UPL Limited, Unit-5, Jhagadia K - Green Business Centre

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UPL Limited, Unit-5, Jhagadia

Kishor Kumar - Manager (Energy Cell )

Hemant Warhekar - Sr Manager (Energy Cell )

Suresh Kalla - Sr Manager (Technical Department)

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Business FactsUPL is positioned as a knowledge hub that innovates products for the benefit of farmers the world over.

Our portfolio of total crop solution products enhances farm profitability. This portfolio extends from seeds

to post-harvest solutions. Representing a one-stop farmer solution.

Farmer Engagement

Aquatics

Post Harvest

Bio Solutions

Crop Protection

Seeds

Global status as a post-patentcrop protection chemicals company

2nd

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Manufacturing Sites

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Brief Introduction to UPL Ltd. Unit-5, Jhagadia

21st National Award for Excellence in Energy Management 2019, CII

• Largest unit of UPL

• Captive Power Plant of 26 MW and 15 MW.

• We have 4 Improvement Cells : Energy Cell, Maxpro, Maxpro+, Green Cell

• Manufacturer of : Fungicides, Insecticides, Herbicides and Chemicals

Crop Protection Herbicides Fungicides Insecticides

Soil & Water Technologies

CCP, PCL3, TPPI, Acrolein, CS2

Chemicals

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Jhagadia Industrial Estate –4200 acres or 1707 Hectares

UPL Site is spread over an area of 219 acres i.e., 89 Hectares (890000 Sq. mtrs)

Jhagadia Site – Aerial View


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2. Energy Consumption Overview


102251

134974151348

186100

289797 289861

0

50000

100000

150000

200000

250000

300000

350000

0

20000

40000

60000

80000

100000

120000

140000

160000

2017-2018 2018-2019 2019-2020

MT

MTO

E

Energy Consumption & Production

Overall Energy Consumption Production

4%

96%

2019-2020

Annual Electrical Energy Consumption

Annual Thermal Energy Consumption

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2. Energy Consumption Overview


889634965178

1292401

1460180

0

200000

400000

600000

800000

1000000

1200000

1400000

1600000

2016-2017 2017-2018 2018-2019 2019-2020

mill

ion

kca

l

Annual Thermal Energy Consumption

61.8

66.66 66.67

61.97

0

10

20

30

40

50

60

70

80

2016-2017 2017-2018 2018-2019 2019-2020

mill

ion

kW

h

Annual Electrical Energy Consumption

5641199

5186341

4459677

5037518

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

2016-2017 2017-2018 2018-2019 2019-2020

Kca

l/To

n o

f p

rod

uct

ion

Specific Thermal Energy Consumption

392

358

230214

0

50

100

150

200

250

300

350

400

450

2016-2017 2017-2018 2018-2019 2019-2020

kWh

/To

n o

f p

rod

uct

ion

Specific Electrical Energy Consumption

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3. Sp. Energy Consumption in last 3 years (FY 2017-20)


8% Reduction

35% Reduction

7% Reduction

8% Reduction 14%

Reduction

12% Increment

Reason for Increment in Specific Thermal Energy Consumption : Introduction of new energy intensive Products and Plants.

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3. Sp. Energy Consumption in last 3 years (FY 2017-20)


12.08 12.0011.87

11.43

12.50

11.06

11.4511.27

10.00

10.50

11.00

11.50

12.00

12.50

13.00

2016-17 2017-18 2018-19 2019-20

Norm Comparision - CCP

Total (GJ/MT) Budget Total (GJ/MT) Actual

13.58 13.48

12.77

13.45

12.7412.48

11.50

12.00

12.50

13.00

13.50

14.00

2017-18 2018-19 2019-20

Norm Comparision - MNZ


335.92

304.99307.77

311.06305.94

296.42

270.00

280.00

290.00

300.00

310.00

320.00

330.00

340.00

2017-18 2018-19 2019-20

Norm Comparision - GF1


45.2850.45 52.52

74.38

48.90

40.26

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

2017-18 2018-19 2019-20

Norm Comparision - UPI 12


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4. Information on Competitors, National & Global benchmark


List of Major Encon project planned in FY 2020-21

392

358

230214

189

0

50

100

150

200

250

300

350

400

450

2016-2017 2017-2018 2018-2019 2019-2020 Proposed 20-21

kWh

/To

n o

f p

rod

uct

ion

Specific Electrical Energy Consumption

11% Reduction

5641199

5186341

4459677

50375184882158

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

2016-2017 2017-2018 2018-2019 2019-2020 Proposed 20-21

Kca

l/To

n o

f p

rod

uct

ion

Specific Thermal Energy Consumption

3% Reduction

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4. Information on Competitors, National & Global benchmark


List of Major Encon project planned in FY 2020-21

Sr. No. Title of ProjectAnnual Electrical

Saving (kWh)

Annual Thermal Saving Investment Made

(Rs million)Quantity Unit of Measurement Million kcal

1 Back pressure Turbine in place of Pressure reducing station for steam 923077 9

2 Steam reduction by Heat integration Methanol & Ethanol recovery column 17424242 kg of steam 14554 30

3 Reflux optimization distillation column by increasing column height by 4 Mtr 15151515 kg of steam 12656 20

4 Variable nozzle thermocompressor installation to recover flash steam 4090909 kg of steam 3417 3

5 VFD for Secondary air fan 353846 2

6 Power boiler Blowdown Flash recovery to preheat condensate to deaerator 1946488 kg of Coal 8175 10

7 Heat recovery from blowdown water and preheat DM water 695870 kg of Coal 2923 1

8 Refrigerant liquid overfeed system for reactor to optimize power consumption 3168000 10

9 Low pressure blower to reduce power in CS2 furnace 792000 1

10 Steam optimization in Distillation column by reducing vacuum 3960000 kg of steam 3308 0

11 Roof Top Solar Power 1944462 47

Total 7181385 43269025 45032.6 132

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5. Energy Saving projects implemented in for last three years


Summary of project implemented in last three years

2017-18 2018-19 2019-20

No. of Proposals 12 8 14

Payback Months 7 4 7

Invetments (Rs million) 38 30 67

Savings (Rs million) 63 96 124

0

20

40

60

80

100

120

140

0

2

4

6

8

10

12

14

16

18

20

EnCon Projects

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EnCon Projects for Year 2017-18

Sr. No. Title of Project

Annual Electrical

Saving (kWh)

Annual Electrical

Cost Saving(Rs million)

Annual Thermal Saving Annual Thermal


Total Annual Savings(Rs million)

Investment Made

(Rs million)

Payback (Months)Quantity

Unit of Measurement

1Power consumption reduction by replacing to correct duty pump for utility

2774194 17.2 17.2 9.1 6

2Steam consumption reduction in Multiple effect evaporator by VFBD Air Pre-heating using waste heat

2347418 kg of steam 3.5 3.5 2.1 7.2

3 Replacement of HPMV lights to LED lights 866452 5.4 5.4 4.1 9

4Power Plant DM water Pre heating using waste heat of condensate

1572917 kg of coal 7.6 7.6 2.4 4

5Power consumption reduction at power plant by avoiding buffer tank for condensate

602742 3.7 3.7 3.8 12

6 Air Compressor stopped by Load optimization 269355 1.7 1.7 0.0 0

7Power generation by Installing Back Pressure Turbine in place of Pressure reducing Valve

950400 6.3 6.3 6.6 12

8 DM water Pre heating using waste heat from process condenser 3960000 kg of steam 5.1 5.1 2.0 5

9Power consumption reduction by replacing Reciprocating Air compressor to Screw air compressor

532258 3.3 3.3 1.6 6

10 Flash Steam Recovery by closed loop flash jet pump 1911469 kg of steam 2.9 2.9 1.7 7

11Pulley Change and Evaporative condenser in place of shell and tube condenser for reciprocation compressor & chiller

391452 2.4 2.4 1.8 9

12 Flash Jet Pump to Recover Heat from Flash Steam 2608987 kg of steam 3.9 3.9 2.4 7

Total 6386852 40 12400791 23 63 38

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Annual Electrical

Saving (kWh)

Annual Electrical





Investment Made

(Rs million)

Payback (Months)

QuantityUnit of

Measurement

1Elimination primary pumping for Chilled water and brine & evaporative condenser in chiller for new projects

2352941 15.6 15.6 6.7 5

2Replacing Shell and tube condenser with Evaporative Condenser for Brine Chiller

1297134 8.6 8.6 6.0 8

3 Flash steam recovery using Variable Nozzle thermocompressor 3383459 kg of steam 4.5 4.5 2.8 7

4Natural Gas consumption reduction in Spray Dryer by Air Pre-heating with flash steam

247029 SM3 of NG 7.9 7.9 5.7 9

5Eliminating use of primary pump by utilizing gravitational head for Chiller in existing plants

780692 5.2 5.2 0.5 1

6Steam consumption reduction by Heat Integration for pre heating column feed by column outlet vapour and flash steam.

2635338 kg of steam 3.5 3.5 4.1 14

7NG norm reduction by incinerator Air pre-heating by flash steam

159475 SM3 of NG 5.1 5.1 2.7 6

8Online Condenser cleaning system at power plant for turbine condenser

6850800 45.4 45.4 1.2 0.3

Total11281567 75 6425301 21 95.8

29.7

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Annual Electrical

Saving (kWh)

Annual Electrical





Investment Made

(Rs million)

Payback (Months)Quantity

Unit of Measurement

1Power Generation trough Back Pressure turbine in place of steam pressure reducing station

3523077 22.90 22.90 17.8 9

2 Use of gravity flow and eliminated chilled water primary pumps 792000 5.15 5.15 1.0 2

3 Steam Reduction in evaporator by heat integration 2803030 kg of steam 3.70 3.70 4.0 13

4 Incinerator Air pre-heating by using flash steam 145714 SM3 of NG 5.10 5.10 2.4 6

5Brine chiller power optimization by using evaporative Condenser

153846 1.00 1.00 3.7 44

6 VFBD Air Pre-heating by waste Condensate heat 2651515 Kg of Steam 3.50 3.50 2.8 10

7Heat Recovery from process reactor vapor to preheat DM water for boiler

15227273 kg of steam 20.10 20.10 11.1 7

8Condensate recovery 50 KL/Hr by installing condensate polishing unit

6448210 kg of coal 34.78 34.78 16.0 6

9Variable nozzle thermocompressor installation to recover flash steam

3409091 kg of steam 4.50 4.50 2.8 7

10 NG Reduction by Pre-heating SPD air by Steam 225714 SM3 of NG 7.90 7.90 5.7 9

11Auxiliary cooling water pump stopped using EPANET simulation of water distribution

453846 2.95 2.95 0.0 0

12 Chilled water pump optimization 396000 2.57 2.57 0.0 0

13 CFBC Boiler Blowdown Flash recovery 889823 kg of coal 4.80 4.80 0.0 0

14 Process CW Pump Optimization with impeller trimming 810277 5.27 5.27 0.0 0

Total 6129046 40 31800371 84 124 67

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6. Innovative Projects implemented


Project : PCL3 condensation heat recovery by preheating powerplant DM Water

Idea : To Recover PCL3 condensation heat i.e. 13.44 lac. kCal/h.

Before: All the generated heat was rejected in cooling tower.

After: By using HNP oil as heat exchanging medium between PCL3 and DM Water, heat was recovered to preheat DM water.

Benefits:1. Saving in terms of steam 1388 TPA2. Water evaporation reduction 15392 KLPA3. Cost Saving Rs. 201 LPA , Total investments Rs. 111.6 Lacs

After successfully implementing in one of the reactors we are planning to implement the same in other reactors with potential additional saving of Rs. 402 LPA.

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6. Innovative Projects implemented


COLD DM WATER INLET

HOT DM WATER OUTLET

PCL3 Vapour @78 Deg. C.

Trombone Cooler

Catch POT

Ref

lux

Co

lum

n

New

PC

L3 C

on

den

ser

Catch POT

HNPStorage

Tank

PHE

COLD HNP IN

HOT HNP OUT

COOLING TOWER

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7. Utilization of Renewable Energy sources


Technology Type of Energy Onsite/ OffsitePurchase / Own

GenerationInstalled

Capacity (MW)

Generation (Million kWh)

for 2019-20

% of overall electrical energy

Solar PV Cell Solar Energy OffsitePurchase through

Agreement7 6 9%

Wind Turbine Wind Energy OffsitePurchase through

Agreement3.6 9 15%

Unit PartySolar / Wind

Capacity (MW)

Lacs. kwh for 2019-20

Savings(Rs. Lacs)

PL00 Party A Solar 2.2 28 79

PL01Party A Wind 2.1 49 136

Party A Solar 1.8 23 64

PL02 Party A Solar 2.5 12 35

PL05

Party B Wind 2.1 59 177

Party C Wind 1.5 34 95

Party A Solar 7 56 160

Total

Solar 4 13.5 120 338

Wind 3 5.7 141 408

Total 7 19.2 261 746

Renewable power purchase through “Long term Agreement”

Group Capacity : 19.2 MWUnit Capacity : 10.6 MW

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7. Utilization of Renewable Energy sources


Renewable Power Purchase 2017-18 2018-19 2019-20

No of Project Implemented - 1 2

Capacity Addition (MW) - 2.1 8.5

Power Generation(Million kWh - 3.4 14.9

Group total capacity(MW) - 4.2 19.2

Unit total capacity(MW) - 2.1 8.5

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8. Waste utilization and management


2017-2018 2018-2019 2019-2020

Type of waste generated

Quantity of waste generated (MT/year)

Disposal methodType of waste

generatedQuantity of waste

generated (MT/year)Disposal method

Type of waste generated

Quantity of waste generated (MT/year)

Disposal method

Solid 31332 Landfill Solid 45514 Landfill Solid 69844 Landfill

Liquid 3818 Incineration Liquid 5463 Incineration Liquid 6753 Incineration

• We have common hazardous waste treatment facility called as BEIL, Bharuch . BEIL promoted by Industries in Bharuch District with major shareholding by Tatva Global Environment Private Limited (known as ‘Tatva’ group), the Company promoted by the Directors of UPL Limited.

• In 2019-2020, Incinerable liquid 1280 MT/year (19% of total liquid) send to cement industries out of total 6753 MT/Year as a alternative fuel.

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9. GHG Inventorisation


2015-2016

2016-2017

2017-2018

2018-2019

2019-2020

2020-2021

Target

kgCO2 / Ton of Final Product 2800 2400 2200 1900 2135 1964

0

500

1000

1500

2000

2500

3000

Carbon Emission

0

500

1000

1500

2000

2500

3000

2015-2016 2016-2017 2017-2018 2018-2019 2019-2020

kgC

O2

/ T

on

of

Fin

al P

rod

uct

Carbon Emission

Sp.CO2 Generation Scope 1 Sp.CO2 Generation Scope 2

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11. Teamwork, Employee Involvement & Monitoring


1. Daily Monitoring system: Utility Report, Power distribution report, Energy Tracker (monthly).2. Review Meeting chaired by :

• Monthly Review meeting: Energy Cell, group production head, maintenance head, Unit Head & Director .

3. Separate Capex is allotted to energy conservation projects

This Tracker is formed every month from the data from monthly reports.

Also for major products tracking is done for energy.

We receive this report daily, which includes Power import and distribution

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4. Energy efficiency / awareness training programAll staff, contract workers and workmen are aware on energy performance. On joining of new employee during induction

energy philosophy being discussed. Every Friday ‘Energy-Talk’ happens across all cross functional department to aware about energy efficiency. Approximately 70% staff aware about energy conservation.

Energy Management Policy

Water Conservation Policy

Revised Energy Conservation Book for Weekly/Daily Talk

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Energy Quiz duringEnergy

Conservation Week

Revised Energy Booklet

Unveiling at Energy

Conservation Week

Weekly Energy talk on Shop Floor

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12. Implementation of ISO 50001/Green Co/IGBC rating


1. Implemented ISO 50001 at Unit -2, in process for Unit-1. In Unit-5 new project is coming up and under stabilization.2. Investment over turnover % (Excluding Plant Expansion Investment)

1. 2016-17 : 0.80 %2. 2017-18 : 0.93%3. 2018-19 : 0.85%4. 2019-20 : 0.42%

UPL Unit-5 Canteen and Meeting building is certified by IGBC

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13. Other Innovative technologies implemented


Installed online monitoring system for Chillers, with the help of IOT and Automation.Advantages : Data can monitor from anywhere in company WAN, Trend/Data can be downloaded for analysis and study.By this we have optimized the chiller operation.

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14. Long Term Vision on EE


1. Long term target of energy efficiency

a) Integrate Energy management with business objective

b) Ensure energy efficiency while procuring significant energy consuming products and services

c) Organize periodic training to all personnel

d) ISO 50001 certification for all units

e) Implementation of advanced technologies

f) 100% condensate recovery of recoverable condensate

g) 20% renewable energy of total consumption

2. What support you require to achieve those target

a) Collaboration with institution, forums and organization to explore new technology

b) Knowledge sharing with cross functional team

c) Special budget for new technology


Milestones & Achievements

2018

2016

2015

2014

2010

2011

2012

2013

2017

21.ISO 50001:2011, Energy Management System - First Unit in Agrochemical Sector to be certified

13. UPL Excellence Award14. Steam Tech Award –PL02* F&S Mfg. Excellence –15. PL01 (Challengers)16. PL02 (Challengers)IGMC Silver Award 2015 by IRIM

10. UPL Mfg. Excellence Award - PPA* F&S Mfg. Excellence for 11. PL01 (Challengers)12. PL02 (Challengers)

5. UPL Mfg. Excellence Award – PPA* F&S Mfg. Excellence for 6. PL017. PL028. PL059. FICCI Award – PL02

17. FICCI award for energyefficiency PL02

18. QCFI award for PL0519. BEE First prize for PL02 20. BEE COM for PL01

3. UPL Mfg. Excellence Award –Savings4. ICC Award – PL02

2. UPL Mfg. Excellence Award -Savings

1. National Energy conservation award – PL00

2009

EC cell formed 2009

2020

2019

22. Future of Energy management submit & award - 201823. ISO 50001 surveillance audit Completion at PL02

24. CII 20th National Award for Excellence in Energy Management 2019 • Excellent Energy Efficient Unit• Innovative Project





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Thank You

Hemant Warhekar - [email protected] - +91 9099034428Suresh Kalla - [email protected] - +91 8238022352Kishor Kumar- [email protected] - +91 9512177585

mailto:[email protected]



Documents

UPL Limited, Unit-5, Jhagadia K - Green Business Centre