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First Workshop on Best Practices in Energy Efficiency in Textile Sector

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Date/Time
Date(s) - 28/11/2015
9:30 am - 5:30 pm

Location
Raymond Limited

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28 November, 2015, Thane, Maharashtra : The 1st Textile sector workshop for promoting exchange of “Best practices in Energy Efficiency in Textile sector” under Knowledge Exchange Platform (KEP) initiative was hosted by Raymond Limited, on 28th November, 2015 at Raymond Limited, Thane, Maharashtra. KEP is a joint initiative of Bureau of Energy Efficiency (BEE) and Institute for Industrial Productivity (IIP) for promoting energy efficiency through best practice transfer in industries covered under the Perform Achieve and Trade (PAT) scheme. KEP provides the institutional framework to catalyze the transfer of best practices within and across the industry sectors covered under PAT Scheme.

The workshop was inaugurated by Shri Harish K. Chatterjee, Vice President (Manufacturing), Raymond Limited. In his inaugural address, he congratulated BEE and IIP for establishing the Knowledge Exchange Platform, which will assist the industries to share ideas and best practices such as selecting more efficient equipment, conducting regular energy audits and putting in place robust energy management systems to meet the challenges posed by rising manufacturing cost and changing climate. He also highlighted that knowledge and best practice sharing will motivate the industries to adopt the most viable energy efficiency improvement linked strategies and projects that are technically feasible and economically justified. He concluded his inaugural address with an assurance that Raymond will support this initiative in all its future activities and also to see that KEP becomes sustainable.

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Shri Harish K. Chatterjee, Vice President (Manufacturing), Raymond Limited, delivering his inaugural address

Welcome address was delivered by Ms. Ritu Bharadwaj, Senior Program Manager, Institute for Industrial Productivity (IIP). She made a brief presentation on the rationale behind KEP, objectives and vision and the milestones achieved so far with the continued support of industries. Ms. Bharadwaj highlighted the fact that although KEP although being in infancy stage, has undertaken commendable work since its inception in February 2015 . Four Best practices workshops for Aluminium, Cement, Paper and Pulp and Thermal Power sector have been successfully organized, attended by more than 850 industry professionals. She also highlighted that cross sectoral knowledge transfer has also been high on KEP’s agenda and this was initiated by sharing of best practices in thermal power sector through a workshop and exposure visit for the benefit of other industry sectors having large captive power plants.  60 plants from all the PAT sectors have agreed to participate in Friendly Energy Efficiency Exchange Visits. Policy Roundtables on ESCerts Trading, Financing and Spent Pot Liners (SPL), a hazardous waste, generated from the aluminium sector and its gainful utilization in the cement industry, have been organized.

She also informed the participants KEP has launched an interactive website (www.knowledgeplatform.in) that facilitates knowledge transfer and discussion between stakeholder groups related to different PAT sectors and requested participants to give their feedback on different features to ensure that it met industry’s expectations and needs. She also mentioned that IIP was committed to work alongside BEE in taking this initiative forward and helping the industry achieve PAT objectives. While concluding her welcome address, Ms. Bhardwaj hoped that with these initiatives, KEP will be able to deliver significant energy efficiency benefits for the industrial sector and help sustain continuous improvement by promoting cost effective efficiency measures.

Special address was delivered by Shri K. K. Chakarvarti, Expert Consultant, BEE. In his address, he mentioned that the success of KEP depended on pro-active industry participation. Vote of thanks was delivered by Shri A. A. Bambardekar, Director (Works), Raymond Limited, Vapi. He conveyed his thanks to the dignitaries, speakers and delegates for their presence and participation in the workshop and assured the full support of Raymond Limited in future activities under KEP initiative.

The inaugural event was followed by three technical sessions and a panel discussion. The first technical session was Chaired by Shri Vinod Padmanabhan, Director (Works), Raymond Limited, Chhindwara. The discussion in the session focused on Energy Conservation Act 2001, PAT Scheme , Trading mechanism proposed for Energy Saving Certificates (ESCerts) and Best Practices on energy efficiency. BEE made a presentation on the Energy Conservation Act and PAT Scheme wherein the participants were informed about the current status as well as next steps proposed with regard to PAT Scheme and M&V. The presentation also covered the methodology to be adopted for second PAT cycle and the new plants and sectors proposed to be added in second cycle of PAT.

Besides PAT, the session also focused on sharing of experience of the industry on implementation of innovative best practices. The industries that shared their experience included Raymond Limited, Mandhana Industries Limited (Shirting Division), RSWM Limited, Ankur Limited (a part of Arvind Limited), BSL Suitings and Aarti International Limited.

Sharing and discussing their innovative best practices, the presentation by Raymond Limited, focused on benefits achieved by installation of new type of solar heater for better efficiency, Waste Heat Recovery (WHR) System aligned with air compressor, replacement of exhaust fans by turbo ventilators and installation of Variable Frequency Drives (VFD) at Air Washer towers and use of Aerofoil design of fans. The presentation by Mandhana Industries Limited (Shirting Division) highlighted the energy savings achieved by reducing the compressed air pressure for the cleaning system, continuous air consumption monitoring of airjet Looms , internal air leakage monitoring and replacing aluminum fan with FRP fan in humidification plant, which led to an annual monetary saving of Rs. 13.20 Lakhs, Rs. 47.30 Lakhs and Rs. 3.20 Lakhs respectively. The presentation by RSMW Limited highlighted the energy efficiency gains achieved by installing VFD in various process streams like Jumbo Jigger, circulation blower, circulation pump , hot air fan, cooling fan and exhaust fan, which led to a total annual saving of 3,33,500 kWh. The presentation by Ankur Limited (a part of Arvind Limited) highlighted energy efficiency gains achieved by replacing old boiler with energy efficient boiler, installation of pressure reducing valves for cleaning air application and replacement of old steam traps with energy efficient traps, which led to annual monetary saving of Rs.  108 Lakhs, Rs. 3.64 Lakhs and Rs. 18.3 Lakhs respectively. The presentation made by BSL Suitings explained the energy efficiency gains achieved by installing VFD on main air fan, replacing 6000 nos. of fluorescent 40 Watt (Electronic Blast) tube lights with 20 watt LED tubes and replacing street lights fitted with 125 Watt sodium vapour lamps with 40 W LED lamps, which led to annual monetary saving of Rs. 3.90 Lakhs, Rs. 52.50 Lakhs and Rs. 5.60 Lakhs respectively. The presentation by Aarti International Limited illustrated the benefits achieved by optimizing the air changes in 3 sheds, which led to annual monetary saving of Rs. 174.60 Lakhs, Rs. 118.80 Lakhs and Rs. 30.30 Lakhs respectively. Explaining best practice approaches to achieve energy efficiency, a presentation by Mr. R. Muthukrishnan, explained the measures implemented to reduce the cost of energy in the process utilities.

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Shri Vinod Padmanabhan with the panelists of the first technical session

The second technical session was focused on sharing of experience of the industry on implementation of innovative best practices, was Chaired by Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency. The industries that shared their experience included Senergy Consultants Pvt. Limited, DLI Power (India) Pvt. Limited, Century Rayon, Shahad and Banswara Syntex Limited

The presentation by Senergy Consultants Pvt. Limited, highlighted the various options through which energy saving can be achieved in Air Handling Units (AHU). The presentation by DLI Power (India) Pvt. Limited highlighted the ways to conduct energy audit of electricity bill detailing the incentives & penalties, kVAR capacity addition for improving P.F to maximum possible limit and incentives that can be gained from Electricity Distribution Companies by Load Factor improvement. The presentation by Century Rayon highlighted the energy efficiency gains achieved by replacement of water ring vacuum pump with mist condenser and power factor (PF) improvement, which led to an annual monetary savings of Rs 110.26 Lakhs and Rs. 91.00 Lakhs respectively. The presentation by Banswara Syntex Limited focused on the energy efficiency gains which can be achieved by replacing old motors with energy efficient motors, reducing maintenance frequency schedules and monitoring electricity supply frequency.

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Shri K K Chakarvarti with the panelists of the second technical session

 The third technical session focused on energy efficient technologies available for textile sector. The session was Chaired by Shri A. A. Bambardekar , Director (Works), Raymond Limited, Vapi. This session was planned in a manner that it brought together the technology providers and industry representatives with a view to promote interactions between the two stakeholder groups that can help in facilitating adoption of cleaner technologies. The session had presentations on technologies available for various operating areas viz. energy efficient jet-type fan less cooling towers  by AMREC Group, automation and energy saving in textile industries through Variable Frequency Drive by Danfoss Industries Pvt. Limited, Energy Management System (EnMs) as a PAT compliance tool for DCs by RSM GC Advisory Services Pvt. Limited, GreenErgy- an energy monitoring system by Greenovative Energy Solutions, Pune and  solutions to improve upon energy efficiency in compressed air system for textile sector by Atlas Copco (India) Limited.

A table top exhibition was also organized which showcased the energy efficient technologies by the leading technology providers viz. Greenovative Energy Solutions, Pune and Danfoss Industries Pvt. Limited.

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Shri A. A. Bambardekar with the panelists of the third technical session

Technical sessions was followed by a panel discussion on future strategies to be adopted and need for promoting innovative, new and cutting edge technologies and cross-sectoral best practices. The panelists were the members of Sector Learning Group. The panelist briefly explained the key discussion points of the SLG meeting, which was held a day before the workshop (27th November, 2015) and concluded that KEP can play an important role in facilitating policy discussions around PAT, particularly, as it is moving in to the next cycle where the textile industry is expected to have new targets and more plants are expected to come under the ambit of PAT. Panelist also felt that KEP will be in a position to assist the industries to meet the new targets by bringing in international best practices and technologies.

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SLG members as the Panelists at the Panel discussion

On behalf of Bureau of Energy Efficiency and Institute for Industrial Productivity, Ms. Ritu Bharadwaj  thanked the top management of Raymond Limited, in particular, Shri Harish K. Chatterjee, Vice-President (Manufacturing),   Shri A. A. Bambardekar , Director (Works), Vapi,   Shri Vinod Padmanabhan , Director (Works),  Chhindwara, Shri Ajay Baldua, Engineering – General Manager, Shri Sanjay Bokare, DGM and the entire team of Raymond Limited for extending their earnest support to the KEP initiative and pulling through an event of this scale.

Shri K. K. Chakarvarti thanked all the speakers and delegates who participated in the workshop and thanked them for their comments and suggestions and assured that each will be given consideration so that future workshops will be even more of a success.

The workshop had participation from over 150 eminent industry leaders of textile sector, energy auditors and energy managers, industry association, research associations, technology providers and senior Industry professionals amongst many others.

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Participants at the 1st Textile Sector Workshop under Knowledge Exchange Platform initiative

1ST WORKSHOP ON BEST PRACTICES IN ENERGY EFFICIENCY IN TEXTILE SECTOR
INAUGURAL SESSION (9.30 AM- 10.00 AM)
Welcome Address, introduction and expectations from the workshop Ms. Ritu Bharadwaj, Senior Program Manager, Institute for Industrial Productivity, India
Special AddressShri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Inaugural AddressShri Harish K. Chatterjee, Vice-President (Manufacturing), Raymond Limited
Vote of ThanksShri A. A. Bambardekar , Director (Works), Raymond Limited, Vapi
TEA BREAK (10.00 AM -10.20 AM)
TECHNICAL SESSION I (10.20 AM - 1.00 PM)Best Practice Presentation by Industry Representatives
ChairmanShri Vinod Padmanabhan , Director (Works), Raymond Limited, Chhindwara
Energy Conservation Act and PAT Scheme by Bureau of Energy EfficiencyShri K. K. Chakarvarti, Expert Consultant
Best Practices adopted by Raymond LimitedShri J. M. Joshi, General Manager (Engineering)
Best Practices adopted by Mandhana Industries Limited (Shirting Division)Shri Atul S. Kakad, Energy Conservation Engineer
Best Practices adopted by RSWM LimitedShri B. P. Singh, HOD (Engineering)
Best Practices adopted by Ankur Limited, a part of Arvind LimitedShri Jayesh Thakar, Senior Manager (Engineering)
Best Practices adopted by BSL SuitingsShri Pradeep Upadhyay, Manager(Engineering)
Best Practices adopted by Aarti International LimitedShri Arvind Prashar, Engineering Department
Costing of Utilities and Energy Conservation in Textile sector Shri R. Muthukrishnan, Independent Consultant
LUNCH BREAK (1.00PM-2.00PM)
TECHNICAL SESSION II (2.00 PM - 3.00 PM)Best Practice Presentation by Industry Representatives
Energy Efficiency- Best Practices in Textile Industry by Senergy Consultants Pvt. LimitedShri Ravindra Datar, Director
Electrical Energy Audit of Electricity Bill and Few Tips Common for all industries by DLI Power (India) Pvt. LimitedShri M. N. Menghrajani, Manager (Projects)
Best Practices adopted by Century Rayon, ShahadShri Rajdeep Hegde –DGM (Boiler House)
Best Practices adopted by Banswara Syntex LimitedShri S. R. Jain, Vice President, Engineering
TECHNICAL SESSION- III (3.00PM - 4.15 PM) Energy Efficient Technologies for Textile Sector
ChairmanShri A. A. Bambardekar , Director (Works), Raymond Limited, Vapi
Energy Efficient Jet type Fan less Cooling Towers by AMREC GroupShri Shailesh Harani, Managing Director
Automation and Energy Saving in Textile through Variable Frequency Drive by Danfoss Industries Pvt. LimitedShri Amit Chaurasia, Manager (West region)
Energy Management System as a PAT compliance tool for DCs by RSM GC Advisory Services Pvt. LimitedShri Anupam Das Purkayastha, Director
GreenErgy – An energy monitoring system by Greenovative Energy Solutions, PuneShri Vinit Kulkarni, Head Marketing
Energy Conservation in Compressed Air Systems - Textile Industry by Atlas CopcoShri Arnab Maitra, Key Account Manager
TEA BREAK (4.15 PM -4.30 PM)
PANEL DISCUSSION (4.30 PM - 4.50 PM) : SLG MEMBERS
Future Strategies to be adopted; need for promoting innovative, new and cutting edge technologies and identify the areas for sharing of Cross- Sectoral Best practices
CONCLUDING REMARKS (4.50 PM - 5.00 PM) Shri Harish K. Chatterjee, Vice-President (Manufacturing), Raymond Limited

Ms. Ritu Bharadwaj, Senior Program Manager, Institute for Industrial Productivity

Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency

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