Presentation on Energy saving by Alternative Operations of Aerators - PowerPoint PPT Presentation

ENERGY SAVING Presentation on Energy saving by Alternative Operations of Aerators in ETP and STP Aeration Tank. Presented By : R. S. Patel. (Head – Engineering) ARVIND LIMITED DIV. ANKUR TEXTILES. 1

SWADESHI MOVEMENT Early 1900s • Swadeshi = “One’s own country", Self sufficiency • Boycott British goods • Indians produce own goods People boycott the fabric • Indians school – nationalist education coming from England The Year 1930 • The Lalbhai’s reasoned that the demand for fine and superfine fabrics still existed. • Any Indian company that met this demand would surely prosper. • The three brothers, Kasturbhai, Narottambhai and Chimanbhai, decided to setup a mill to produce superfine fabric. • And a company called Arvind Limited was born in 1931 2

WHAT IS ARVIND ? Annual Turnover Rs 10,000 Cr Textiles Composites & Garments Advance materials Real Estate Brands Telecom Retails Engineering 3

TEXTILES…. • Denim TEXTILES • Woven fabric-Shirting • Woven Fabric-Bottom Weight. • Woven fabric – Life Style-Voiles. • Technical Textiles • Knits 4

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. Turn Over, ₹ in Cr. 419 392 360 347 328 270 226 5

PRODUCTION – SP. THERMAL & SP. ELE. ENERGY Production - Sp.Thermal and Sp.Electrical Energy 4,667 30 5000 4500 4,037 3,949 3,828 25 4000 3500 20 16.4 15.4 3000 15.0 13.9 15 2500 2000 10 1500 5.3 5.2 5.2 3.4 1000 5 500 0 0 2013-14 2014-15 2015-16 2016-17 Sp. Thermal Energy in Mil. Kcal/MT Specific Electrical Energy in Mil Kcal/MT Production in Ton 6

How to optimize energy consumption..  Continuous & proactive Efforts.  Internal Audit Team for Energy Management.  Day to day monitoring of all utility consumption.  Strong management support.  Assistance from External teams, i.e. Thermax, Forbs Marshall, Inspiron, Energy audit services Etc. 7

Energy Conservation Organogram 8

ENCON PROJECTS IMPLEMENTED During the year2014-15, 2015-16 & 2016-17 No. of Projects : 30 Total Amount Invested : ₹ 75.34 Million Cost Saving Achieved : ₹ 45.12 Million Electrical Energy Saved : 36.83 Lacs kWh Thermal Energy Saved : 1651 MTOE 9

Energy Saving Steps – FY14-15 ELECTRICAL Sr. Project Location Energy saving step details ProjectDescription Saving Investment Pay Back Period KWH/Year ₹/Year ₹ Months 1 Invertors on H-Plant Fan Invertors on Spinning H-Plant 623808 5146416 960000 Motors Fans. Total 16 No. Invertors on Weaving & Winding 225264 1858428 700000 2.8 H-Plant Fans. Total 13 No. Total For Invertors 849072 7004844 1660000 2 L E D Project 160 No LED fittings in place of 74857 617570 368000 7.2 fluorescent fitting Grand Total (Electric) 923929 7622414 2028000 3.2 THERMAL Sr. Project Location Energy saving step details ProjectDescription Saving of coal Investment Pay Back Period MT/Year ₹/Year ₹ Months 1 Fuel saving by collection of Installation of condensate pump 144 806400 550000 8.2 condensate recovery TOTAL SAVING + INVESTMENT in FY15 144 8428814 2578000 3.7 10

Energy Saving Steps - FY15-16 ELECTRICAL Sr. Project Energy saving step details ProjectDescription Saving Investment Pay Back Period KWH/Year ₹/Year ₹ Months 1 L E D Project 160 No LED fittings in place of 37628 310431 136000 5.3 fluorescent fitting 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 250 1395000 1000000 8.6 system on 8 MT/Hr FBC Boiler 2 Fuel saving by Installation of 8 MT/Hr FBC boiler in 1418 7912440 8000000 12.1 replacement of boiler place of 6 MT/Hr smoke tube boiler Total 1668 9307440 9000000 11.6 SAVING + INVESTMENT in FY16 1668 9617871 9136000 11.4 11

Energy Saving Steps - FY 16-17 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 170767 1314906 548000 5.0 Florescent fitting 2 Power saving by Replacement of 28 Nos of High bay lights 65856 507091 224000 5.3 LED of 400 Watts by 120 Watts LED fittings 3 Power saving by Replacement of 7 Nos of High bay lights 8232 63386 56000 10.6 LED of 400 Watts by 120 Watts LED fittings compound light 4 Power Saving DC Drive convert to invertor drive in 117600 905520 110000 1.5 WARPINGM/C 5 Power Saving Replacement of PUMP in ETP 84000 646800 48000 0.9 2NOS 30HP INSTALL 20HP 6 Power Saving Replacement of compressor motor 241500 1859550 30000 0.2 pulley. 7 Power Saving Replacement of Aerators motors in ETP 84000 646800 800000 14.8 2Nos 30HP INSTALL 20HP Continued… 12

Energy Saving Steps Electrical- FY17 continued… 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 161700 1245090 25000000 240.9 replaced by X5 mopdel) 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 9450 72765 10000 1.7 Cooling Fan -1 no M/C 14 Power Saving Replaced Auto Corner suction motor pulley in 2 30800 237160 10000 0.5 m/cs 15 Power Saving Installed Invertors 10 Nos SFAN/RFAN in 420000 3234000 320000 1.2 Winding Dept. Continued… 13

Energy Saving Steps Electrical- FY17 continued… 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 3528 27166 50000 22.1 dyeing area. 17 Install Monitor roof in Godown - 3528 27166 500000 220.9 removed 24 - 40 W tube lights in top floors 18 Low eff to high eff. Replaced Low eff. Stenter by High eff. 283073 2179662 19300000 106.3 19 Energy Saving by Total 7 nos of Aerators are put on 346302 2666525 175000 0.8 Alternative operation of alternative drive. ETP and STP Aerators 20 Save Energy and water To maintain water pressure at 1.5 89436 688657 60000 1.1 consumption through Kg/cm2 round the clock by installing Water Pressure control invertors and pressure transdudar on water supply. Reduced water consumption by 145 KL/day. 21 Invertors on H Plant fan Invertors on H plant fans- Total 6 nos 252000 1940400 150000 0.9 mptors (Spinning) 22 Invertors on H Plant fan Invertors on H plant fans- Total 4 nos 134400 1034880 100000 1.2 mptors (Weaving) SAVING + INVESTMENT Electricals in FY17 2722052 20959800 47764000 27.4 14

Energy Saving Steps FY-17 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, 310000 180000 6.9 Reduced steam cons. 6% 4 PRV on Machines Installed 15 No Pressure Reducing Valves on 15 No. 365800 150000 4.9 comby m/c to reduce steam pressure 5.5 to 3.0 bar 5 Steam cut off switch on 5 Installed 5 Nos. of steam cut off switches when m/c is 1463200 25000 0.2 No. Drying range m/cs. stopped. 6 Reuse of Hot Water Started recirculation and reuse hot water 70000 ltr/day. 899000 60000 0.8 7 Collection of condensate Installed additional pump. 706800 250000 4.2 water 16-17 : TOTAL SAVING + INVESTMENT (Thermal) 6113200 15865000 31.1 16-17 : TOTAL SAVING + INVESTMENT (Electrical) 20959800 47764000 27.4 16-17 : TOTAL SAVING + INVESTMENT (Ele. + Thermal) 27073000 63629000 28.2 15

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.  Aeration tank contains “soup" of starved microbes called activated 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. 16

Aeration Tank Details We have total 3 nos. of aeration tanks for secondary treatment Location Capacity KL HP of each Nos. of Aerator Aerator ETP 1600 25 2 ETP 1200 15 3 STP 1000 20 2 17