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ITC SAHARANPURExcellence in Energy Management - 2017

CII National Award on Excellence in Energy Management

ITC Limited Saharanpur

EnvironmentWater Positive : 14 years in a row

Carbon Positive : 11 consecutive years

Solid waste recycling positive : 9 consecutive years

Soil & moisture conservation over 2,70,000 hectares

47% renewable energy

ITC’s bio-diversity program now covers 4,000hectares

EconomicMarket Capitalization Over $ 44

billion

Turnover: Nearly $ 8 billion

Powered by the vitality of world-class brands

SocialOver 50,000 sustainable livelihoods

for rural women

Primary Education Initiative: Benefitting 4,70,000 children

Empowering 4 million farmers

Approx. 100 million person-days of employment generated through

afforestation programme

ITC: An Exemplar in Triple Bottom Line Performance

Excellence in Energy Management - 2017ITC Limited Saharanpur

Company Profile: ITC Limited Saharanpur

Year of establishment: 1926

Product: Cigarettes & Cut Tobacco

Capacity of Production: 35 BNC, 3 shift operation

Manpower: 822 employees & 250 ESPs

SEC: 9% reduction (YoY)

RE Portfolio:9%

Water: Benchmark in Specific Consumption



Process Flow in ITC Saharanpur

Lamina /Stem DCCC Cutters KLD

Cut Tobacco

Finished Goods Storage

Automated Manufacturing Facility: Energy Efficient Process

& Machinery

Flavoring & Mixing

Shipping

Primary Manufacturing Process

Cigarette MakingCigarette Packing

Secondary Manufacturing Process

Energy Management

Excellence in Energy

Energy

Management Systems

Design

Process

Awareness

. . . Sustainability beyond boundary

Energy Management Philosophy at ITC Saharanpur


ITC Limited Saharanpur Excellence in Energy Management - 2017

ITC Saharanpur Energy Management Organization

Branch Manager

Production Manager

I/C SMD

Staff & Workmen

I/C PMD

Staff & Workmen

EHS Manager

EHS Team

Branch Engineer

Utility Manager -Electrical

Staff & Workmen

Utility Manger-

Mechanical

Staff & Workmen

Central Energy Team

Departmental Energy Team

Design Validation Team

Sankalp Task Force

UNiS Task Force

Steam & Air Audit (OEM)

Third Party /TERI Audits

Corporate Audits

Divisional Audits

Peer AuditsPlant level

Audits

ALL ROUND MANAGEMENT COMMITMENT

IDEATE

SUSTAIN

Excellence in Energy Management - 2017

Electrical Energy Monitoring

Energy Management - Close Monitoring

Online monitoring of electrical loading of all sources by energy management system

Real time monitoring of power consumption of major equipment by energy management system

Real time monitoring of power factor for all major load

Daily monitoring of Grid utilization

AMC for 33KV supply line for Preventive maintenance and faster repair

Daily performance monitoring of DG and Solar plant

On receipt Fuel quality monitoring

Daily boiler performance monitoring-EVR

Daily Steam consumption monitoring

Daily analysis of Exceptions

Monthly Steam trap monitoring

Condensate recovery monitoring and analysis

Thermal Energy Monitoring


Consolidated Reporting and Management Reviews

Daily Exception Reporting

Weekly Review by Department Head

Energy Performance Review by Unit Head

Quarterly Sustainability Data Reporting to Corporate

Yearly Energy Performance Review by Divisional Management

Detailed Energy Audit by External Certified Auditors every Three Years

Audit Recommendation implementation validation by Corporate Auditors

EnCon Projects


Investments

33 kV & SUPS for Grid Utilization Improvement

High Bay LED in Shop floor (initially Metal Halides)

Condensate & Waste Heat Recovery from PMD

Screw Compressors instead of Vertical Reciprocating

Energy Efficient cyclone fan induction in PMD

Just-do-its

Half-bins for Stem Conditioning

Idle run arresting at Packaging-unit Heaters

Dust Removal System Optimization in SMD

Power Factor improvement to 0.99

Steam Consumption optimization at PMD STS

Innovations

Celdak Pads in AHU

Polycarbonate Sheet in Shop floor for Natural Lighting

Motion sensor enabled fans

Heat Recovery Compressor

Liquid Off-take system for Canteen LPG consumption


Snapshot of Energy Conservation at ITC Saharanpur

10.28

8.54

7.366.5

7

7.5

8

8.5

9

9.5

10

10.5

14-15 15-16 16-17

Energy cost Rs./1000 cigarette

14%

17%Investment

1457.7 lacsAnnual Saving

321.3

CONTINUOUS IMPROVEMENT FOR SUSTAINABLE DEVELOPMENT

SUPS 1650 KVA

33KV line commissioning

1500 KVA DG


12.22 Cr (Invest)

2.34 Cr/annum (Saving)

15-16:1650 KVA SUPS Commissioned16-17:• Line installed • Charging &

Industrial Status

Improving Grid Utilization & GHG Inventorization

Upgradation from 11 kV to 33 kV

81%

94% 97%

70%

80%

90%

100%

2014-15 2015-16 2016-17

Grid Utilization6918

1644 9250

5000

10000

2014-15 2015-16 2016-17

DG Running Hrs.


Recovering Waste Heat from Process

18.2 L (Invest)

9.6 L/annum (Saving)

LAMINA PROCESSINGSLICING CONDITIONING CUTTING

STEM PROCESSING

CONDITIONING

MIXING & FLAVOURING

FINAL CUT TOBACCO

CUTTING EXPANSION & DRYING

LAMINA BALES

DRY STEMS

EXPANSION & DRYING

100% Condensate Recovery from all indirect heating process100% Flash Steam Recovery from Recovered Condensate

Waste Heat Recovery from Stem Expansion Exhaust (Direct Heating)Plan: Waste Heat Recovery from Lamina Expansion Exhaust

75 L (Invest)

30.5L/annum(Saving)


Energy Efficient Lighting Across Shop Floor

171185 174

131118

6952 39

SMD PMD WMS Other

Metal Halide (MWh) LED (MWh)661

279

0

100

200

300

400

500

600

700

Before After

Lighting load/annum

58%


Just-Do-It Projects

Half-bins for Stem Conditioning

Idle run arresting at Packaging-unit Heaters

Dust Removal System Optimization in SMD

Power Factor improvement to 0.99

Steam Consumption optimization at PMD STS

2 L (Invest)

15 L/annum (Saving)

Employee-driven Ideation

Core Committee Validation

Implementation & Sustenance

Management Review

विचार से आकार तक

Innovations


8 L (Invest)



Innovation: Celdak Pads in AHU

• UNiS – Conservation of Water & Energy Event

• Employee suggestions received on Celdak pads

• ITC Utility Team conducted initial feasibility study

• Third party verification of the idea

• Implementation plan of project

Recycling of water

Reduction in Power

Product quality improvement

Reduction in Steam

consumption

1706

1050

292

5

505

1005

1505

2005

2014-15 2015-16 2016-17

Steam consumption (Tons)

32 L (Invest)



Innovation: Polycarbonate Sheets for Natural Lighting

118

6952

39

104

40 30 33

SMD PMD WMS + Shipping

Other

Before PC Sheet After PC Sheet

Shop floor lighting load (MWh)Replaced existing North Light Glass Panelswith transparent & durable PolycarbonateSheets

Commissioned in entire manufacturing block


Other Innovations in the Factory

LDR and Occupancy sensor based lighting

Heat Recovery Compressor

Light pipe in DRF for natural lighting

Remote operated lighting

Occupancy based Air circulator

Automatic tube cleaning for chiller

Energy Efficient fan

Solar Street lights

102 L(Invest)

22 L/annum(Saving)

Commit

• Introduction to Unit’s Policy towards Sustainability

• Oath towards all-round energy conservation

Involve

• 4 EnCon Agencies: Awareness towards Sustainability

• Participation: 700+ employees & 300+ ESPs

Ideate

• UNiS Team: Committed towards continuous ideation

• UNiS Event: 90+ EnCon Projects ideated by Employees

Energy Conservation through People Engagement

विचार से आकार

तकOATH FOR ENCON

WATER SAVING ACTIVITYAD MAD: ENCON

ENCON EXHIBITION

ARRESTING LEAKAGES REWARDS & RECOGNITION

Renewable Energy


Ladder Lifeline Extension

143kWp installation

Additional Members‘U’ Type Clamp

100% utilization of roof area

Central Power Evacuation: 11kms cable

Utilization of parking area through PEB Erection

Standing Seam Clamping solution at FGS

Structural Strengthening of Godown

Sustenance: Cleaning setup, Lifelines


Rooftop Solar Power Plant at ITC Saharanpur

Phase 1: 630 kWp (October’15) Phase 2: 140 kWp (April’16) Phase 3: 82 kWp (plan)

Plan

Real time monitoring performance

Maintenance By OEMWeekly Cleaning Schedule

Daily monitoring of Generation Monthly A3 Reporting to HO

High pressure jet cleaning system


Rooftop Solar Power Plant at ITC Saharanpur


Renewable Energy Portfolio of ITC Saharanpur

Inter-state Wind Energy Wheeling

3 MW 100%

Offsite Solar Power Plant

10 MWp 79%

Rooftop Solar Power Plant

770 kWp 8% RE

Polycarbonate Sheets in Shop Floor (+1% RE)

• Representations: Chief Sec., Principle Sec, UPERC & UPNEDA

• Petitions Filed to UPERC

• Representation made to NRLDC• Acceptance from UPPTCL• NOC awaited from UPPVNL

Indices



Energy Indices ITC Saharanpur

833

816809 806

802 799 798 797

770

780

790

800

810

820

830

840

FY 15-16 LED Light across factory

Compressor air leakage audit

Celdek pad for SMD and CTH AHU

Shutdown related initiatives

Switch machines Idle load

Energy Efficient Cyclone Fans

CTS shaker feeder to gravity feeding

Energy KWh Unit/Mnc 5% Reduction over FY 15-16

12.63

13.513.8

12.00

12.50

13.00

13.50

14.00

14-15 15-16 16-17

kg steam/kg fuel ---Boiler Efficiency

81%

94%97%

70%

75%

80%

85%

90%

95%

100%

2014-15 2015-16 2016-17

Grid Utilization 16% Improvement 9% Improvement

6.505.92

5.40

4.62

3.00

3.50

4.00

4.50

5.00

5.50

6.00

6.50

2014-15 2015-16 2016-17 Benchmark

SEC Benchmarking GJ/Mnc

3.9

3.3

3.0

2.5

2.7

2.9

3.1

3.3

3.5

3.7

3.9

4.1

2014-15 2015-16 2016-17

Electrical –SEC GJ/MNC

2.65

2.57

2.372.3

2.4

2.5

2.6

2.7

2014-15 2015-16 2016-17

Thermal –SEC GJ/MNC

Energy Indices ITC Saharanpur

9% Reduction YOY 15697

1316412736

11000

11500

12000

12500

13000

13500

14000

14500

15000

15500

16000

2014-15 2015-16 2016-17C

O2

Em

issi

on

(T)

CO2 Emission9%

23% Reduction Over FY14-15



9%

Beyond Boundaries


Solar Streetlights in localcommunities

Investment: Rs. 16 lakhsTotal Solar street light installed: 50

Encon-Beyond Boundaries

Title of Project YearName of the

VendorName of service

provided Energy Saved

117 Nos. 70W Streetlights replaced with

45W LED Street lights2016-17

ITC Residential

Colony

M/S Kumar Electric work

12880 kWh/year

Energy Efficient lights and fans installation

2016-17ITC Marketing

officeM/S Kumar

Electric work8250

kWh/year

Turbo ventilators fixing in Godown

2016-17M/S V.K

AssociatesM/S V.K

Associates14910

kWh/year

Knowledge Sharing withGovernment officials

EnCon awareness session in nearby school

Awareness EnCon session to contract workmen

EnCon awareness in nearby villagers


Thank You


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