GOPAL GLASS WORKS LTD

PRESENTATION FOR

CII NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT 2020

TEAM

PURVISH SHAH (DIRECTOR)

SAMEER GAUTAM (GENERAL MANAGER)

C M RAVAL (ELECTRICAL HEAD)

About the organizationGopal Glass group is a 40 year old company and the largest Patterned (Figured) and Wired glass manufacturer inIndia with 450 tons/day production capacity, most cost efficient plant & having 60 % national market share.

Products:

Patterned Glass

Patterned (Figured) glass is a kind of decorative translucent flat glass with embossed patterns on one orboth surfaces. With the special property of decoration, figured glass can fully allow the light to pass through andon the other hand, can limit or prevent clear view effectively. It is used in partitions, windows, decorativeglazing, furniture, bathrooms, etc.

Wired Glass

The wire mesh is passed through the molten glass coming out from the throat of furnace while otherprocesses are same that of manufacturing Figured glass. It is used in industrial, institutional and residentialbuildings for safety purpose.

We are pioneer in manufacturing 2 mm Anti Glair Rolled Glass which is widely used in photo framing.

We are role model for technology benchmark in domestic Patterned glass industry with highest patent(registered glass designs) and are consuming more than 50 % electricity from renewables (both solar and wind).

We are a zero debt company and had acquired a sick unit and made it profitable within 2 years.

Certifications

ISO 9001 ISO 14001 ISO 45001

Energy Consumption Overview

Year Production in MT Electrical million KWh Thermal million KCal Overall TOE

2017-18 53975 3.0271 94751 9734

2018-19 83870 * 8.4877 120055 12733

2019-20 86107 8.7489 121992 12950

7524, 6%

121992, 94%

TOTAL ENERGY CONSUMPTION MILLION KCAL 2019-20

Electrical Thermal

* In March 2018 we revamped an old furnace from 80 TPD to 180 TPD with Electric boosting

Specific Energy Consumption

1581484

1326787 1319464

1100000

1200000

1300000

1400000

1500000

1600000

1700000

KCAL/TON

THERMAL SEC

2017-18 2018-19 2019-20

Electrical SEC is without electric boosting, however it is included in Thermal SEC

50.526 47.938

41.438

0

10

20

30

40

50

60

KWH/TON

ELECTRICAL SEC

2017-18 2018-19 2019-20

We have reduced our Electrical SEC in 2019-20 by 18% from 2017-18We have reduced our Thermal SEC in 2019-20 by 16.5% from 2017-18

Competitors, National & Global Benchmarks

47.93

45.23

48.61

43

44

45

46

47

48

49

KWH/TON

ELECTRICAL SEC FOR 2018-19

GOPAL GLASS GOBIND GLASS TRIVENI GLASS

13267871559078

1850601

0

500000

1000000

1500000

2000000

KCAL/TON

THERMAL SEC FOR 2018-19

GOPAL GLASS GOBIND GLASS TRIVENI GLASS

DATA IS TAKEN FROM THE ANNUAL REPORT OF THE RESPCETIVE COMPANIES

Gobind Glass is a group company of Gopal Glass.Gopal Glass provides several processed raw materials to Gobind Glass, so its Electrical SEC is higher

Competitors, National & Global Benchmarks

BEE energy conservation guidelines 2019 for MSME glass industry suggests typically 1305000 Kcal per ton of glass melt for furnaces below 200 TPDTERI’s 2012 report on Glass industry suggest 1386320 Kcal per ton of glass melt for pressed or figured glass.Our Energy data includes melting, forming and annealing thermal energy consumption, whereas BEE and TERI data is for glass melting energy need only.

1326787

1305000

1386320

1250000

1300000

1350000

1400000

KCAL/TON

THERMAL SEC BENCHMARK FOR 2019-20

GOPAL GLASS BEE TERI * There are no specific global benchmarks available

List of major Encon projects for 2020-21

Sr.No.

TITLE OF PROJECT ANNUAL SAVING INVESTMENT RS IN LAKH

COMMENT

1 Revamping of unit II Old furnace of 75 TPD to new design 85 TPD, with same furnace area

a Deep Refiner Increases thermal efficiency

b Online O2 monitoring in flue gas

Decreases heat loss

c Furnace Camera 6000 Million 100 Improves operating performance

d Improved Insulation Kcal Reduces heat loss

E Three different fuel firing simultaneously

Gives flexibility of cheapest fuel selection

F Auto Burners in Lehr Optimises the Lehr temp. control

2 VFD’s for Machine cooling, Lehr cooling blowers

29000 KWh 3 Payback in 1.5 years

3 LED Fittings 8300 KWh 2 Payback in 4 years

Energy saving projects implemented in 2017-18

Sr. No. PROJECT DETAILS INVESTMENTS IN LAKH RS

SAVINGS IN KWH

SAVINGSIN RS.

PAYBACK IN YEAR

1 Voltage optimization for single phase loads

3.5 12400 93000 3.7 years

2 IE3 motors 4.4 6806 51045 8 years

3 Replaced conventional welding machine by IGBT invertor based

4 8267 62000 6.5 years

4 Replaced copper choke tube light with led lights

7 48472 363540 2 years

TOTAL 18.9 75945 569585 Average 3.16 years

Energy saving projects implemented in 2018-19

Sr. No. PROJECT DETAILS INVESTMENTS IN LAKH RS

SAVINGS INUNITS

SAVINGSIN RS.

PAYBACK IN YEAR

1 Revamp of unit III old Furnace with new energy efficient furnace

1525 12200Million Kcal

435 Lakh 3.5 years

2 PIR sensors used in toilet blocks 1.5 1419 KWh + water saving

10600 14 years

3 Introduced VFD’s for tank and throat cooling blowers

6.1 8267 4.15 lakh 1.5 years

4 Replaced copper choke tube light with led lights

2 5037 37190 5.4 years

TOTAL 1535 75945 440 Lakh Average 3.48 years

Energy saving projects implemented in 2019-20

Sr. No. PROJECT DETAILS INVESTMENTS IN LAKH RS

SAVINGS INUNITS

SAVINGSIN RS.

PAYBACK IN YEAR

1 Blast Furnace Slag as alternate raw material

7.2 320 Million Kcal

11.6 Lakh

8 months

2 Natural Gas usage increased compared to Furnace oil

0 4.23 lakh Kwh

30 Lakh -

3 IE3 motors 3.1 11342 Kwh 83700 4 years

4 Jet Pump for Vehicle cleaning 0.1 888 Kwh 6600 2 years

5 Water Temperature control using PID & VFD in Cooling Tower

0 19800 Kwh 1.46 -

6 Metal Halide Fitting replaced by LED fittings

1.35 9548 Kwh 70400 2 years

7 PIR sensors used in toilet blocks 2.14 6286 Kwh + water saving

46384 5 years

8 Smart savers in all AC across the plant

1.75 15921 Kwh 1.18 Lakh

1.5 years

Unique Project

USE OF BLAST FURNACE SLAG (CALUMITE) AS ALTERNATE RAW MATERIAL using April 2019 onwards

The composition of slag is of glassy nature and source ofAl2O3, SiO2, CaO and MgO.As it is already molten and precalcined, it is responsible fordriving off CO2 & increases silica dissolution and reducesmelting energy needs. Moreover, it reduces seeds, blisters andother defects in the glass.It has found limited use due to variability in chemicalcomposition, its irregular physical sizing, contamination andalso high & variable iron content.We conducted several lab tests with varying percentage ofslag in the batch and found suitability replacing 1-2% of virginraw materials.We replaced 0.5 to 0.7% in flint glass and 1.5 to 2% incoloured glass production.

BLAST FURNACE SLAG (CALUMITE) BENEFIT• We reduced virgin raw material use.• We increased the glass pull while using the slag with

the same thermal energy input, which resulted in SECreduction. In total we saved 320 million Kcal in 2019-20resulted in saving of 11.6 lakh Rs.

TAKEAWAYLarge amount of slag is still landfilled apart from cement users, which can be used by all glass manufacturersIndustry has to formulate their own batch composition for its suitability of use.In a way its win-win situation to use slag as it reduces energy, saves raw material and save environment.

Innovative Project

1. REVAMPING OF OLD 85 TPD FURNACE WITH ENERGY EFFICIENT 180 TPD FURNACE WITH TWO FOREHEARTHS COMMISSIONED IN MARCH 18

The old furnace was a shallow furnace consuming lot of energy and not yielding desired outputquantity and quality.Operating parameters and design were analysed & simulated in glass furnace design software. Theresult showed that we can utilise the existing infrastructure with some modifications to increase thefurnace size and output and drastically reduce the SEC.

SALIENT FEATURES OF NEW FURNACE

• Large furnace area – from 40 to 70 sq. metres.• Unique design of Fining shelf with deep refiner – reduces energy & improves

quality• Electric boosting - minimal heat loss• Online oxygen monitoring in flue gas – optimises air ratio and saves energy• Semi sealed dog house – reduce heat loss• Improved furnace insulation – reduce heat loss• Two forehearths – simultaneous production of two different design• Online furnace camera – better control of furnace operation• Auto burners for annealing lehr temp control – improves glass annealing• Firing Skid with 3 different fuels – flexibility for using cheapest fuel• Pick and place type robots – reduces manpower and accidents

KEY BENEFITS• We have drastically reduced our SEC from 1436 kcal/kg to 1304 kcal/kg for the

molten glass in the new furnace. The annual thermal saving is 12200 million Kcalwhich translates into 435 lakh Rs. Saving annually.

• The project cost is 1525 lakh Rs. and the payback is 42 months• With the modern & sophisticated controls and furnace camera, we have very

smooth and consistent furnace operation and low maintenance and areexpecting furnace life to improve from 7 to 9 years.

TAKEAWAY• It is India's first and world’s 4th furnace with fining shelf and deep refiner which

helped in energy saving, quality improvement and increasing yield.

Innovative Project

2. AUTOMATIC OPTICAL CULLET(GLASS SCRAP) SORTER PLANT commissioned in Jan 2018

Problem identification and need for the projectCullet which is predominantly sorted manually in India, still contains lots of impurities (due to humanfactor), which creates production loss and furnace imbalanceThe manual sorting process was done during day time and the output quantity @60 tons/day was notmatching to production needs @ 120 tons/dayWith every 10% cullet increase one can reduce energy by 2-3%, as the melting temperature of cullet is900 to 950 Deg C, whereas batch needs 1450 Deg C, moreover we can save 1.2 times virgin raw materials.

Analysis & SolutionWe sent several samples for trials at REDWAVE’s test facility in Austria (Supplier of the plant)Results were encouraging with 99% sorting efficiency for impurities and 95% efficiency for colourseparationWe collaborated with REDWAVE for complete plant design, supply of machine and commissioning theplant with throughput of 12 Tons per hour.

MANUAL SORTING

INFEED CULLET REJECTED IMPURITIES COLOUR SORTING

NEW PROCESS FLOW

YEARGLASSPULL IN TON

CULLET IN TON

% USE

CULLET INCREASE IN TON

ENERGY SAVINGMill. KCAL

THERMAL SAVING IN LAKH RS.

BATCH COST PER TON OF GLASS

CULLET WITHPROCESS COST PER TON

BATCH COST SAVING IN LAKH RS.

2017-18 59913 21960 36.65 BASE

2018-19 93095 36538 39.24 2415 692.717 28.03 6980 5100 45.40

2019-20 95578 37513 39.25 2480 711.382 28.80 7000 5000 49.60

* From the operational data, we saved 287000 kcal from replacing 1.2 ton batch with 1 ton of cullet

MONETORY IMPACT – The total project cost is 422 lakh Rs. And the payback is around 60-62 months.ENVIRONMENT IMPACT – We saved 296 tons of CO2 equivalent

We saved 5000 tons of virgin raw materials in 2 yearsINTANGIBLE IMPACT – Increase in furnace life due to lower operating temperatures

Glass quality improved due to soft melting

NOTE - We bought throwaway waste cullet from a reputed float glass manufacturer and made it usable which otherwise would have been sent to landfill

RESULT

UNIQUENESS AND TAKEAWAY• It is the first and only installation till date in India.• The cullet recycling rate in India is at 40/45% and rest is landfilled whereas in

developed countries it is at >70%. We can reduce landfilling and save rawmaterial.

• Average cullet usage of flat glass industry in India is 25 to 30% whereas it can beincreased upto 40-45% without compromising glass quality. We can save energy

• Due to inability of manual colour sorting, one needs to use clear(flint) cullet indifferent coloured glass production, which increases usage of several colouringoxides. We can save precious colouring metallic oxides and environment

FINALLY IF WE INSTALL SEVERAL SUCH PLANTS ACROSS THE NATION, WE CAN SAVE SUBSTANTIAL ENERGY, SAVE RAW MATERIALS, REDUCE CO2 AND SAVE THE PLANET

!!!!!!!!!

Utilization of Renewable Energy Sources

YEAR TECHNOLOGY TYPE OF ENERGY

ONSITE / OFFSITE

INSTALLED CAPACITY

GENERATION IN MILLION KWh

% OF OVERALL IN ELECTRICAL ENERGY

2017-18 Wind Electrical Offsite 2.45 MW 3.7109 122.59%

2018-19 Wind Electrical Offsite 2.45 MW 4.1988 49.47%

2019-20 Wind Electrical Offsite 2.45 MW 3.6923

2019-20 Roof top Solar PV

Electrical Onsite 0.675 MW 0.878152.24%

Rooftop solar – 0.675 MW installed in May 2019 at investment of 220 lakh Rs.Wind Turbine - 1.65 MW installed in 2008 & 0.8 MW installed in 2015

We have electrical connected load of 1500 KVA, as per Gujarat government norms one can not install renewables more than 50% of connected load for ongrid connections.

We are exploring alternate means for adding renewables.

Sr. No. Year Waste Details Quantity GCV Heat value Waste as percentage

of total fuel

1 2019-20 Low viscous Waste Oil

0.5 ton 10300 kcal/kg 8500 kcal/kg Negligible

Waste Utilization and Management

Sr. No. Year Type of Waste Generated Quantity Disposal Method

1 2019-20 ETP Sludge 252 Kg Central Waste Disposal Facility

2 2019-20 Waste Oil 850 Kg Band saw blade cooling

GHG Inventorisation & Plan

Sr. No. Year Absolute Emission in Ton CO2

Emission Intensity in kgCO2/ton of product

1 2017-18 21916 406.04

2 2018-19 33224 396.14

3 2019-20 31570 366.64

Action plan• By using Blast Furnace Slag (calumite) & increase in % use of cullet, virgin raw material consumption

gets reduced and thermal energy needed is lowered.• Replacing use of Furnace Oil with Natural Gas (Domestic & Imported RLNG)• Switching to electric forklift for warehouse instead of Diesel forklift.• During Grid unavailability, switching off non core activities, which reduces diesel consumption for DG

sets.• Exploring possibility of increasing weight of glass box from 475 kg to 520 kg, which lowers packing

material requirements and other activities.

• 3000 Eucalyptus tree saplings sown in 2019-20 at our factory premises.

• Short term Target : 350 Kg CO2 / Ton of Final Product in 2 years

Green Supply Chain Management

1. SODA ASH SUPPLIER – TATA CHEMICALS AND NIRMA LTDSwitching from standalone bulker using pneumatic conveying of Soda Ash to tilting bulker with gravityunloading and elevator conveying resulted in saving of electricity and helped to spare a 37KW screwcompressor.

It was first time conceived & implemented by us and then deployed across the Indian glass industry.

2. CUSTOMER MEETDuring our dealers meet, we demonstrated mechanised glass case handling which helped our dealers forunderstanding the concept and helped for horizontal deployment. (VFDs in crane, IE3 motor, Elec. Forklift)

3. SILICA SAND SUPPLIER – MEMON MINERALSEarlier we used to procure washed silica sand with 7-8 % moisture and were natural drying at our end. Nowwe are procuring it with 0.5 % moisture and supplier is drying at its end.BenefitThere is less spillage of water during transit.We get more material per truck as water is eliminated.During last year we procured 9600 tons and saved 34 round trips of 180 kms.

Green Supply Chain Management

ACTION PLAN

• To introduce loose glass sheet despatches on returnable racks within 100 km radius – save on wooden packing boxes

• Increase weight of glass per box from 475 to 520 kgs - helps in increasing weight carried per truck & subsequently reduces freight cost per ton

• Minimizing procuring raw materials in bag packing – helps saving plastic usage• Increasing silo capacity to store raw materials – Unload directly to batch plant Silo rather than

godowns, which reduces internal material movements

Monitoring Reports

Daily Energy Consumption / Generation

Aug-2020 CONSUMPTION WTG Generation

DateAir Comp. Packing /

Robot

Air Comp. Process

CarpentryCullet Sorter

Unit 1Unit 2 + Utility

Unit -3 BoosterGEB Main

D G Set Solar Plant Total1.65 MW( Vestas )

0.8 MW( WindWorld )

01-Aug-20 431 496 70 384 0 1654 4560 14390 19826 0 3500 23326 1750 1013

02-Aug-20 430 400 70 224 0 776 4728 14270 18764 0 3930 22694 1200 1075

03-Aug-20 410 400 20 352 0 958 4728 15010 19318 0 3730 23048 3350 845

04-Aug-20 413 536 80 440 0 2162 4560 14430 20072 0 3300 23372 750 3052

05-Aug-20 416 532 80 424 0 2785 4224 14670 21760 0 2610 24370 2550 1916

06-Aug-20 425 460 50 416 1127 2548 4464 15380 23450 40 890 24380 1650 3195

07-Aug-20 424 476 90 432 1983 1248 4224 15020 21842 0 2640 24482 3150 6929

ELECTRICAL ENERGY MONITORING SHEET

DAILY THERMAL ENERGY CONSUMPTION REPORT DAILY PRODUCTION REPORT

Energy Efficiency Management System

Approach towards a project takes place in 4 stages

1. PlanIdea insightDevelop MethodologySet target & measuresDevelop action plan

1. Implement Monitor ProgressMeasure the gainsCommunicate results

1. CheckExamine resultsVerify effectivenessExplore opportunities

1. ReviewCorrect shortcomingsReview objectives & targetsUpdate new action plan

Energy Management Cell

Director

General Manager

Energy Manager

HODs

Team Members

Teamwork & Employee Involvement

• Display of Slogans and Banners at various locations in factory premises for promotion of Energy Conservation amongst the employees.

• Formation of small Group Activities and Task Force. Cell at department level to ensure involvement of Workmen in Energy Conservation Activities.

• Conduct the workshop on energy Efficient Motors, pumps, compressors and invited delegates from out side Industries.

• Continuous motivation to all members through reorganization and reward

Training and Fire safety Mock Drill

Energy Efficiency Philosophy

• Reduce specific energy consumption of the plant. • Use renewable energy sources wherever possible. • Rationalize the consumption of fossil fuels. • Implement the innovative techniques to reduce energy consumption. • Comply with the Energy Legislation and other regulations. • Take measure in Energy Management system by being proactive, innovative and

cost effective including procurement of energy efficient product and services.• Integrate energy efficiency into our business planning, decision making and

performance review at the highest level.

AccoladesBest Innovation in Energy Efficiency - Winner

Best Energy Efficient Organisation - Winner

Glass Bulletin Green Initiative award, 2019 - Winner

Accolades

THANK YOU

PURVISH SHAHDIRECTORpurvish@gopalglass.com+91 9879594452