Flow of Presentation

Specific Energy Consumption –Benchmarking

01Thermal & Electrical Interventions

03Waste To Energy: Innovative Approach

Biogas Plant: 19m3/day.

05Sustainable Society

Biogas and Solid waste Management

07

Energy Conservation-Technology Map.

02Renewable Energy

1 MW Rooftop Solar Power .

04Employee

Engagement

TPM

06

Electrical Supervisor

Branch Engineer

Energy Manager

I/C Electrical

MFG Executive

HR Executive

Utility Supervisor

Commercial Executive

ESP Member

Central Management Committee

The Energy Management Committee consists of Management, non-Management and Service Providers who actively takes part in the meeting

Energy Management organization Chart

TECHNOLOGY

Feasibility

Viability

BUSINESS

Usability, Desirability

HUMAN VALUES

DESIGN &

INTERACTIVITY

ORGANIZATION

BEHAVIOR

MANUFACTURING

Design

Innovation

Energy Management

Divisional and International benchmarks!!

Energy Audits-Expert

Internal Brain Storming

& Learning

Awareness Building

Bench Marking

Innovations

Approach

4.743

4.617

2015-16 2016-17

GJ/MNC

4.625.4

5.82

8.04

9.82

MGR SER PUN BLR BAT

GJ/MNC

GJ/MNC 16-17

Energy/MNC

Thermal Energy (FO & LPG)

LPG

Electrical Energy

EnCon Projects/Practices: Technology Map

5

• Hot Condensate Recovery system including SOPTs

• Process heat recovery• Feed water heating through

Solar Heater• Economizers• Air-fuel ratio optimization to

1.5-2.5%• Steam Trap monitoring

Steam generated (Tobacco Processing)

• Substitution of LPG with Biogasgenerated from Tobacco Waste

LPG / Biogasconsumption

• LED lighting for shop floor

• LED street lights for compound lighting

• Light Pipe

Lighting

• Screw compressors for better efficiency

• Aluminum line to supply compressed air line with minimal pressure drops

• Auto-cut off valves

Compressed Air

• Chilled condensate recycling system

• AHU Cooling coils replacement

• Auto Tube Cleaning System

• VRV system

HVAC

• Interlocks for to prevent idle losses on compressed air and DRF lines

• VFD installed on DRFs for optimal consumption

• Compressed air leakage audits by production teams on shop floor

Motors/Rotating parts on Shop floor (Cigarette manufacturing)

Solar 1 MWpBiogas: 19 m3/day

05

04

03

02

01

Condensate water recovery for feed water heating

Process heat recovery for feed water heating .

Economizer for Boiler No. 1

Optimized Air-Fuel ratio (1.5-2.5%)

Strengthening maintenance & Minimizing Breakdowns

Thermal Energy – Supply Side

12.4

13.3

FY 15-16 FY 16-17

Evaporation Ratio

Waste Heat Recovery UnitWater in temp. = 35 *CWater out temp. = 69 *C

Thermal Energy – Demand Side

Reducing Consumption: SOPTs for Comas and KLD driers

Optimizing Consumption:PRV for Admoist

Minimize losses:Arresting leakage, focus on increasing condensate recovery

Reducing Losses:Monitoring steam traps & Plug leakages

Steam Hours:Reduction in steam hours, increase in steam-hour throughput

836

822

760

FY 14-15 FY 15-16 FY 16-17Steam/TOT

530

242200

2014-15 2015-16 FY 16-17HVAC Steam (Tons)

Revamp of HVAC system to increase humidification through air washers

7.5 % reduction

Waste to Energy – Innovative Approach

First tobacco sand (process waste) to biogas conversion plant installed

Composite Pit

Tobacco dust in feeding tank

Digest the dust using anaerobic digester

Send the effluent to ETP for treatment

Output

Anaerobic

Digester

Collection of bio gas

17.67

15.6813.99

LPG (Tons)

LPG Consumption Trend

14-15 15-16 16-17

Output

Catalyst : pH>7 • Achieved by less tobacco mixed with large amount of water (1kg :20L)• Neutralizing tobacco’s acidic nature

Electrical Performance – Units/MNC

744732

680

2015-16 2016-17 2017-18 …

Units/MNC

Auto Cut off Valves Incorporated to reduce compressed air wastage.

Saved 15 units/hr of idle consumption

HVAC revamp to save 6 units/mnc of consumption

Compressed Air Unit Audited to continuous leakages, to save 20

units/mnc

Auto tube Cleaning system for HVAC

DRF drive frequency optimized by running two drive

Key Efforts

10

732

797

938959

MGR SRE PUN BLR

Units/MNC

Automatic Tube Cleaning System

Energy savings with ATCS

Periodic cleaning each 6 months

ATCS – Continuous Automatic Cleaning

Periodic cleaningEvery 1*F increase in Condenser approach increases power consumption by 1.5%

Potential Savings of 43.4 Mwh

MGF UF RO

TDS : 2500PPMPH:7.2

From W.W.T.P To CoolingTower

TDS : <200 PPMPH:6.6

Renewable Energy: SolarFocus on continuous replacement of conventional energy with renewable energy

Commissioned 1.063 MW of Rooftop Solar Plant in Sep’15

11

10%

14%

24%

3%

10%14%

2014-15 2015-16 2016-17

% Renewable Energy Share

Electrical Energy substitution Total energy substituted

Online Panel level Monitoring system – Breakdown diagnosis

and resolution

Water based cleaning of Solar panels – Higher efficiency/PR

Sustainability

326

806

1075

2014-15 2015-16 2016-17

GHG Reduction (in Tonnes)

Pressurized Recycled water pipeline across factory for

cleaning

3.8

9.38

12.35

2014-15 2015-16 2016-17

Units Generated in Lacs

13

Daily area wise Energy consumptions are monitored and circulated to top level executives.

Energy consumptions reviewed, analyzed & corrective actions planned in

- Daily production meetings

- Weekly Energy Management cell meeting

- Monthly Performance review by HODs & Factory Head.

Designated Energy Manager and Encon Members facilitates the reviews

- Implementation status of suggestions from Encon Task Force (workmen ) are

reviewed in monthly performance reviews.

- Energy consumption trends, Encon project status and new project proposals are

reviewed in Monthly Operational Group Meetings.

Encon Task Forces: Employee Engagement-TPM

0

1000

2000

3000

4000

5000

1 4 7 10 13 16 19 22 25 28 31

Generation

STEAM/HR in kg/hr EVR

0

200

400

600

800

1000

1200

1400

0

2000

4000

6000

1 5 9 13 17 21 25 29 33

Consumption

THROUGHPUT (w.r.t Steam hrs)

STEAM/TOT

TPM-Key Initiative and Results

• Identified Pressure Drop avenues ( Rerouting/

modification/Automation of demand for reducing

idle run) and corrected through selective

replacement of bag filters in SMD & PMD

• Reduction of DRF fan frequency post reduction

of PD

• New VFD installation at lamina & central DRF

• Identification, Selection and

correction of Existing Power

Factor correction to replace

defective Capacitors

• Design Change of APFC for

better control at Centralized

Panel is in progress

Power Factor improved to 0.99

DRF

DRF fan frequency reduced to 38HZ from 45Hz

PMD consumption reduced 24KW/TOT to 17Kw/TOT

Power Factor improvement

• Identification, elimination, Re-routing of

compressed air lines which reduces 300m

pipelines at SMD and leakage associated

• Identified leakages and defective spares

replaced

• Segregation of Cleaning and Process line to

reduce pressure set point for cleaning

• Implemented maintenance schedule for

components to reduce defects/leakages

Compressor

SMD compressor Set point reduced to 5.9 bar from 6.2

PMD compressor set point reduced to 5.8 Bar from 6.2

132

119

Pre Post

Compressor Unit/MNC

34

19

Pre Post

DRF Unit/MNC

0.97

0.99

Pre Post

Power Factor

15

Employee Engagement• Training Session • Celebration of Key Events • Events Extensive Communication

Organise Quiz contest, Skit competition, Slogan & Suggestion Contest conducted along with recognition

Participated by Employee’s and

ESP’s.

Biogas Plants installed in nearby villages and households are getting benefit38 plants of 2m3/day capacity each

Sustainable Society

16

Household Garbage

Recyclables

Non-Recyclables+

Kitchen Waste

Green waste

BiodegradableSolid Waste

RecyclableSolid Waste

Non-DegradableSolid Waste

Solid to recycling units

Dumping(Landfills)

Organic Composite

Solid waste Management at Munger

Sustainable Society

Seco

nd

ary

Segr

egat

ionP

rimary Segregatio

n

18

ITC Triple Bottom Line

The only Company in the world of its size to be carbon, water and solid waste recycling positive

Carbon Positive organisationRenewable Energy Share

Zero Liquid Discharge 100% Solid Waste Recycling

19

1.Energy ManagementUnits/MNC-680 (2017-18)Units/MNC-590(2017-21).

2.Renewable Energy5Mw Offsite Solar plant-2020

3.Water ManagementKL/MNC-2017-18:4.24Kl/MNC-2017-21: 3.86

4.Waste Management

Upgradation of Bio gas to 100m3 -2018

8.Environ friendly MaterialsExploring Environment friendly Materials-

Biodegradable plastics, filters , led free pain etc.

7.Greening the supply chainStandarisation of vendor selection

criteria based on green parameters and provide support

6.Regulatory FrameworkScan regulatory framework

continuously and frame suitable strategies

5.Green RecognitionsIGBC platinum Certification renewal-2017

Exploring and applying various national and international Green award.

Greenovation– Roadmap of Green Journey 2017-20

1

2

3

4

5

6

7

8

Greenovation