%

Captive Power23%

Govt. Power65%

Admin.1%

Solvent recovery

1%EHS9%

QC & QA4%

Warehouse2%

Mfg.27%

Utilities56%

Energy

Intense Areas

Chilling Plants

Boiler

Compressed Air

Non-Renewable

Resources

Consumption

Coal - 58,750 Tons

Diesel - 339 KL

631Lakh Units

Consumed

in 2016



Renewable Energy Usage at Site

In-House Solar Power Generation SystemsExternal Solar Power

93,72,021 KWHPurchased during

Apr’16 - Mar’17

Rooftop Solar on grid system

System capacity :10 KW

Annual Production:13500 KW

Installed : Dec-15

Investment : Rs. 6 Lac

Solar Water Heaters

No. of Systems : 10 Nos

System capacity : 200 LPD

Energy Savings :27000 KWH

Installed : Dec-16

Investment : Rs. 5 Lac


ENERGY SAVING PROJECTS


Chillers

Chiller ID Commissioned Running days

CH-1825 Dec-15 613

CH-1823 Dec-15 610

CH-1807 April-16 512

CH-1808 Aug-16 389

CH-1806 Aug-16 387

CH-1829 Aug-16 386

CH-1837 Aug-16 385

CH-1832 Aug-16 372

CH-1818 Sept-16 363

CH-1816 Sept-16 352

CH-1833 Sept-16 348

CH-1812 Sept-16 342

CH-1830 Nov-16 296

CH-1831 Nov-16 294

CH-1805 Nov-16 275

Pumps

PLC with skidControl valves

Sponge ballMulti color HMI

Innovative Project - I: Online Tube Cleaning System (1/3)

12% Energy Efficiency Improved in Water Cooled Chillers



[VALUE]%[VALUE]% [VALUE]% [VALUE]% [VALUE]% [VALUE]% [VALUE]%

[VALUE]%[VALUE]%

[VALUE]% [VALUE]%[VALUE]% [VALUE]%

[VALUE]%

80

82

84

86

88

90

92

1 2 3 4 5 6 7

% o

f IP

A R

ecov

ery

Percentage of Solvent Recovery

Before After

ATCS for Turbine Condenser Solvent Recovery Plant



UoM Co-Gen Chillers SRP

Investment Lakh INR 16 45 24

Annual savings Lakh INR 23.6 53.4 180

Annual Energy saving Units -- 8,90,000 32,553

Annual Coal

savings Tons 701 -- 717

ROI Months 8 10 2

Advantages

➟ Continuously operating at maximum

Efficiency.

➟ 12% Energy Efficiency Improvement in

Water Cooled Chillers

➟ Avoids two shutdowns in turbine

generator.

➟ 4-5 % reduction in solvent losses in

Solvent Recovery plant.

➟ Fully automatic.

➟ Ensures 100% clean tubes.

➟ Single System for Multiple Heat

Exchangers.

➟ No water wastage.


Innovative Project - II: Water Management Initiative (1/2)

WATER CONSERVATION DATA

(Unit-8)

Total number of Needle type

aerators Installed100 Nos

Water savings per day 18 KL

Water savings per year 6678 KL

Annual water cost savings 2.5 Lakhs

Annual Effluent treatment cost 18 Lakhs

Annual Energy cost Savings 0.4 Lakhs

Total cost savings per year 21 Lakhs

capital cost Taps 0.3 lakhs

ROI 5 days

New innovative Needle type

aerators were installed for

washbasin taps

Com

pari

son


Innovative Project - II: Water Management Initiative (2/2)

New innovative Needle type

aerators were installed for

washbasin taps

WATER CONSERVATION DATA(Unit - 1, 2, 3, 7, 8, 9, 10, 11, 12, Corporate and R&D)

Total number of Needle type

aerators Installed478 Nos

Water savings per day 80 KL

Water savings per year 28,335 KL

Annual water cost savings 16 Lakhs

Annual Effluent treatment cost 72 Lakhs

Annual Energy cost Savings 1.2 Lakhs

Total cost savings per year 90 Lakhs

Capital Cost for Taps 1 lakhs

ROI 4 days

Com

pari

son

Implemented at all Mylan

API Units, Corporate and R&D


Innovative Project - III: Water Cooled Split Air Conditioner

3 star split Air ConditionerWater cooled split air

conditioner

R-22 gas R-410A gas

Heat recovery not possibleHeat recovery from outdoor unit

(Annual Coal Savings 50 Tons)

280-290 Electrical units/day 100-110 Electrical units/day

➟ Investment : 10 Lakhs

➟ Annual Savings : 07 Lakhs

➟ Annual Energy savings: 66,267 KWH

➟ Annual Coal Savings : 50 Tons

➟ ROI : 17 months

Water Cooled AC Layout in Turbine room


Innovative Project - IV: Innovative Cleaning Solutions

Adopted innovating cleaning solutions for maximizing efficiency in Air cooled HVAC chillers,

Condensing units, Air conditioners, Air compressors & Diesel generators.

Coil Jet Mini split bib kit Flow jet

Carries all the water and

cleaning AC indoor, out door and

condensing units up to 5 Ton.

Clean the indoor unit of AC with

combination of coil jet. Keeps walls &

floors safe from water and over spray

It easy to clean HVAC coils,

evaporator coils and large air-

cooled refrigeration units


Energy Management Initiatives


Initiative - 1: Energy efficient Dry Air systems

26

Pressure drop across the Drier < 0.2 bar

Installed in 2015 Year

Investment made 101 Lakhs

Annual energy savings 8,33,000 KWH

Annual Cost savings 50 Lakhs

ROI 24 Months

Adjustable Dew point settings

VFD compressor and blower

Zero purge loss heated Drier

Dew point based tower change over

Uni

quen

ess

of th

e Sy

stem


Initiative - 2: Process Operational Controls

On/Off Control valves for Vacuum Tray Driers

Manual ON/OFFcontrol valve

Pharma area

➟ Implemented year : 2015 & 16

➟ No. of Vacuum tray driers : 66 Nos

➟ Investment made : 7.9 Lakhs

➟ Annual Energy Savings : 1,83,000 Units

➟ Annual cost savings : 11 Lakhs

➟ ROI : 9 Months

Elimination of idle running in vacuum

pumps and hot water pumps during

sampling, loading and unloading time


Initiative - 3: Retro fitting of bubbling bed systemB

ub

bli

ng

bed

Bo

iler

Auto fuel feeding

Efficiency improved from 60% to 80%

Improvement in Coal handling

Alternative fuel option

Ad

van

tag

es

Installed in 2014 Year

Investment made 90 Lakh Rupees

Annual Cost savings 220 Lakh Rupees

ROI 5 Months

5 TPH Boiler

Man power reduction

4 TPH Boiler


Initiative - 4: Chilling Plant Automation

Control panels provided for reciprocating

Chillers 12 no's to make precise control of

operation including primary pumps.

➟ Implemented year : 2015

➟ Investment made : 12 Lakhs

➟ Annual energy savings : 18 Lakhs

➟ ROI : 8 Months


Initiative - 5: Optimization of Air compressors by eliminating

Unload Power

➟ Implemented year : 2015

➟ No of Drying plants : 03 Nos


➟ Annual savings : 11 Lakhs

➟ Annual Energy savings : 1.83 Lakh KWH

➟ ROI : 14 months

Drying Plants unload power is eliminated by

providing Variable frequency drive.

Precise control of operation and constant

pressure supply at user end


Initiative - 6: Retrofit VFD solution Nitrogen Plant

➟ Implemented Year : 2015


➟ Annual savings : 12 lakhs

➟ Annual Energy savings : 1,93,300 KWH

➟ ROI : 8 Months


Initiative - 7: Back Pressure Turbine


➟ Investment made : 20 Mn

➟ Annual savings : 29.5 Mn

➟ Annual coal savings : 9100 Tons

➟ Water Savings : 7000 KL

➟ ROI : 8 Months

A. 5 Tons/hr process steam additionally available from the co-gen plant

B. Auxiliary power consumption reduction 22 Lakh Units per Year

EXISTING SYSTEM PROPOSED SYSTEM


Initiative - 8: Heat Recovery System for 4&5 TPH Boilers




➟ Annual Coal savings : 515 Tons

➟ ROI : 13 Months

Pressurized deaerator installed to utilize the heat content in flash

steam & to reduce the fuel consumption in boiler by increasing

boiler feed water temperature

Installed Pressurized De-aerator instead of Natural De-aerator




➟ Annual Coal savings : 263 Tons

➟ ROI : 12 Months

Installed APH instead WPH to utilize waste heat from flue gases to

increase air temperature from 35 To 90°C

Installed Air Preheater instead of water Pre heater for 4 & 5T boilers

5 TPH Boiler 4 TPH Boiler


Initiative - 9: Energy Efficient Chillers

➟ Implemented Year : 2016 & 2017


➟ Annual Energy savings : 45 Lakhs

➟ ROI : 15 Months

Installed Energy Efficient water cooled Screw type Chiller in

place of 3 reciprocating Chillers

Capacity : 90TR@ -20°C and 83TR @ -20°C

Location : Utility-1 &7

Higher capacity efficient, dual mode, Water

cooled, Variable speed screw type Chiller

➟ Precise capacity control with VFD

➟ Step-less capacity control from 100% to 25%

➟ Improved power factor

IMPROVEMENTS

IN DESIGN


Initiative - 10: Cooling Towers

➟ Implemented Year : 2013 & 2015

➟ Total number of fans arranged : 23 Nos



➟ ROI : 10 Months

Replaced aluminum blades with FRP blades for all utility

blocksFRP fan blade

VFD for CT fan

➟ Implemented Year : 2013, 2015 & 2016

➟ Total number of VFDs arranged : 22 Nos



➟ ROI : 9 Months

Provided variable frequency drive for Cooling tower fans


Zero Investment Initiatives


➟ Annual cost savings : 4.2 Lakhs

➟ Annual Energy Savings : 70,000 KWH

Modulated the operating pressure of Air Compressors of Nitrogen plant

✏ Equipment : NT-1802, 1803, 1804, 1805

✏ Before Modification : 6.0 to 7.0 kg/cm2

✏ After Modification : 5.8 to 6.4 kg/cm2


➟ Annual cost savings : 8.1 Lakhs

➟ Annual Energy Savings : 1,33,000 KWH

Supply frequency of Turbine generator was reduced from 50 HZ to

49.5 HZ


Green Supply chain

Initiatives shared to Contract manufacturing units ( CMU’s)

Elimination of damper control by proving VFD for unclassified Air handling units

Energy efficient LED lights in place of Mercury vapor lamps.

Needle Type Aerators Installation for Canteen and washroom taps.

Energy Efficiency Improvement in water cooled chillers by providing on line

tube cleaning system.

Energy efficient Nitrile Rubber insulation in place of old themocoal insulation.


SEC Reduction


Specific Energy Consumption

21.12

20.54

19.56

18

19

20

21

22

2015 2016 2017

KW

/KG

Atorvastatin (ATT)

11.3411.14

10.4

8

9

10

11

12

13

2015 2016 2017

KW

/KG

Tenofovir (TCF)

17.817.31

16.64

12

13

14

15

16

17

18

19

2015 2016 2017

KW

/KG

Efavirenz (EFD)


Specific Energy Consumption

Nitrogen Plant Capacity:300 Nm3/Hr

Motor : 180 HP

Chilling Plant Capacity : 200 TR

Design : + 5 ºC

Motor : 240 HP

0.57

0.49

0.4

0.45

0.5

0.55

0.6

Before VFD After VFD

KW

/NM

3

Nitrogen Plant (NT-1806)

1.05

0.81

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

1.2

With out ATCS With ATCS

KW

/TR

Chilling plant (CH-1832)


INITIATIVES IN 2017


Initiatives in 2017 (1/2)

Energy efficient 300 TR screw Chiller installed in place of

conventional 95 TR Chillers of 3 Nos in Utility - 9

Common Online Tube Cleaning System for 5 Chillers in

Utility - 3 & 7

Solvent vapor losses reduction by providing Online Tube

Cleaning System in SRP-2


Initiatives in 2017 (2/2)

Installation of Compact pressured powered pump package unit

in MB-4, 8, 9 & 10.

Introduced Energy efficient motors (IE3) of 10 Nos in place of

existing rewinding motors.

Installed 4 Nos of Parallel pumping system in Utility-1, 6, 7 & 8.


Waste Utilization


Utilization of waste material as fuel

Type of Residue 2014 2015 2016

Methanol MLs 2508 MT 6556 MT 3677 MT

Mixed spent solvent

1827 MT 2778 MT 2533 MT

Process Organic residue(Liquid Form)

Volatile organic solvents from Stripper 1184 MT 1423 MT 2002 MT

Process organic salts (Solid form) 110 MT 104 MT 80 MT

This Hazardous Waste is supplied to cement Industries to used as fuel in cement kiln


RESULTS ACHIEVED


Results Achieved

4.0

8.7 9.310.9

14.1

2013 2014 2015 2016 2017

Energy Cost Savings (in Rs. Cr)

440 495 1,350

5,584

12,297

2013 2014 2015 2016 2017

Coal Savings (in Tons)

35

31 32

31

34

2013 2014 2015 2016 2017

No. of Energy Saving Ideas Implemented

19

39 45

66 75

2013 2014 2015 2016 2017

Electrical Energy Savings (Lakh Units)

2,532 4,486 6,567

16,112

28,535

2013 2014 2015 2016 2017

Green House Gas Emissions Reduction (in Tons)

95

232 187

362

148

2013 2014 2015 2016 2017

Capital Cost (in Rs. Lakhs)


Future Plans


Future Plans

• Implementation of Online Tube cleaning system for all heat exchangers to reduce electrical Energy and Solvent vapor losses.

• Replacing Reciprocating conventional chillers with energy efficient screw chillers.

• 100 % LED lighting to be achieved in our facility.

• 8% of Total Electrical Energy Consumption reduction in next 4 Years.

• 20% Water reduction through recycling & control measures through management initiatives.

• 30% Solar power utilization targeted at site Through PPA and PV modules .

• 10% SEC reduction for TCF, VST, EFD products in next three years.


Documents

The Mylan Story UNIT-8 - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/General/Myla… · 11 This document contains confidential and proprietary information