UNILEVER INDIA EXPORTS LIMITED INSTANT TEA FACTORY … · boiler water temperature, drum level and pressure. These excursions reduce boiler steam efficiency by sub-cooling the boiler

© Confederation of Indian Industry

ANJAN MAJI – FACTORY MANAGERBALAKRISHAN – ENGG MANAGER

UNILEVER INDIA EXPORTS LIMITED INSTANT TEA FACTORY

ETAH


Brief introduction on Unit

Location : Etah, India (UP)

Year of establishment : 1996

Built in capacity : 1100 Tons

Product : Instant tea powder for Lipton Ice tea premix

Variants : CWS (Cold water soluble)

Green Tea, Evian Brite and Saint Brite

HWS (Hot water soluble) HIT

Key Technology : 3 stage extraction process with spray dryer

: SCADA application for Process automation& control

One of the 3 Unilever sites of Instant Tea across the world contributing to 27% of Unilever’s tea powder supply in 2017


Brief introduction – Instant Tea Process

3 Stage Extraction

TEA SPENT

TROLLEY

SPRAY

DRYER

PACKING

PUMP

1st EVAPORATOR

2nd EVAPORATOR

HOT LIQUOR

INSOLUBLES

SEPARATION

COLD LIQUOR

INSOLUBLES

SEPARATION

GLYCOL

PHE

For cooling

Tea Waste WaterIndirect

Steam

Te

a L

iqu

or

Te

a

sp

en

t


Sp. Power Consumption Trend

3963

3627

3362

3000

3500

4000

2015-16 2016-17 2017-18

Specific Energy Cons.KWH/Ton

▪ Energy Efficient Motor (IE3) & Pump installation▪ Pump capacity optimization based on requirement▪ Replacement with Planetary gearbox▪ VFD for compressor & 11KVA Express feeder▪ ATB in Chiller, Combined Cooling tower and Diffused Aerator▪ Productivity improvement through yield increase in process


Sp. Thermal Energy Consumption trend

73731

68540

57454

40000

60000

80000

2015-16 2016-17 2017-18

Specific Thermal Energy (KJ/Kgs)

▪ Evaporation ratio improvement in Boiler▪ Auto Steam cutoff valves in all process equipment▪ In Boiler – O2 Analyzer, Sonic soot blower, Auto blow down & 3D

Element controller ▪ Servo Based Burner for HAG▪ HAG Flue gas Heat recovery


Bench Mark with Ceytea plant Power (Sri Lanka)

Plant : Ceytea Instant Tea Plant – Sri Lanka

Location : Sri Lanka

Built in capacity : 3500 Tons

Product : Instant tea powder for Lipton Ice tea premix

Variants : CWS (Cold water soluble)-Saint Brite and Dark

Key Technology : 3 stage extraction process with spray dryer

: SCADA application for Process automation& control

Spec. Power per Ton : 2076 KW/Ton

Spec. Steam per Ton : 15.75 tons of steam/Ton


2076335 265

245 245 196

3362

0

2000

4000

Spec. Power Reduction water Map KWH/Ton

CEYTEA - 2076 KWH/Ton

Etah - 3362 KWH/Ton

0400800

1200

210558

229 100612

35215

475976

373 171

921428

18

Electrical Energy Bench Mark Etah vs Ceytea

CEYTEA - 2076 KWH/Ton Etah - 3362 KWH/Ton

Spec. Power - Gap & Road Map


Spec. Thermal Energy - Gap & Road Map

CEYTEA - 15.8 Ton of steam/TonEtah - 20.7 Tons of steam/Ton

05101520 1.2

8.2 3.2 0.6 0.6 0.8 1.21.5

11.6 5.4 0.6 0.4 0 1.2

Thermal Energy Bench Mark Etah vs Ceytea

CEYTEA - 15.8 Ton of steam/Ton Etah - 20.7 Tons of steam/Ton

15.8

1.8 0.80.8 0.8

0.7

20.7

10

15

20

Spec.Steam Reduction water flow chart Tons/Ton


Energy Saving projects implemented in FY 2015-16

Title of the project

Annual ele cost savings (Rs Mn)

Annual thermal

cost savings (Rs Mn)

Total Annual savings

Investment made

Payback in

Months

Boiler Evaporation ratio improvement

0 1.45 1.45 1.85 15

SABD Project - 2015 ( Planetary gearbox, VFD for air compressor & Cooling tower, DE system, auto steam cutoff valve)

1.35 0 1.35 3 26

11KVA Express Feeder 0 10.2 10.2 9.4 11





Annual thermal



Investment made

Payback in

Months

Energy Efficient Motor in Plant 0.84 0 0.84 1.1 16Energy Efficient Pumps in plant 0.8 0 0.8 1.2 18

SABD Projects - Thermal Energy Reduction - Online Flue gas Analyzer and synchronizing with FD & PA fan & Fuel feeder, Steam optimization throught the plant by installaling Flow meter, Traps & Moistire separator in header,

0 5.3 5.3 7.6 16

3D Element controller in Boiler 0 0.5 0.5 0.8 19

Yield Improvement - Back pressure plate, Tea water Ratio, Online flushing of screw, MF meter

0.7 2.23 2.93 3.7 15





Annual thermal



Investment made

Payback in

Months

Pump Optimization to reduce Power

0.72 0 0.72 1.5 25

Boiler Efficiency Improvement 0 1.7 1.7 2.6 18

Combined Cooling tower 1.1 1.1 1.1 2.5 25

SABD projects - Servo based Burner, Steam control valves, ATB system in Chiller etc

0.72 2.1 2.82 4 16

HAG Flue Gas heat recovery system 0 2.6 2.6 3.5 16

Diffused Aerator in ETP 0.67 0 0.67 1.85 26


Energy Savings Projects

➢ IMPROVED THE POWER FACTOR FROM

0.97 TO .984

➢ INSTALLED PREMIUM LEVEL EFFICIENCY

MOTORS

➢ OPTIMIZED THE UTILITY LOAD BY

RUNNING OPTIMIZED CAPACITY

EQUIPMENT’S, CHILLER, AIR COMPRESSOR


ON/OFF level control gives sudden volumes of sub-cooled water in the boilers steaming capacity, which results in large excursions in the boiler water temperature, drum level and pressure. These excursions reduce boiler steam efficiency by sub-cooling the boiler feed water for the sudden mass/heat upset

❑110% Excess air ❑11-12 % of O2 level❑3-4% Combustion

efficiency improvement ❑Black smoke reduction

❑Boiler was tunes at 3.3 TPH.

❑Screw feeder and FD fan tuned at 4.2 TPH.

❑Combustion efficiency improvement.


3D

ELEMENT

Oxygen

Analyzer

SC Feeder

tuning @4 .2

TPH



❑Increased feed water temperature up to 96 deg.

❑Automatic temperature control system installation at APV tank.

FEED WATER

TEMP INCREASE

TEMPERATURE

CONTROL SYSTEM

AT APV

❑Excess heated water went out.

❑Was maintaining the TDS 2500 PPM

❑Maintain cosinsistly 11 bar pressure by maint3500 TDS.

ABD SYSTEM

INSTALLATION


Pump Optimization – Rs 15 Lakhs Annualized savings started from Mar 2017

Sonic Soot Blower & Steam Fuel ratio improvement projects in Boiler – Rs 15 Lakhs Annualized savings started from Mar 2018

HAG Flue Gas Heat recovery system to preheat Spray drier Supply Air – Rs 8 Lakhs Annualized savings started from Mar 2018




Induced Cooling tower for Process Evaporation system which will improve plant Efficiency through Better Heat Transfer. Annualized savings 10Lakhs started from April 2018

Automatic Tube Brushing system for Chiller - Rs 6 Lakhs Annualized savings started from Mar 2018

Servo based air & fuel control HSD burner for Spray Drier – Rs 7 Lakhs Annualized savings started from Mar 2018



Solar street lights. 7lights are installed across the plant.

Temperature Based steam control valve for Soft water Preheating in Extraction Process. 10L Annualized Savings started from Mar 2018

Temperature Based steam control valve for Leaf Heater (3Nos) operation in Extraction Process. 6L Annualized Savings started from Mar 2018


Innovative Projects implemented

Name of

the

Project

Brief description on

why innovative

Trigger for

implementing

the project

Re

plic

abil

ity

Year

of

Imple

menta

tion

Annual

Savings

( Rs. In

lakhs)

Invest

ment

( Rs. In

lakhs

Flue Gas Heat recovery from Indirect Fired HAG

Indirect Fired HAG flue gas was venting to atmosphere which was have with 300 deg C and flow of 750m3/hour. we have taken a call to utilize that heat to preheat the supply air to spray drier before heating diesel fired burner

To reduce HSD consumption in Diesel burner and utilize the flue gas heat which was venting to atmosphere

YES 2018 10 35



Name of

the

Project


why innovative

Trigger for

implementing

the project

Re

plic

abil

ity

Year

of

Imple

menta

tion

Annual

Savings

( Rs. In

lakhs)

Invest

ment

( Rs. In

lakhs

Combined Cooling tower

It was a practice to use two different cooling tower for process. and we were consuming energy for fans as well pumps in both the cooling tower. we have taken a call to go for single cooling tower to use for entire process and made with double fan which can be stopped any one during winter season

Huge power consumption by running both the cooling tower for process requirement

YES 2018 11 21



Name of

the

Project


why innovative

Trigger for

implementing

the project

Re

plic

abil

ity

Year

of

Imple

menta

tion

Annual

Savings

( Rs. In

lakhs)

Invest

ment

( Rs. In

lakhs

ATB system in Chiller

Auto Tube brushing system in Chiller for descaling the tubes in fixed intervals which will increase the heat transfer and give better chilling at low power generation

We observed that huge scaling in the tubes during annual cleaning periods. we found that it was impacting the heat transfer and consuming huge power. we have taken a call to install auto tube cleaning system

YES 2018 8 12


Innovative Projects

40KL HSD savings Equal to 10 Lakhs

savings/annum


Innovative Projects

Induced Cooling tower for Process Evaporation system which will improve plant Efficiency through Better Heat Transfer. Annualized savings 11Lakhs started from April 2018

Automatic Tube Brushing system for Chiller - Rs 8 Lakhs Annualized savings started from Mar 2018


Utilisation of Renewable energy sources & Future Plan

81% of overall Energy is generating from Renewable Energy Biomass Boiler – Fuel is Mixture of Rice Husk & Tea Waste

Proposed Savings

Sl.No

Year Project

Annual Electrical savings (KWH)

Annual Thermal Energy Savings

(HSD in KL)

1 2018-19 Roof Top Solar panel installation 1800002 2019-20 Biofuel in place of Fossil fuel (Diesel) 240

3 2018-19Usage of BMB Steam to Eliminate Electrical heater 66000


Utilisation of waste material as fuel

3090

2040

2761

0

1000

2000

3000

4000

2015-16 2016-17 2017-18

TEA WASTE in MT (Biomass Fuel)

35% of Tea Waste used in Boiler as Biomass fuel which is generated from the Instant Tea Process. We are installing In-House Tea spent drier to maximize the Tea waste usage upto

55%


GHG disclosure

3483

32773362

2500

2700

2900

3100

3300

3500

3700

2015-16 2016-17 2017-18

Tons of CO2 from Power & HSD

CO2 generation from Electricity and HSD. And 184kgs of R134 refrigerant in the site.


Green Supply Chain – Green Purchase Policy

100% RA Certified Raw Material used for Instant Tea Process

Unilever Responsible Sourcing Policy – Business should be conducted in a manner which embraces Sustainability and reduces Environmental Impact


Green Supply Chain – Projects & Benefits


Annual Electric

al Savings (KWH)


Annual Thermal savings

with units

Annual thermal cost

savings (Rs Mn)


Investment made

Payback in

Months

Boiler Evaporation ratio improvement

0 0 7000 Kcal 1.45 1.45 1.85 15

SABD Project - 2015 135479 1.35 0 0 1.35 3 26

11KVA Express Feeder 0 0255 Klof HSD

10.2 10.2 9.4 11

Energy Efficient Motor in Plant

88228 0.84 0 0 0.84 1.1 16

Energy Efficient Pumps in plant

85657 0.8 0 0 0.8 1.2 18

SABD Projects - 2016 0 01952 tons of steam

5.3 5.3 7.6 16

3D Element controller in Boiler

0 0172 tons of fuel

0.5 0.5 0.8 19


Green Supply Chain – Projects and Benefits


Annual Electric

al Savings (KWH)


Annual Thermal savings

with units

Annual thermal cost

savings (Rs Mn)


Investment made

Payback in

Months

Yield Improvement 67500 0.7164 tons of Steam

2.23 2.93 3.7 15

Pump Optimization to reduce Power

72000 0.72 0 0 0.72 1.5 25

Boiler Efficiency Improvement

0 0666 tons of fuel

1.7 1.7 2.6 18

Combined Cooling tower 110000 1.1 0 1.1 1.1 2.5 25

SABD projects - 2017 72400 0.721200 tons of steam

2.1 2.82 4 16

HAG Flue Gas heat recovery system

0 01550 tons of steam

2.6 2.6 3.5 16

Diffused Aerator in ETP 61344 0.67 0 0 0.67 1.85 26


Green Supply Chain – Evaluation Process

Evaluation on Energy reduction, Savings & IRR verification and Approval through capex

portal by Central team


Daily performance Monitoring

Environment performance Monitoring and reporting system

Daily monitoring system for Energy and Efficiency. Daily performance is getting reviewed by Factory Head


Capex allocation for Energy saving projects

Dedicated Capex is available for Energy and Sustainable projects and it is being allocated centrally from Unilever HO. No limit on Energy savings capex


Team work & Employee Involvement

Energy Savings projects are identified through Kaizens and Implemented by Factory Team. Factory team members are trained for Energy reduction activities


Encon projects investment %

618.4

16.50

200

400

600

800

Turnover of the company INR Mn Invested in Encon Projects INR Mn

Encon Projects Investment - Year 2017-18

Investment – 3% on overall Turnover


Sustainability Award at NFEST

34

Sustainability Award at NFEST 2018 at its 1st International conference at New Delhi


Thank you

Documents

UNILEVER INDIA EXPORTS LIMITED INSTANT TEA FACTORY … · boiler water temperature, drum level and pressure. These excursions reduce boiler steam efficiency by sub-cooling the boiler