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30-31st August, 2017
NATIONAL AWARD FOR EXCELLENCE IN ENERGY
MANAGEMENT AND EFFICIENCY
Agenda
• Plant Profile
• Good and Green
• Plant performance for last three years
• Overview of Energy Management System
• Energy conservation projects
• Innovative projects at GIL- Valia
• Best Practices implemented on Energy front amongst associates
• Way Forward
Plant Profile
• Market Leader in Oleo Chemicals and
surfactant in India
• Integrated Oleo Chemicals complex
established in 1990
• Two plants of Fatty alcohol at one
location
• Caters to the raw material needs of
consumer good sectors – Personal care,
home care, tyre industry and specialized
applications
• Exports to over 80 countries across 6
continents
Godrej Industries (Chemicals), Valia plant
Products
Fatty Acids & Glycerin
Fatty Alcohols
Surfactants
Cosmetics
Toiletries
Rubber
Polymer
Pharmaceutical
Humectants
Cosmetics
Industrial applications
Personal Care
Laundry
Shampoos
Conditioners
Toothpaste
Cosmetics
Detergents
Key Categories Applications Key Customers
GOOD & GREEN
OVERVIEW
Our journey
We aspire to create a more
employable Indian
workforce, build a greener
India, and innovate for
'good' and 'green' products
We are furthering this
commitment through
'shared value' initiatives
that create both social
and business benefits
We articulated our
commitment towards
building a more inclusive
and greener India –
Godrej Good & Green
2011 2017 2020
Our goals
Achieve zero waste to landfill,
carbon neutrality and a positive
water balance, while reducing
specific energy consumption by
30% and increasing the use of
renewable energy by 30%
Train 1 million youth in skills
that will enhance their
earning potential
Generate a third of our
portfolio revenues from 'good'
and/or 'green' products
Ensuring
Employability
Greener
India
Product
Innovation
VALIA PLANT
ENERGY DISTRIBUTION
Total energy distribution
12%
88%
Total energy distribution, %
Electrical (Grid Electricity and DG )
Thermal (Natural gas, HSD, Furnace Oil, Biomass Briquette)
Major Changes in last three
years
• Three Biomass Briquette
boiler
• Displaced approximately 60%
Natural gas.
• Reduced SEC by 4.5%
• Reduced Carbon di-oxide
emissions by 58000 TCO2
VALIA PLANT
PERFORMANCE
Specific energy consumption Change to Total
Specific Energy Consumption
Years SEC, GJ/T
(Total)
% Reduction
(FY 11)
2010-11 13.2 0.00
2011-12 14.3 8.21
2012-13 13.1 -1.02
2013-14 12.0 -8.79
2014-15 11.9 -9.79
2015-16 12.1 -8.49
2016-17 11.5 -12.89
Specific Green house gas emissions Scope1+2
Specific GHG Emissions
Years kg CO2 Eq/T % Reduction
(FY 11)
2010-11 930 0.0
2011-12 1004 8.0
2012-13 1005 8.1
2013-14 948 1.9
2014-15 818 -12.0
2015-16 686 -26.2
2016-17 599 -35.6
Renewable energy portfolio
Renewable Share in Total Energy
Years %Renewable % Increase
(FY 11)
2010-11 1.35 0.0
2011-12 1.60 17.9
2012-13 1.82 34.3
2013-14 1.75 29.5
2014-15 20.0 1380.2
2015-16 40.3 2873.5
2016-17 44.2 3162.9
Greener India impact
Goal
% reduction in specific
energy consumption
Reduce specific energy
consumption by 30%
Achievement
Increase renewable
energy sources by 30%
Become carbon
neutral
Have a positive water
balance consumption
% of total energy consumption
from renewable sources
% reduction in specific
greenhouse gas emissions
% reduction in specific
water consumption
% reduction in specific
waste to landfill
Send zero waste
to landfill
VALIA PLANT
ENERGY REDUCTION TARGET
Specific energy reduction target
TARGET (GJ/MT) 2016-17 2017-18 2018-19 2019-20
Total 11.5 11.0 10.25 9.50
SHORT TERM TARGET
TARGET (GJ/MT) BASELINE, 2010-11 2020
Specific Energy Consumption
(Total)
13.2 9.24 (30% reduction
from FY11)
LONG TERM TARGET
VALIA PLANT
ENERGY CONSERVATION PROJECTS
Energy conservation/efficiency projects FY17
Name of the projects Investment (lakh) Savings Annually
Lights replaced with LED 90 7.3 Lakhs Kwh
Installation of heat recovery unit at reformer outlet 2212 Lakhs MJ
Air pre heater at 18B3 outlet 1212 Lakhs MJ
NG recovery from the compressor for reformer 218 Lakhs MJ
Raw water pump replacement 11 lakh Kwh
Energy conservation/efficiency projects FY17
Name of the projects Investment (lakh) Savings Annually
Fatty acid production by De- acidification route rather
than conventional splitting-distillation routeNil
Electricity- 1.69 lakhs Kwh
Steam – 2928 MT
Material Conserved – 24 MT
Water flow measurement had helped in various
energy saving projects 2 2.14 Lakhs Kwh
Heat exchanger for recovering heat from product line
section 21 and 1815 24.5 Lakhs MJ
Replacement of the V belt by cogged belt0.32 68571 Kwh
Energy conservation - innovation
Heat Pipe
GIL, recently installed a Heat Pipe (which has a
higher heat transfer coefficient as compared to
other heat exchangers) for extraction of heat
from a medium grade source in their spray drier
for manufacturing a Sodium Lauryl Sulphate
powder/needles. The savings is around 15
Lakhs per annum. Its going to save around
60,000 M3 of NG. The total investment was
around 7 lakhs with payback less than a year
Compressor Heat Recovery
GIL, started preheating the boiler feed water
with help of heat coming out of compressor. The
source water at 33 C was heated up to 48 C
with a flow of 8m3/h. Its is saving around 375
MT of Briquettes annually. Apart from it the
cooling of compressor is resulting around 24000
Kwh saving in power consumption.
Waste to Energy PLASMA GASIFICATION
Plasma gasification takes all types of waste and
converts into energy and vitrified slag. Plasma
extracts the carbon and hydrogen from the
feedstock and converts it into syngas which is used
to power a syngas engine which will cater for self
consumption. The slag generated by the plasma
gasification is a vitrified slag which can be used as
construction material and laying roads. Thus there
is absolutely Zero waste.2TPD Plasma waste to
energy plant at GIL,
Valia
Benefits:
1. Able to Process 2TPD waste
2. Replacing 2.85 lakhs of NG annually
3. Savings around INR 88 Lakhs as waste deposal cost
New Briquette Boiler
Godrej Industries Limited having a time bound goal
of becoming Carbon neutral has installed third
briquette boiler at our Valia factory. This is going to
reduce our further dependency on Natural Gas. It
is proving 2.5 Million Kcal for heating thermic fluid
and 6TPH Steam for process.
Third Briquette boiler
at GIL, Valia
Benefits:
1. NG Replaced by 4735 M3/day
2. Around 12000MT of CO2 Eq reduction
Life Cycle Assessment for SLS and SLES
We have conducted Life
Cycle Assessment of our
two products SLS and
SLES
.
Environmental Parameters (Per ton of product) SLS SLES
Global Warming Potential
(kg CO2)638 1050
Blue Water Consumption (t water) 19.7 16.2
Acidification Potential (kg SO2 equiv.) 12.4 11
Eutrophication Potential (kg PO4 equiv.) 1.66 1.26
Human Toxicity Potential (kg DCB equiv.) 2430 1650
Terrestrial Ecotoxicity Potential (kg DCB equiv.) 14.60 10.50
Supply Chain
• We have formulated a sustainable procurement
policy to go deep into the value chain and to
hand hold our suppliers for environmental and
social sustainability.
• We have reduced our Scope 3 (inbound and
outbound) emissions by 30% diverting our
finished good from JNPT to Hazaria port. Which
is reducing the transport distance by 516 Km.
Distance from JNPT to Valia 370
Distance between Hazira to Valia 112
Way forward
• Reduce specific
energy by 30%
• Caron Neutrality
• Renewable energy
Process Reengineering and Process Innovation
Investing in clean technologies
Life Cycle assessment of various products
Evaluating Green Chemistry
Integrating energy conservation education and
enhancing supplier performance
TRAINING & AWARENESS
OVERVIEW
Environment day and energy conservation week
Energy Conservation Week Leakage Tagging
“Train the trainer” “Awareness sessions”
Suggestions schemes
57suggestions
42Implemented
ENERGY MANAGEMENT SYSTEM
OVERVIEW
Energy management cell
FACTORY HEADCORPORATE GROUP
ENERGY TEAM
(CORDINATORS)ENERGY MANAGER
SMALL GROUPS
(TEAM MEMBERS)
• Strategic Planning
• Quarterly Review
• Project facilitation
• Strategic Planning
• Monthly Review
• Daily Monitoring
• Monthly Review
• Daily Monitoring
• Identification and execution
of projects• Daily Monitoring
• Annual Activity Plan
• Initiate activity to improve monitoring
• Equipment performance Analysis
• Conduct Internal Workshop
• Daily Monitoring of Specific
Energy
• Assisting in execution of
projects
Energy monitoring and review
SoFi Enterprise Sustainability Performance Software for Sustainability
Management and Data analysis and reporting
Review
Monthly
Review
Quarterly
Review
Plant Level &
Corporate Level
GILAC Level chaired by
Mr. N B Godrej
Governing Council at
Group Level chaired by
Mr. J N Godrej and Mr. N
B Godrej
Half yearly
ReviewDaily
Review
Plant Level
Daily reports
AWARDS AND RECOGNITION
OVERVIEW
Awards and recognition
GIL, Valia plant received the CII
Greenco silver rating in 2015
Godrej Industries has ranked on the
CDP India’s Climate Disclosure
Leadership
CII National Award for Excellence in
Energy Management - 2016
CII Innovative project awards - 2016
CONTACT US
www.godrejgoodandgreen.com
THANK YOU FOR YOUR TIME AND CONSIDERATION