Welspun Group | Name of Business Welspun Group | Welspun India Limited Energy & Resource Management – WIL , Anjar 5 th MAR 2013
Welspun Group | Name of BusinessWelspun Group | Welspun India Limited
Energy & Resource Management – WIL , Anjar5th MAR 2013
Welspun Group | Name of Business
About Welspun ………….
Over the past 25 years ,
Welspun has emerged as one
of the India’s fastest growing
multinationals. From a modest
beginning , Welspun is now a
Welspun Group | Welspun India Limited
Core Businesses…
-Home Textile
-Pipes
-Plate & Coil
-Steel
-Powerbeginning , Welspun is now a
USD 3 billion conglomerate
having a strong international
brand equity , with an
unwavering commitment and
passion towards excellence ,
Driven by our Motto :
“ Dare to Commit “
-Power
-Renewable Energy
-Infrastructure
Welspun Group | Name of Business
Welspun India Limited Welspun India Limited
Welspun Group | Welspun India Limited
Energy & Resources :
1). Electricity - Machine , compressors , HVAC , water & waste water
2). Thermal energy - Steam , Hot water , Thermic heat 2). Thermal energy - Steam , Hot water , Thermic heat
3). Gas – LPG or Natural gas
& water - the most precious resource now a days
Welspun Group | Name of Business
Electricity Electricity -- Present PatternPresent Pattern
Welspun Group | Welspun India Limited
Share of Electricity Uses
Spinning Machines
Weaving Prep & Looms
Processing and Made-ups
Compressed Air Compressed Air
Humidification & HVAC
Water & Waste Water Division
Boiler & Heat
Lighting & Others -
Welspun Group | Name of Business
Thermal Energy Thermal Energy -- Present PatternPresent Pattern
Welspun Group | Welspun India Limited
Sizing
Desizing & Pretreatment
Merserizing
Cont. Dyeing Range
Washer
Finishing -Steam Finishing -Steam
Finishing - Thermic Heat
Caustic Recovery Plant
Distribution Losses &Misc
Welspun Group | Name of Business
Welspun India Limited Welspun India Limited –– Way to Energy Conservation Way to Energy Conservation
Welspun Group | Welspun India Limited
Our Strength
•Top Management Support
•Measure & Monitoring System
Our Strength
•Top Management Support
•Measure & Monitoring System•Measure & Monitoring System
•Qualified & Competitive Team
•Periodic Review
•Measure & Monitoring System
•Qualified & Competitive Team
•Periodic Review
Welspun Group | Name of Business
Electricity Conservation Electricity Conservation –– Major Steps taken in last 2 yearsMajor Steps taken in last 2 years
Welspun Group | Welspun India Limited
Target Area Major Steps Target Achieved Tools Adopted
Units/day Units/day
Compressed Air 1). Leakage Minimization 10000 9150 Flow & Energy Metering
2). Pressure Optimization Internal Audit
3). Cleaning Air Control Leakdetection
4). Loading & Unloading Pattern Awareness Program
HVAC 1). VFD at return fans 3000 3587 Flow & Energy Metering
2). Avoid Throttling to Pumps Cordination with prodn Dept
3). Avoid Fan Damper Throttling
4). Modification in Pneumafil Return Trench
Water , Waste Water 1). Trimming Impellers as per Actual Reqn 2500 2788 Internal Audit
and Pumping Systems 2). Avoid Discharge Valve Throlling Flow & Energy Metering
3). Operating on VFD w.r.t. Pressure Reqn Pressure Transmitters
4). Run Blowers with VFD w.r.t. Dissolved Oxygen Dissolved oxygen Controlling
5). VFD on Filter Feed Pumps
6).Elimination of Leakages & Wastages
Boiler & Heat Section 1). Effimax Control System 350 245 Efficiency Controller System
2). VFD at ID Fans of AFBC Boilers & TFH Automation
Production Machines 1).VFD at Exhaust Fans of Finishing Machines 4400 3900 Flow & Energy Metering
2).Lighting Rearrangement & Mirror Reflectors
TOTAL 20250 19670 97%
Welspun Group | Name of Business
THERMAL ENERGY Conservation THERMAL ENERGY Conservation –– Major Steps taken in last 2 yearsMajor Steps taken in last 2 years
Welspun Group | Welspun India Limited
Target Area Major Steps Target Achieved Tools Adopted
GENERATION SIDE 1). Efficiency Monitoring System 3.0 2.7 Effimax System
2). Automation of ID & FD fan Operation to reduce Coal Counter Meters
Stack losses & control excess air Flow & Heat Metering
DISTRIBUTION SIDE 1). Insulation - Replaced old Insulation with High Density "HITLIN" 6.5 5.6 Internal Audit
2).Periodic Internal Audit Surface Temperature Meter
3). Ensuring Dry Steam
Coal in MT/day
3). Ensuring Dry Steam
CONSUMER SIDE 1). Metering & Monitoring at Each Machine/process 2.5 3.1 Internal Audit
2). Internal Audits for leakages & radiation losses Flow & Heat Metering
3). Steam Trap -Performance Checking
4). Reuse of Steam Condensate in Process M/cs
5). Reuse of Hot Condensate & Hot Circulation Water
of Caustic Recovery Plant
6). Heat Exchangers at Each Machine Drain to recover Heat
7). Control of Exhuast fans of Finishing machines
8). Air Preheating from Stenter Exhaust
TOTAL 12 11.4 95%
Welspun Group | Name of Business
Water Water -- The Most Precious Resource ( Not less than a Fuel ) The Most Precious Resource ( Not less than a Fuel )
Welspun Group | Welspun India Limited
Target Area Major Steps Tools Adopted
TREATMENT SECTION 1). Recovery from Waste Water 90+% 88.80% Waste Water recovery plant
2). Resue of usable drains like Cooling Water etc 300KLD 320KLD Internal Audit & Cordination
3). Reutilize the Filter drains by re-clarifying 200KLD 150KLD Treatability Studies
AT CONSUMER END 1). Metering & Monitoring at Each Stage , Process & Machine Flow Meters & Controls
( BED SHEET PROCESS ) 2). Optimize the water requirement at each stage Internal Audits
Target Achieved
60L/kg of
Fabric
57.2 L/Kg
of Bed ( BED SHEET PROCESS ) 2). Optimize the water requirement at each stage Internal Audits
3). Periodical Audit for leakage & wastages
4). Resue of Cooling water & usable hot water into the process
AT CONSUMER END 1). Metering & Monitoring at Each Stage , Process & Machine Flow Meters & Controls
( TERRY TOWEL PROCESS )2). Optimize the water requirement at each stage Internal Audits
3). Periodical Audit for leakage & wastages
4). Resue of Cooling water & usable hot water into the process
HARVESTING Rain Water Harvesting Through Trench & Canal Network Harvesting Network1200
Million
L/year
58L/kg of
Fabric
from
49L/kg for
Processin
47 L/Kg of
Terry
Towel
Processed
(19%)
Fabric
from
75L/kg for
Processin
of Bed
Sheet
Processed
(24%)
Welspun Group | Name of Business
SUMMARY SUMMARY -- CONSERVATION IN LAST 2 YEARSCONSERVATION IN LAST 2 YEARS
Welspun Group | Welspun India Limited
Electrical Saving : 19670 Units /day
or Equivalent to 1512 TOE per annum
Coal ( Fossil Fuel ) Saving : 11.4 MT Coal /DayCoal ( Fossil Fuel ) Saving : 11.4 MT Coal /Day
or Equivalent to 1632 TOE per annum
Water Conservation :- Rain Water Harvesting of average 1200 Million Lt / year- Waste Water recovery – 2000 Million Lt/ year- Conservation & Reuse - 720 Million Lt /Year
Welspun Group | Name of Business
RENEWABLE ENERGY RENEWABLE ENERGY
Welspun Group | Welspun India Limited
Welspun India Limited
Has Taken Initiative within premises and Installed Nisargruna BioGas Generation plant from Canteen & all other Biodegradable waste . The Plant can handle 5MT of waste per day. Presently feeding 1.5-2.0 MT waste per day and generating methane equivalent to 30Kg of LPG used for cooking in Canteen .generating methane equivalent to 30Kg of LPG used for cooking in Canteen .
Welspun Energy Limited
“WEL” have made plans keeping in mind our long-term goal – to make India energy-independent. Over the next three years, we will develop several renewable energy based power projects. Our capacity buildup plans is helping us create pipelines for developing over 750 MW of solar projects and a wind capacity of 1000 MW.
It has already commissioned 75 MW Solar Projects in India and another 35MW will be added in coming few weeks.
Welspun Group | Name of BusinessWelspun Group | Welspun India Limited
THANKS5th March 2013