Sriperumbudur N.Karuppusamy Senior Manager C.Vignesh Kumar … · 2018-09-13 · © Confederation of Indian Industry N.Karuppusamy –Senior Manager C.Vignesh Kumar –Executive Sriperumbudur

© Confederation of Indian Industry

N.Karuppusamy – Senior Manager

C.Vignesh Kumar – Executive

Sriperumbudur


Brief introduction on Company

▪ Asian paints, Sriperumbudur plant commissioned in the year 2005 with

an initial capacity of 30,000 KL per annum.

▪ Current production capacity is 1.4 Lac KL per annum

▪ Manufacture Interior and Exterior Decorative Water based Paints.

▪ First Automated plant of Asian paints ltd.

▪ Operates with almost 100 % Renewable energy since 2017-18.

▪ Water neutral plant - 225 % in the year 2017-18

▪ Bio diversity rating – 52 in the year 2017-18

IBBI - India Business and Biodiversity Initiative

▪ Zero liquid discharge since inception (2005).

© Confederation of Indian Industry3

Polymer

Processing

Mixing

Packing

Emulsion storage

Process Flow

Tank farm

Silo

D.C

Packing material


1. Sp. Energy Consumption in last 3 years

100 % LED conversion

TSD Agitator modification

Utility Automation

Kaizen / Energy cell

Process Optimization

Pressure Based Pumping System

Air pressure optimization

Energy Management System

24%


3a. Energy Saving projects implemented in FY 2015-16

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1 Pressure based pumping system 3,53,919 3.07 5.54 22

2Conventional lamps to LED conversion - Godown,

Silo, office 1,42,860 1.24 2.19 21

3 Air pressure setting optimization 6.5 to 5.5 bar 2,18,400 1.38 0.09 1

4 Replacement of Conventional AC to Inverter duty AC 18,144 0.16 0.60 46

5 Common FRL in an air tree 11840 0.08 0.45 84

6 Weekly timer for godown lighting 8650 0.05 0.02 5

Every year we execute around 60-70 nos of energy conservation ideas / projects


3b. Energy Saving projects implemented in FY 2016-17


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1 TSD agitator modification 2,49,600 2.08 16.5 8

2 Energy saving initiative –Portable comp / Motion se 1,35,000 1.13 3.49 37

3 100 % LED conversion 1,17,055 0.98 3.63 45

4 200 TR Energy efficient chiller 90,000 0.78 3.53 54

5 Monomer storage temp. set point optimization 78,000 0.49 0 1

6 Cold well separation for different application 21,000 0.18 0.9 59

7 Replacement of Conventional AC to Inverter duty AC 15,552 0.13 0.80 71


3c. Energy Saving projects implemented in FY 2017-18


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1 TSD agitator modification 2,99,520 1.89 19.8 10

2 TSD motor capacity optimization 37,440 0.24 3.63 22

3 Energy efficient - conveying blower 1,87,200 1.19 4.96 20

4 Aeration blower optimization using VFD 61,776 0.39 0.75 2

5 Modular air piping network 39,000 0.25 2.65 10

6 Powder Conveying optimization 2,10,600 1.33 0 0


2.Information on Competitors,National &Global benchmark

Competitor SPC trend – National and Global

Dulux Group Corporate Sustainability Report 2017

Nerolac

Courtesy

Kansai Nerolac Sustainability Report 2017


2. Information on Competitors, National & Global benchmark

SPC of Asian Paints plants in 17-18


4. Innovative Projects Implemented-Chennai Express


4. Innovative Projects Implemented-Chennai Express


4. Innovative Projects Implemented – Elimination of Pump


4. Innovative Projects Implemented – Elimination of pump


4.Innovative Projects-Powder conveying optimization

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Blower

TSD

RAL

Before Project


4. Innovative Projects-Powder conveying optimization

• Powder conveying system

• Used to transfer powder from Storage vessel to Process equipment

@ 800-900 m bar

• Each powder has different density .

• High density powders are difficult to convey & decides the

conveying rate

• Innovative Solution

• Studied the system, found high density powders are few

• Installed pressure sensor in the system and feed was controlled

based on the pressure in the system.

• This had increased the conveying rate of low density powder

significantly and hence power consumption is reduced.


4.Innovative Projects-Powder conveying optimization

16

Blower

TSD

RAL

Pressure

Switch

VFD

After Project


Oct 2014 Solar 800 KW

Feb 2016 Wind 1.5 MW

Mar 2017 Wind 2 MW

Mar 2018 Solar 150 KW

5. Utilisation of renewable energy sources


2015-16

Solar 953252

Wind 129304

%RE = 12%

18

2016-17

Solar 911010

Wind 3094383

%RE= 43%

2017-18

Solar 925564

Wind 8006277

%RE= 97%

5. Utilisation of renewable energy sources


Boiler steam condensate recovery water reused as raw water

Boiler steam obtained/day = 1200kg

Boiler Running hours/day = 12hrs

Recovery water from steam = 18kl

(i.e) (1200kg*12hr)/0.8 (0.8 is dryness factor)

Saving = Rs.19,656

motor capacity= 5.5kw

Flow rate = 10m3/hr

Currently we are working on using STP treated water for process

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6. Utilisation of waste material as fuel


- Information on GHG Inventorisation and public disclosure

7. GHG Inventorisation

Category FY15-16 FY16-17 FY17-18

Scope 1 (tCO2e)Direct emission 1,249 906 1,129

Scope 2 (tCO2e)EB 6,845 4,929 874


8. Green Supply Chain

1. EMS – Energy Management System

❑ Fetches energy consumption and generation data automatically and generates report

❑ Compare energy consumption across individual section and across plants

❑ Monitor generation and consumption at a single place

❑ Analyse and act on the higher consumption then and there

2. Central Energy cell

❑ A group of managers across all plants meet and share ideas

❑ Energy consumption and Energy conservation ideas implemented in individual plants

highlighted in this forum

❑ Facilitate horizontal deployment of projects across all plants


8. Green Supply Chain

3. RE 36 by 2020

❑ Government of India taken a RE target of 40% by 2030

❑ Asian paints ltd taken a mission of RE 36% by 2020.

❑ In FY 18 – 19, Srip RE is close to 100 %

❑ And at supply chain level RE is at 35 %


1. Daily Monitoring System

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9. Team work, Employee Involvement & Monitoring

❑ Energy Management System


2. Plant energy cell – Cross functional team meets every month to share their energy saving

ideas



3.Separate budget for Energy Conservation


Year Budget in INR million

2015 – 16 8.33

2016 – 17 28.85

2017 - 18 29.14



E-Day Poster Energy Saving Projects

4. Energy Saving Awareness Program

❑ SriP Energy Day


Energy Products LED

Energy Day Energy Day



❑ Stall on energy conservation products

❑ Awareness to employees on Plant

SPC and its impact to environment / cost

Awareness program conducted to employees

on Energy Conservation @ Home



Idea Drop Box Gamesa Wind Mill Field Visit


❑ What an idea Sirji contest-2015 -16 / 2016-17 , winners are given with LED lamps /

Solar emergency lamps to spread awareness

❑ Windmill visit for contest Winners


5. Projects implemented through Kaizens


Year Operators Technicians Officers Executives Total SPC Kaizens

2015-16 4 6 57 9 76

2016-17 5 2 24 5 36

2017-18 5 7 28 2 42


10. Implementation of ISO 50001/Green Co/IGBC rating

NA


Any other relevant information

Other awards, acknowledgement

31

CII Kaizen Award- Operator & Officers CII Safety Award


Any other relevant information

Other awards, acknowledgement

32


Thank you

Sriperumbudur N.Karuppusamy Senior Manager C.Vignesh Kumar … · 2018-09-13 · © Confederation of Indian Industry N.Karuppusamy –Senior Manager C.Vignesh Kumar –Executive Sriperumbudur

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