August, 2018

NATIONAL AWARD FOR EXCELLENCE IN ENERGY

MANAGEMENT AND EFFICIENCY

Agenda

• Plant profile

• Plant performance for the last three years

• Overview of Energy Management System

• Energy conservation projects

• Innovative projects at GIL- Valia

• Best practices implemented on energy efficiency compared with associates

• Supply Chain Sustainability & Awards

Plant Profile

➢ Manufacturers of

▪ Fatty Alcohol

▪ Fatty Acid

▪ Glycerin

▪ Surfactant

▪ Specialty Products derived from

fatty acid and fatty alcohol

➢ 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

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 3 years

• Installed three Biomass

Briquette boilers

• Displaced approximately 75%

Natural Gas

• Reduced SEC by ~13%

• Reduced Carbon Di-oxide

emissions by 36000 TCO2

VALIA PLANT

PERFORMANCE

Specific energy consumption reduction trend

SEC MJ/T0

2

4

6

8

10

12

14

16

2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2020

14.313.07

12.04 11.91 12.0811.5

10.69.97

SE

C G

J/M

T

Year

SEC trend, GJ/MT of product

27%reduction from FY11-12

Energy- Last three years

GIL

ValiaReduction in specific energy

consumption in last three years

KEY

ACHIEVE

-MENTS

1 Energy Efficiency Projects like Heat pipe, Micro turbine,

Baccomber cooling system etc.

2 Policy Suite

3 Awards: CII, FICCI and ICC

13%

Specific Green house gas emissions Scope1+2

930

1004 1005948

818

686

599

524

0

200

400

600

800

1000

1200

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18

Kg CO2 Eq/MT of product

Kg CO2 Eq/T

43%reduction from FY10-11

1.35 1.6 1.82 1.75

20

40.3

44.246.1

0

5

10

15

20

25

30

35

40

45

50

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18

% Renewable

% Renewable

Renewable energy portfolio

GHG and Renewable Energy - Last three years

GIL

ValiaSpecific GHG emissions

reduced in last three year

KEY

ACHIEVE

-MENTS

GIL

ValiaEnergy comes from

Renewable sources

1 Energy efficiency projects

2 Briquette Boilers

3 Solar roof tops

24% 46%

Projects- GHG and Renewable Energy

Solar Roof Top Capacity : 248.7 kW.

Projects- GHG and Renewable Energy

Biomass Briquette Boiler 3: 6 TPH

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.

Benefits:

1. NG Replaced by 4735 M3/day

2. Around 12000MT of CO2 Eq reduction

Greener India impact

Goal

29.6% 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

42% of total energy consumption

from renewable sources

42 % reduction in specific

greenhouse gas emissions

33% reduction in specific

water consumption

45% reduction in specific

waste to landfill

Send zero waste

to landfill

VALIA PLANT

ENERGY REDUCTION TARGET

Specific energy reduction target

TARGET (GJ/MT) 2018-19 2019-20

Total 9.98 9.68

SHORT TERM TARGET

TARGET (GJ/MT) BASELINE, 2010-11 2020

Specific Energy Consumption (Total) 13.2 9.2 (30% reduction from

FY11)

LONG TERM TARGET

VALIA PLANT

ENERGY CONSERVATION PROJECTS

Energy conservation/efficiency projects FY16

Projects Energy

reduction

Investment Saving

Heat Pipe installation in Section 5 & Section 21 Thermal 12 120000 sm3 NG

Replaced Thermostatic Expansion valve with

electronic expansion valve in Identified Chillers

Electrical 2.5 91666 KWH

Replaced V-belt with Cogged Flat belt in identified

blowers

Electrical 10 58300 KWH

Energy saver device installation in Air Conditioner

Units.

Electrical 7.08 100000 KWH

Replace existing Light fixture with LED Electrical 6.5 83000 KWH

CT fan rpm regulation on temp. in Delta phase II

area

Electrical Nil 2500 KWH

Energy conservation/efficiency projects FY17

Projects Energy

reduction

Investment Pay back

(Month)

Saving /

Month (Lakh)

Installation of Heat pipe in SPD plant Thermal 5 Lakh 3 2.4

CHW circulation modification in Pastillator Electrical 2 Lakh <1m 12.0

Installation of LED lighting Electrical 3 Lakh 12 0.30

6G02 Compressor old valve replaced Electrical 6 Lakh 12 0.50

Installation of Steam Turbine Electrical 45 Lakh 18 2.50

Installation of VFD in Raw water pump Electrical 0.9 Lakh 4 0.25

Installation of VFD for 6G04 A/B

Combustion air fan

Electrical 10 Lakh 22 0.47

Energy conservation - innovation

Micro Turbine

Most steam systems currently uses pressure

reducing stations to reduce steam pressure.

In place of that Micro turbine can be used to

generate electricity from it and with that

reduce the pressure to desire.

Micro turbine itself is a well proven technology

with the shelf life of 15-20 years. In GIL,

steam pressure from 18 bar to 3 bar for

process applications is reduced through a

micro turbine and in process electricity is

being generated to the tune of 100 KWH

which is purely clean and green energy. It is

installed in parallel to conventional pressure

reducing system.

It has a payback of 18 months with an

investment of INR 45 lakhs.

Micro Turbine installed at Godrej Valia

Energy conservation - innovation

Regenerative Drive for Reformer FD

Fan

Reformer FD Fan was running on UPS with

Damper control, Providing VFD directly with

UPS may lead to increased Harmonics.

Regenerative drive is design to operate on

raw power failure. It operates on Ups

backup without interruption.

With this we are able to achieve saving of

270 KW./day. Pay back is of 14 months.

Regenerative Drive

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 more than 50%

diverting our finished good from JNPT to

Hazaria port. Which is reducing the transport

distance by 516 Km.

Way forward

Innovations

and

Technologies

Process

Reengineering

and Process

Innovation

Clean

Technologies

Value Chain

Sustainability Suppliers

Assessment

Life Cycle

AssessmentGreen

Chemistry

TRAINING & AWARENESS

OVERVIEW

Environment day and energy conservation week

Energy Conservation Week Leakage Tagging

Training & Awareness Programs Training & Awareness Programs

Encon Week - 2017

46suggestions

33Implemented

ENERGY MANAGEMENT SYSTEM

OVERVIEW

Energy management cell

Energy Auditor – Mr BJP

Team A- AO Team B- Area 3Team C

SurfactantTeam D Section

6/7Team E Delta 3

Energy Manager – Mr

RSA

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 Gold rating in 2018.

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