ARVIND LIMITED Division. ANKUR TEXTILES. Ahmedabad

ARVIND LIMITED

Division. ANKUR TEXTILES. Ahmedabad Presentation on Energy saving Focused on power saving by Alternative Operations of Aerators in ETP and STP Aeration Tank. Presented By : R. S. Patel. (Head – Engineering)

• Arvind Limited Started in 1931- with Aim to produce high end Super fine fabric with 52560 Spindles and 1122 looms.

• First year turn over was Rs 45.76 Lakhs which reached to 11000 plus cr. Rs. Last year .

• In 1987 Arvind Entered in to Export market.

• By 1991 Arvind was third largest Denim manufacturing company in the world.

• In 1997 State of Art textile unit was started at Santenj having largest of it kind in Shirting, gabardine and Knits.

• It is ISO 14001 and ISO 9001 Company. Our labs are NABL - ISO 17025 Certified.

• World famous brand like Levis, Lee Wrangler are our customer. Mega mart and The Arvind store are our channels.

• Beside Textiles Arvind is in following business. 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.

In Textile there are lots of variances like type of raw material (Cotton, poly, P/C, Modal, viscos, lycra, nylon etc.), Count of yarn (From 6 to 170) and construction of fabric. There are no national or global standard norms of specific energy consumption. Industry have to fix its bench marks on the basis of past consumption data. BEE had given targets to individual industry under PAT scheme and industry takes Energy saving actions to achieve PAT targets.

Ankur have formed Energy conservation team, constant follow-up and audit of day to day energy and water consumption.

With our continuous efforts we achieved 9 % saving in thermal and 41% in Electrical energy in last 3 years.

During the year, 2015-16 &2016-17&2017-18 No. of Projects : 32

Total Amount Invested : ₹ .90 Million

Cost Saving Achieved : ₹ 30. Million

Electrical Energy Saved : 27.59 Lacs kWh

Thermal Energy Saved : 1569 MTOE

ELECTRICAL Sr. Project Energy saving step details Project Description 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 Installation of EFFIMAX 250 1395000 1000000 8.6 Effimax monitoring system on 8 MT/Hr FBC Boiler 2 Fuel saving by Installation of 8 MT/Hr FBC 1418 7912440 8000000 12.1 replacement of boiler in place of 6 MT/Hr boiler smoke tube boiler Total 1668 9307440 9000000 11.6 SAVING + INVESTMENT in FY-15-16 1668 9617871 9136000 11.4

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 65856 507091 224000 5.3 LED lights of 400 Watts by 120 Watts LED fittings 3 Power saving by Replacement of 7 Nos of High bay 8232 63386 56000 10.6 LED lights 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 84000 646800 800000 14.8 ETP 2Nos 30HP INSTALL 20HP

Continue… © Confederation of Indian Industry 3b&c. Energy Saving projects implemented in FY 2016-17-18

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 123200 948640 120000 1.5 Exhaust 11 Power Saving REPLACE AUTO CORNER M/C 2NOS (138 161700 1245090 25000000 240.9 were replaced by X5 mopdel) 12 Power Saving Installed Invertor in Boiler I D Fan 1 Nos 64680 498036 75000 1.8 M/c 13 Power Saving Installed Temerature controller in 9450 72765 10000 1.7 compressor Cooling Fan -1 no M/C 14 Power Saving Replaced Auto Corner suction motor 30800 237160 10000 0.5 pulley in 2 m/cs 15 Power Saving Installed Invertors 10 Nos SFAN/RFAN in 420000 3234000 320000 1.2 Winding Dept.

Continue… © Confederation of Indian Industry 3b&c. Energy Saving projects implemented in FY 2016-17-18

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 FY: 16-17-18 2722052 20959800 47764000 27.4

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 824600 200000 2.9 m/c. 2 Stenter upgradation Replace low efficiency Stenter by high eff. stenter 1543800 15000000 116.6 m/c 3 Steam Trap Replaced 36 No. thermodynamic trap by float type 310000 180000 6.9 Replacement trap, 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 Installed 5 Nos. of steam cut off switches when 1463200 25000 0.2 on 5 No. Drying range m/c is stopped. m/cs. 6 Reuse of Hot Water Started recirculation and reuse hot water 70000 899000 60000 0.8 ltr/day. 7 Collection of Installed additional pump. 706800 250000 4.2 condensate water 16-17 -18: TOTAL SAVING + INVESTMENT (Thermal) 6113200 15865000 31.1 16-17-18 : TOTAL SAVING + INVESTMENT (Electrical) 20959800 47764000 27.4 16-17-18 : TOTAL SAVING + INVESTMENT (Ele. + Thermal) 27073000 63629000 28.2

1) REPLECMENT OF COMPRESSOR MOTOR PULLY power consumption - 155 x 23x 350 = 1247750 KWH/year power consumption - 125 x 23x 350 = 1006250 KWH/year 1247750 1006250 saving kwh 241500

2) Save Energy and water consumption through Water system Pressure control To control water pressure at 1.5 Kg/CM2 Round the clock by installing invertors and pressure transducer on water supply. Reduced water consumption by 145 KL/day.

3) Total 5 no of Aerators of ETP and 2 Nos of Aerators working continuously Power consumption .705672 KWH/year. Total 3 no of Aerators of ETP and two no Aerators of STP are working Alternatively with invertor and two Aerators of ETP working Alternatively. Power consumption 359370 KWH/year

 Micro organisms such as bacteria and protozoa can use the small particles and dissolved organic matter, not removed in primary treatment, as food.  Aeratio tak otais “soup" of starved iroes alled ativated 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.

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

-We have installed 512 KW Solar panels on our roof top. Beside of Energy to conserve natural resources... (1) We have installed Sewage Treatment Plant having 15 KLD capacity. WE take raw sewage from Corporation drainage line, treat it and use as process water. ( 65 % of total process water is used from this STP) This is first textile unit in India having such a large plant.

(2) We started rain water harvesting in under ground bore well.

Reduction in CO2 emission in 2017-18 is 9 % in quantity and 24% in per ton of production in last three years. Quantity in Ton Sr. No Co2 Emission Source 2015-16 2016-17 2017-18 1 Electricity Consumption 22260 16501 12667 2 CNG Gas 491 487 473 3 Coal 26273 26496 30222 4 DOC - Agro Waste Fuel 77 881 1294 5 Total 49102 44365 44656 Quantative % Saving Compare 6 to 15-16 9.65 9.05 7 Producton in MT 4037.23 4666.93 4869.67 8 Ton of Co2/Ton of Production 12.16218 9.506326 9.170259 Per Ton Production % Saving 9 Compare to 15-16 21.84 24.60