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© Confederation of Indian Industry
ARVIND LIMITED
Division. ANKUR TEXTILES. Ahmedabad
Presentation on Energy saving
Focused on power saving by
Alternative Operations of Aerators
in
ETP and STP Aeration Tank.
Presented By :
R. S. Patel.
(Head – Engineering)
© Confederation of Indian Industry
Brief introduction on Company/Unit
• Arvind Limited Started in 1931- with Aim to produce high end Super fine fabric with 52560 Spindles and
1122 looms.
• First year turn over was Rs 45.76 Lakhs which reached to 11000 plus cr. Rs. Last year .
• In 1987 Arvind Entered in to Export market.
• By 1991 Arvind was third largest Denim manufacturing company in the world.
• In 1997 State of Art textile unit was started at Santenj having largest of it kind in Shirting, gabardine and
Knits.
• It is ISO 14001 and ISO 9001 Company. Our labs are NABL - ISO 17025 Certified.
• World famous brand like Levis, Lee Wrangler are our customer. Mega mart and The Arvind store are our
channels.
• Beside Textiles Arvind is in following business.
TE
XT
ILES
© Confederation of Indian Industry
Woven fabric –Life Style-Voiles – Ankur Textiles..
- Ankur is one of the oldest working composite Textile mill
in Ahmedabad started in 1914.
- In 1979 Arvind Group take over this unit.
- In last five year our turnover growth is @ 12% and
planned to reach 500 Cr. by FY20.
© Confederation of Indian Industry
1. Sp. Energy Consumption in last 3 years
© Confederation of Indian Industry
In Textile there are lots of variances like type of raw material (Cotton, poly, P/C,
Modal, viscos, lycra, nylon etc.), Count of yarn (From 6 to 170) and
construction of fabric. There are no national or global standard norms of
specific energy consumption. Industry have to fix its bench marks on the basis
of past consumption data. BEE had given targets to individual industry under
PAT scheme and industry takes Energy saving actions to achieve PAT targets.
Ankur have formed Energy conservation team, constant follow-up and audit of
day to day energy and water consumption.
With our continuous efforts we achieved 9 % saving in thermal and 41% in
Electrical energy in last 3 years.
2. Information on Competitors, National & Global benchmark
© Confederation of Indian Industry
ENCON PROJECTS IMPLEMENTED
During the year, 2015-16 &2016-17&2017-18
No. of Projects : 32
Total Amount Invested : ₹ .90 Million
Cost Saving Achieved : ₹ 30. Million
Electrical Energy Saved : 27.59 Lacs kWh
Thermal Energy Saved : 1569 MTOE
© Confederation of Indian Industry
3a. Energy Saving projects implemented in FY 2015-16
ELECTRICAL Sr. Project Energy saving step details
Project Description Saving Investment Pay Back Period
KWH/Year ₹/Year ₹ Months 1 L E D Project 160 No LED fittings in place of
fluorescent fitting
37628 310431 136000 5.3
THERMAL Sr. Project Energy saving step details
ProjectDescription Saving of coal Investment Pay Back Period
MT/Year ₹/Year ₹ Months 1 Fuel Saving by
Effimax Installation of EFFIMAX
monitoring system on 8
MT/Hr FBC Boiler
250 1395000 1000000 8.6
2 Fuel saving by
replacement of
boiler
Installation of 8 MT/Hr FBC
boiler in place of 6 MT/Hr
smoke tube boiler
1418 7912440 8000000 12.1
Total 1668 9307440 9000000 11.6
SAVING + INVESTMENT in FY-15-16 1668 9617871 9136000 11.4
© Confederation of Indian Industry
3b&c. Energy Saving projects implemented in FY 2016-17-18
ELECTRICAL
Sr. Project Energy saving step details
Project Description Saving Investment Pay Back Period
KWH/Year ₹/Year ₹ Months
1 LED Project 730 Nos of LED fitting in place of
Florescent fitting
170767 1314906 548000 5.0
2 Power saving by
LED
Replacement of 28 Nos of High bay
lights of 400 Watts by 120 Watts LED
fittings
65856 507091 224000 5.3
3 Power saving by
LED
Replacement of 7 Nos of High bay
lights of 400 Watts by 120 Watts LED
fittings compound light
8232 63386 56000 10.6
4 Power Saving
DC Drive convert to invertor drive in
WARPINGM/C
117600 905520 110000 1.5
5 Power Saving Replacement of PUMP in ETP
2NOS 30HP INSTALL 20HP
84000 646800 48000 0.9
6 Power Saving Replacement of compressor motor
pulley.
241500 1859550 30000 0.2
7 Power Saving Replacement of Aerators motors in
ETP 2Nos 30HP INSTALL 20HP
84000 646800 800000 14.8
Continue…
© Confederation of Indian Industry
3b&c. Energy Saving projects implemented in FY 2016-17-18
Sr. Project Energy saving step details
ProjectDescription Saving Investment Pay Back
Period
KWH / Yr ₹ / Yr ₹ Months
8 Power Saving Installed Doffing motor on Card m/c 21000 161700 48000 3.6
9 Power Saving Installed Invertor on Roll folding m/c. 7000 53900 30000 6.7
10 Power Saving Installed invertors on 8 Stenters for
Exhaust
123200 948640 120000 1.5
11 Power Saving REPLACE AUTO CORNER M/C 2NOS (138
were replaced by X5 mopdel)
161700 1245090 25000000 240.9
12 Power Saving Installed Invertor in Boiler I D Fan 1 Nos
M/c
64680 498036 75000 1.8
13 Power Saving Installed Temerature controller in
compressor Cooling Fan -1 no M/C
9450 72765 10000 1.7
14 Power Saving Replaced Auto Corner suction motor
pulley in 2 m/cs
30800 237160 10000 0.5
15 Power Saving Installed Invertors 10 Nos SFAN/RFAN in
Winding Dept.
420000 3234000 320000 1.2
Continue…
© Confederation of Indian Industry
3b&c. Energy Saving projects implemented in FY 2016-17-18
Sr. Project Energy saving step details
ProjectDescription Saving Investment Pay Back Period
kwh / Yr. ₹ / Yr. ₹ Months
16 Power Saving Installed Fibre roof for day light in Jet
dyeing area.
3528 27166 50000 22.1
17 Install Monitor roof in Godown -
removed 24 - 40 W tube lights in top
floors
3528 27166 500000 220.9
18 Low eff to high eff. Replaced Low eff. Stenter by High eff. 283073 2179662 19300000 106.3
19 Energy Saving by
Alternative operation of
ETP and STP Aerators
Total 7 nos of Aerators are put on
alternative drive.
346302 2666525 175000 0.8
20 Save Energy and water
consumption through
Water Pressure control
To maintain water pressure at 1.5
Kg/cm2 round the clock by installing
invertors and pressure transdudar on
water supply. Reduced water
consumption by 145 KL/day.
89436 688657 60000 1.1
21 Invertors on H Plant fan
mptors
Invertors on H plant fans- Total 6 nos
(Spinning)
252000 1940400 150000 0.9
22 Invertors on H Plant fan
mptors
Invertors on H plant fans- Total 4 nos
(Weaving)
134400 1034880 100000 1.2
SAVING + INVESTMENT Electricals in FY: 16-17-18 2722052 20959800 47764000 27.4
© Confederation of Indian Industry
3b&c. Energy Saving projects implemented in FY 2016-17-18
THERMAL
Sr. Project Energy saving step details
ProjectDescription Saving of coal Investment Pay Back
Period
₹/Year ₹ Months
1 Thermal Energy Installed Invertors in Stenter M/c for Exhaust 8
m/c.
824600 200000 2.9
2 Stenter upgradation Replace low efficiency Stenter by high eff. stenter
m/c
1543800 15000000 116.6
3 Steam Trap
Replacement
Replaced 36 No. thermodynamic trap by float type
trap, Reduced steam cons. 6%
310000 180000 6.9
4 PRV on Machines Installed 15 No Pressure Reducing Valves on 15 No.
comby m/c to reduce steam pressure 5.5 to 3.0 bar
365800 150000 4.9
5 Steam cut off switch
on 5 No. Drying range
m/cs.
Installed 5 Nos. of steam cut off switches when
m/c is stopped.
1463200 25000 0.2
6 Reuse of Hot Water Started recirculation and reuse hot water 70000
ltr/day.
899000 60000 0.8
7 Collection of
condensate water
Installed additional pump. 706800 250000 4.2
16-17 -18: TOTAL SAVING + INVESTMENT (Thermal) 6113200 15865000 31.1
16-17-18 : TOTAL SAVING + INVESTMENT (Electrical) 20959800 47764000 27.4
16-17-18 : TOTAL SAVING + INVESTMENT (Ele. + Thermal) 27073000 63629000 28.2
© Confederation of Indian Industry
1) REPLECMENT OF COMPRESSOR MOTOR PULLY
power consumption - 155 x 23x 350 = 1247750 KWH/year power
consumption - 125 x 23x 350 = 1006250 KWH/year 1247750 1006250
saving kwh 241500
2) Save Energy and water consumption through Water system Pressure
control
To control water pressure at 1.5 Kg/CM2 Round the clock by installing
invertors and pressure transducer on water supply. Reduced water
consumption by 145 KL/day.
3) Total 5 no of Aerators of ETP and 2 Nos of Aerators working continuously
Power consumption .705672 KWH/year. Total 3 no of Aerators of ETP and
two no Aerators of STP are working Alternatively with invertor and two
Aerators of ETP working Alternatively. Power consumption 359370
KWH/year
4. Innovative Projects implemented
© Confederation of Indian Industry
Thought process for power saving
Micro organisms such as bacteria and protozoa can use the small
particles and dissolved organic matter, not removed in primary
treatment, as food.
Aeratio ta k o tai s “soup" of starved i ro es alled a tivated sludge.
They are aerobic organisms so need Oxygen to survive and
requirement of dissolve oxygen is proportionate to the input pollutant
load.
Design of any aeration tank is done for DO level of 2.5 mg/ltr.
As our input load of COD, BOD is lesser to design load DO was
remained 3.5 to 4 mg/ltr.
Excess DO was consuming unnecessary Electrical Energy.
We started thinking various options to reduce DO level.
First option is to reduce Speed of Aerators by installing VFD.
© Confederation of Indian Industry
Energy Saving By Innovative implementation
© Confederation of Indian Industry
Aeration Tank Details
We have total 3 nos. of aeration tanks for
secondary treatment
Location Capacity KL HP of each
Aerator
Nos. of
Aerator
ETP 1600 25 2
ETP 1200 15 3
STP 1000 20 2
© Confederation of Indian Industry
DATA SHEET
© Confederation of Indian Industry
Photographs
© Confederation of Indian Industry
-We have installed 512 KW Solar panels on our roof top.
Beside of Energy to conserve natural resources...
(1) We have installed Sewage Treatment Plant having 15 KLD capacity. WE
take raw sewage from Corporation drainage line, treat it and use as
process water. ( 65 % of total process water is used from this STP) This is
first textile unit in India having such a large plant.
(2) We started rain water harvesting in under ground bore well.
5. Utilisation of renewable energy sources
© Confederation of Indian Industry
Reduction in CO2 emission in 2017-18 is 9 % in
quantity and 24% in per ton of production in last three
years.
7. GHG Inventorisation
Quantity in Ton
Sr. No Co2 Emission Source 2015-16 2016-17 2017-18
1 Electricity Consumption 22260 16501 12667
2 CNG Gas 491 487 473
3 Coal 26273 26496 30222
4 DOC - Agro Waste Fuel 77 881 1294
5 Total 49102 44365 44656
6
Quantative % Saving Compare
to 15-16 9.65 9.05
7 Producton in MT 4037.23 4666.93 4869.67
8 Ton of Co2/Ton of Production 12.16218 9.506326 9.170259
9
Per Ton Production % Saving
Compare to 15-16 21.84 24.60
© Confederation of Indian Industry
9. Team work, Employee Involvement & Monitoring
© Confederation of Indian Industry
Endless Efforts to conserve
energy and natural
resources are must.
Thank you all.
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