Sriperumbudur N.Karuppusamy Senior Manager C.Vignesh Kumar … · 2018-09-13 · © Confederation...
Transcript of Sriperumbudur N.Karuppusamy Senior Manager C.Vignesh Kumar … · 2018-09-13 · © Confederation...
© Confederation of Indian Industry
N.Karuppusamy – Senior Manager
C.Vignesh Kumar – Executive
Sriperumbudur
© Confederation of Indian Industry
Brief introduction on Company
▪ Asian paints, Sriperumbudur plant commissioned in the year 2005 with
an initial capacity of 30,000 KL per annum.
▪ Current production capacity is 1.4 Lac KL per annum
▪ Manufacture Interior and Exterior Decorative Water based Paints.
▪ First Automated plant of Asian paints ltd.
▪ Operates with almost 100 % Renewable energy since 2017-18.
▪ Water neutral plant - 225 % in the year 2017-18
▪ Bio diversity rating – 52 in the year 2017-18
IBBI - India Business and Biodiversity Initiative
▪ Zero liquid discharge since inception (2005).
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Polymer
Processing
Mixing
Packing
Emulsion storage
Process Flow
Tank farm
Silo
D.C
Packing material
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1. Sp. Energy Consumption in last 3 years
100 % LED conversion
TSD Agitator modification
Utility Automation
Kaizen / Energy cell
Process Optimization
Pressure Based Pumping System
Air pressure optimization
Energy Management System
24%
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3a. Energy Saving projects implemented in FY 2015-16
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1 Pressure based pumping system 3,53,919 3.07 5.54 22
2Conventional lamps to LED conversion - Godown,
Silo, office 1,42,860 1.24 2.19 21
3 Air pressure setting optimization 6.5 to 5.5 bar 2,18,400 1.38 0.09 1
4 Replacement of Conventional AC to Inverter duty AC 18,144 0.16 0.60 46
5 Common FRL in an air tree 11840 0.08 0.45 84
6 Weekly timer for godown lighting 8650 0.05 0.02 5
Every year we execute around 60-70 nos of energy conservation ideas / projects
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3b. Energy Saving projects implemented in FY 2016-17
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1 TSD agitator modification 2,49,600 2.08 16.5 8
2 Energy saving initiative –Portable comp / Motion se 1,35,000 1.13 3.49 37
3 100 % LED conversion 1,17,055 0.98 3.63 45
4 200 TR Energy efficient chiller 90,000 0.78 3.53 54
5 Monomer storage temp. set point optimization 78,000 0.49 0 1
6 Cold well separation for different application 21,000 0.18 0.9 59
7 Replacement of Conventional AC to Inverter duty AC 15,552 0.13 0.80 71
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3c. Energy Saving projects implemented in FY 2017-18
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1 TSD agitator modification 2,99,520 1.89 19.8 10
2 TSD motor capacity optimization 37,440 0.24 3.63 22
3 Energy efficient - conveying blower 1,87,200 1.19 4.96 20
4 Aeration blower optimization using VFD 61,776 0.39 0.75 2
5 Modular air piping network 39,000 0.25 2.65 10
6 Powder Conveying optimization 2,10,600 1.33 0 0
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2.Information on Competitors,National &Global benchmark
Competitor SPC trend – National and Global
Dulux Group Corporate Sustainability Report 2017
Nerolac
Courtesy
Kansai Nerolac Sustainability Report 2017
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2. Information on Competitors, National & Global benchmark
SPC of Asian Paints plants in 17-18
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4. Innovative Projects Implemented-Chennai Express
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4. Innovative Projects Implemented-Chennai Express
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4. Innovative Projects Implemented – Elimination of Pump
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4. Innovative Projects Implemented – Elimination of pump
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4.Innovative Projects-Powder conveying optimization
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Blower
TSD
RAL
Before Project
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4. Innovative Projects-Powder conveying optimization
• Powder conveying system
• Used to transfer powder from Storage vessel to Process equipment
@ 800-900 m bar
• Each powder has different density .
• High density powders are difficult to convey & decides the
conveying rate
• Innovative Solution
• Studied the system, found high density powders are few
• Installed pressure sensor in the system and feed was controlled
based on the pressure in the system.
• This had increased the conveying rate of low density powder
significantly and hence power consumption is reduced.
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4.Innovative Projects-Powder conveying optimization
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Blower
TSD
RAL
Pressure
Switch
VFD
After Project
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Oct 2014 Solar 800 KW
Feb 2016 Wind 1.5 MW
Mar 2017 Wind 2 MW
Mar 2018 Solar 150 KW
5. Utilisation of renewable energy sources
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2015-16
Solar 953252
Wind 129304
%RE = 12%
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2016-17
Solar 911010
Wind 3094383
%RE= 43%
2017-18
Solar 925564
Wind 8006277
%RE= 97%
5. Utilisation of renewable energy sources
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Boiler steam condensate recovery water reused as raw water
Boiler steam obtained/day = 1200kg
Boiler Running hours/day = 12hrs
Recovery water from steam = 18kl
(i.e) (1200kg*12hr)/0.8 (0.8 is dryness factor)
Saving = Rs.19,656
motor capacity= 5.5kw
Flow rate = 10m3/hr
Currently we are working on using STP treated water for process
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6. Utilisation of waste material as fuel
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- Information on GHG Inventorisation and public disclosure
7. GHG Inventorisation
Category FY15-16 FY16-17 FY17-18
Scope 1 (tCO2e)Direct emission 1,249 906 1,129
Scope 2 (tCO2e)EB 6,845 4,929 874
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8. Green Supply Chain
1. EMS – Energy Management System
❑ Fetches energy consumption and generation data automatically and generates report
❑ Compare energy consumption across individual section and across plants
❑ Monitor generation and consumption at a single place
❑ Analyse and act on the higher consumption then and there
2. Central Energy cell
❑ A group of managers across all plants meet and share ideas
❑ Energy consumption and Energy conservation ideas implemented in individual plants
highlighted in this forum
❑ Facilitate horizontal deployment of projects across all plants
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8. Green Supply Chain
3. RE 36 by 2020
❑ Government of India taken a RE target of 40% by 2030
❑ Asian paints ltd taken a mission of RE 36% by 2020.
❑ In FY 18 – 19, Srip RE is close to 100 %
❑ And at supply chain level RE is at 35 %
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1. Daily Monitoring System
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9. Team work, Employee Involvement & Monitoring
❑ Energy Management System
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2. Plant energy cell – Cross functional team meets every month to share their energy saving
ideas
9. Team work, Employee Involvement & Monitoring
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3.Separate budget for Energy Conservation
9. Team work, Employee Involvement & Monitoring
Year Budget in INR million
2015 – 16 8.33
2016 – 17 28.85
2017 - 18 29.14
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9. Team work, Employee Involvement & Monitoring
E-Day Poster Energy Saving Projects
4. Energy Saving Awareness Program
❑ SriP Energy Day
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Energy Products LED
Energy Day Energy Day
9. Team work, Employee Involvement & Monitoring
4. Energy Saving Awareness Program
❑ Stall on energy conservation products
❑ Awareness to employees on Plant
SPC and its impact to environment / cost
Awareness program conducted to employees
on Energy Conservation @ Home
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9. Team work, Employee Involvement & Monitoring
Idea Drop Box Gamesa Wind Mill Field Visit
4. Energy Saving Awareness Program
❑ What an idea Sirji contest-2015 -16 / 2016-17 , winners are given with LED lamps /
Solar emergency lamps to spread awareness
❑ Windmill visit for contest Winners
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5. Projects implemented through Kaizens
9. Team work, Employee Involvement & Monitoring
Year Operators Technicians Officers Executives Total SPC Kaizens
2015-16 4 6 57 9 76
2016-17 5 2 24 5 36
2017-18 5 7 28 2 42
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10. Implementation of ISO 50001/Green Co/IGBC rating
NA
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Any other relevant information
Other awards, acknowledgement
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CII Kaizen Award- Operator & Officers CII Safety Award
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Any other relevant information
Other awards, acknowledgement
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Thank you