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Garware Polyester Ltd. Aurangabad. Company Profile. Unit Profile.
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Unit Profile • Garware Polyester Limited is the pioneer in the field of polyester film. The Company has developed various types of films and is exporting to 57 countries in World. The company has excellent infrastructure and strong commitment to Safety, Quality, Energy Conservation , Environment preservation and R&D. • Winner of Highest Export Award-Plex council (Govt. of India, Ministry of Commerce) since last 20 years. • Winner of “Energy Efficient Unit- 2010” by CII. • Winner of 1st award in 2009 in “Plastic Category” on National Level (NECA) • Winner of 2nd award for excellence in Energy Conservation and Management in 5th Maharashtra State Level Award competition in year 2008 in category “Other Industries“. • The company has set up cross functional Energy Conservation Cell, which focuses on energy management and improvement. • The company recognizes the importance of energy conservation, not only to improve the bottom line but also to help the environment and society at large for sustainable growth.
Energy Management Policy • Garware Polyester Limited plays vital role for producing variety of products • with high level of quality standard and prioritizes energy value for the final • product. • Our mission is : • To produce products with minimum use of energy. • Use of cleaner technologies wherever possible and ensuring efficient and uninterrupted supply of utilities to plants. This, we plan by following ways. • Efficient energy generation, utilization and distribution. • Continuous evaluation of performance of plant equipments and processes to achieve most efficient, high standard quality products. • Targeting the under-performance equipments and processes for improvement. • Monitoring and targeting the specific energy consumption to achieve best possible as compared to past performance. • Use of internal and external expertise to achieve targeted performance. • Train employees and implement ideas of energy conservation thorough small ENCON teams. M S Adsul Director-Technical
ENCON Team Structure DIRECTOR - TECHNICAL ENGINEERING HEAD DY. GENERAL MANAGER CENTRAL UTILITY ENCON TEAM FILM PLANT ENCON TEAM POLYMERISATION PLANT ENCON TEAM CENTRAL UTILITY ENCON TEAM CHIKALTHANA PLANT
Energy Monitoring • 1.Daily Energy report is generated by Central Utility on daily basis and circulated to all concerned. • 2.Monthly Based on daily energy report, monthly energy report is prepared and circulated to all concerned. Comparison & analysis of energy consumption is done with previous months and deviations are studied for reduction in Energy Bills. • 3.Yearly Yearly reports generated from data collected as above. Specific energy consumptions are calculated and targets are set for future. Major ENCON projects are listed in annual report.
ENCON Methodology Identification of high energy consuming equipments/processes through internal & external audits. Elimination of inefficient equipment & substitution with new & efficient technologies. Continuous energy performance monitoring through statistical analysis. Brainstorming in small group activities for innovative ideas. Reduction in Carbon foot print & implementation of green projects. Benchmarking with other competitors. Involvements of employees through suggestion schemes & competitions.
Identification of Major losses 1. Failure losses - Breakdown loss 2. Setup / adjustment losses 3. Cutting blade loss 4. Start up loss 5. Minor stoppage / Idling loss. 6. Speed loss - operating at low speeds. 7. Defect / rework loss 8. Scheduled downtime loss 9. Management loss 10. Operating motion loss 11. Line organization loss 12. Logistic loss 13. Measurement and adjustment loss 14. Material Yield loss • 15. Energy loss 16. Die, jig and tool breakage loss
Energy Reduction – Chips Plant 10.42% 6.12% 5.61%
Energy Reduction – Film Plant 5.46% 1.7% 7.5% 0.2% 0.87% 18.91%
ENCON Project : 1 Title : Poly Plant Cutter Cooling Tower • Loss no: 15 • Background of the project : To reduce chilled water load. • Observation made : • Chilled water is used for Poly plant cutter for cooling of chips from 280°C to 40°C. • Cooling water can also be used for cutter cooling. • Technical and Financial Analysis Investment : Rs. 15 Lacs Implemented : Aug. 2009 1st year cost Saving : Rs. 29.38 Lacs Impact of implementation : Reduction in chilled water load by 200 TR/Hr. • On annual basis Electricity cons. (Lacs kWh) Energy consumption before : 9.81 Energy consumption after : 2.61
Before After
Process Flow Diagram of Chilled Water System VAHP MACHINE Chilled water out Cooling water out Film Plant Chilled water in Poly Plant Cooling water in Batch Plant Pump Chilled water return from plants
Single effect Machine Steam consumption single effect machine = 8.1 Kg/TR
Condensor High Temp. Generator Low temp. generator Over flow pipe Cooling Water Evaporator Diluted Solution Inter Solution Concentrated LiBr Refrigerant Chilled Water Cooling Water Refrigerant Vapour Steam/ Flue Gases Absorber Purge Pump Double Effect Machine Steam consumption Double effect machine = 4.1 Kg/TR
Machine Photographs Single Effect Machine - Before Double Effect Machine - After
ENCON Project : 3 • Title : Commissioning of Biomass Fired Boiler • Loss No- 15 • Background of the project : To reduce Furnace oil consumption for Boilers. • Observation made : • Cost of steam on briquette is almost half that of F.O. • Unused IAEC make F.O. fired boiler of 18 MT/Hr capacity is available. • Can be used by installing external furnace for biomass firing. • Existing underutilized go down can be used for boiler operation and briquette storage. • Technical and Financial Analysis : • Investment : Rs. 332 Lacs • Implemented : Jan. 2010 • Impact of implementation :Reduction in Furnace Oil consumption. • Thereby reduction in SO2 by 108000 Kg/annum and estimated reduction in CER by 11000 per annum.
Savings achieved by converting F.O fired Boiler to Biomass fired Boiler • Avg. Furnace oil Reduction = 200 MT/M • Average Cost of Furnace Oil = 34500 Rs./MT • Yearly Cost savings (Fluctuate as per Price variation in the Fuel) = 183 Lacs/Year
Boiler Photographs before and after conversion F.O. Fired Boiler Biomass Fired Boiler after conversion
Before KAIZEN Implementation After KAIZEN Implementation
ENCON Project : 4 • Title :Optimization of Cooling water system • Loss no- 15 • Background of the project : • To reduce power consumption for Cooling water pumping. • Observation made : 1. Cooling water high head and low head requirement areas were identified. 2. It was observed that high head heat exchangers were starving due to low pressure although the flow through pumps was satisfactory. 3. The low head areas were provided with positive isolation wherever possible to reduce the unnecessary power consumption and other heat exchangers were tuned for appropriate diff temp for optimum flow. • Technical and Financial Analysis : • Investment : 0.5 Lacs Implemented : Dec. 2012 • 1st year cost Saving : Rs. 44.06 Lacs • Impact of implementation : Reduction in power consumption—5.04 LkWhper annum
ENCON Project : 5 • Title :Optimization of chilled water system • Background of the project : To reduce power consumption for Chilled water pumping. • Observation made : 1. Chilled water high head and low head requirement areas were identified. 2. It was observed that high head heat exchangers were starving due to low pressure although the flow through pumps was satisfactory. 3. The expansion tank of the system was raised by 8 M of height to improve the suction and discharge head. 4. The low head pumps were put into operation to reduce the power consumption. 5. All heat exchangers were tuned for required chilled water flow. • Technical and Financial Analysis : • Investment : 0.5 Lacs Implemented : Dec. 2012 • 1st year cost Saving : Rs. 26.99 Lacs • Impact of implementation : Reduction in power consumption---5.37LkWh per annum.
ENCON Project : 6 • Title :Optimization of Hot oil system • Background of the project : To reduce power consumption for Hot oil pumping. • Observation made : 1. Hot oil high head and low head requirement areas were identified. 2. It was observed that high head heat exchangers were starving due to low pressure although the flow through pumps was satisfactory. 3. Thermic fluid heater coil flow made fine tuning. 4. Before implementation one high head pump was running with full impeller, after that two pumps impeller trimmed & reduced the head & increased the flow . Technical and Financial Analysis : • Investment : 0.5 Lacs Implemented : Dec. 2012 • 1st year cost Saving : Rs. 19.2 Lacs • Impact of implementation : Reduction in power consumption---3.1 Lac kWh/annum
Efforts on Electrical Energy reduction • Utilization of High efficiency motor for blower. • Blower old motor efficiency was lower i.e 88%. • Before implementation blower motor taking 18.18 Kwh & with high efficiency motor 14.92 Kwh . • Cost Saving : Rs. 1.69 Lacs • Impact of implementation : Reduction in power consumption---0.3Lac kWh/annum
Efforts on Electrical Energy reduction • Conversion of motor connections from delta to star. • Methanol recovery cooling tower fan motor connections changed from delta to star reducing power by 0.16 kwh Calculation: (1.78*24*30*12/100000)*6 • Total Cost Saving : Rs. 1.00 Lacs • Impact of implementation : Reduction in power consumption---0.15Lac kWh/annum
