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Second Workshop on Best Practices in Energy Efficiency in Textile Sector

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Date/Time
Date(s) - 28/06/2016
9:30 am - 5:30 pm

Location
CROWNE PLAZA AHMEDABAD CITY CENTRE

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28 June, 2016, Ahmedabad, Gujarat: The 2nd Workshop on ‘Promoting Exchange of Best Practices in the area of Energy Efficiency in Textile Sector’ was organized on 28th June, 2016 at Ahmedabad, Gujarat. The workshop was hosted by Arvind Limited and organized under the Knowledge Exchange Platform (KEP) initiative. KEP is a joint initiative of Bureau of Energy Efficiency (BEE) and Institute for Industrial Productivity (IIP) to promote energy efficiency by facilitating exchange of knowledge, experiences and best practices in industries covered under the Perform Achieve and Trade (PAT) scheme.

The workshop was inaugurated by Shri Susheel Kaul, CEO- Lifestyle Fabrics (Shirting, Khaki & Knitwear), Arvind Limited.  In his inaugural address, he mentioned that coal will continue to be the primary fuel for the next 2-3 decades and energy efficiency is the only way that textile industry can continue to survive and make profit. He mentioned that although the raw material cost cannot be reduced but there is tremendous scope to reduce the cost of energy that accounts of 14-15% of the total cost of production and enhance the profitability and competitiveness of Indian textile industry. He said that KEP provides an ideal platform to support industry in meeting this objective by stimulating best practice exchange, identifying new areas of development and catalyzing change on ground. He further added that the Indian industry currently has a high level of support from the government under the ‘Make in India’ campaign, so the Industry should reap this opportunity by enhancing efficiency and becoming globally competitive.

Welcome address and introduction to the workshop was provided by Ms. Ritu Bharadwaj, Senior Program Manager, Institute for Industrial Productivity. She provided an update on KEP initiatives and mentioned that in order to ensure that KEP continues to act as a forum for sustain interaction within and across industry sectors, it is important that KEP’s efforts are strengthened by providing continuous input and feedback. She informed that besides initiating sectoral workshop, quarterly newsletter, best practice exchange visits, KEP has also developed an interactive website (www. knowledgeplatform.in). She mentioned that KEP intends to develop this website as a strong tool in promoting not only the KEP activities but also as a one stop solution to all the information needs of the industry.

Shri Girja Shankar, Assistant – Energy  Economist, BEE, in his special address in the inaugural session urged the Industry to continue  providing their support and feedback as KEP moves into the next round of action in the second year. This will be particularly important as KEP now plans to expand and include elements that have not been covered so far.

Shri K. K. Chakarvarti, Expert Consultant , in his special address provided an overview of the textile sector and explained why energy efficiency was important to not just support the growth of the sector but to sustain the livelihoods and jobs of millions of workers dependent on it. Shri. Rakesh Arya, Senior Project Executor, Gujarat Energy Development Authority (GEDA) mentioned that as State Designated Agency they would continue provide all support and input needed to take KEP initiative forward.

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Dignitaries at the inaugural session

The inaugural event was followed by three technical sessions and a panel discussion. The first technical session was Chaired by Shri K K Chakarvarti, Expert Consultant . The discussion in the session focused on Success stories from PAT Cycle 1, Trading mechanism for Energy Saving Certificates (ESCerts), Introduction to PAT Cycle 2 and India’s commitment in Intended Nationally Determined Contributions. BEE presented the success achieved under PAT 1 Cycle for Textile sector and information on the current status as well as the mandatory requirements to be fulfilled by DCs. The presentation on ESCerts by BEE focused on key aspects of ESCerts trading scheme and the progress made so far, which included status of ESCerts Exchange Regulations, roles and responsibilities of entities involved viz. administrator and registry and power exchanges, process flow for extinguishing ESCerts, ESCerts transfer ownership and adjudication flow process. The presentation on PAT 2nd cycle by MCJ Engineers Pvt. Limited covered the methodology to be adopted for second PAT cycle, amendments made in PAT Rules in the area of fuel auto sampler, ESCerts, baseline setting methodology for new and existing DCs, validation of fuel quality and brief on the new plants that are introduced in second cycle of PAT. The salient features of India’s Intended Nationally Determined Contributions (INDC) were shared by the chairman with the delegates. Two proclamations have been made by India in INDC viz. to reduce the emissions intensity of its GDP (gross domestic product) by 33% to 35% by 2030 from 2005 levels, and to generate about 40% cumulative electric power installed capacity from non-fossil fuel based energy resources by 2030 (equivalent to 26–30% of generation in 2030). India will create by 2030 an additional carbon sink of 2.5 to 3 billion tonnes of CO2 equivalent.

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Shri K K Chakarvarti with the panelists of 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 Vinod Padmanabhan, Works Director, Raymond Limited. The industries that shared their experience included Arvind Limited, Banswara Syntex Limited, Raymond Limited, RSWM Limited, Indo Count Industries Limited and Kirloskar Brothers Limited. The presentation by Arvind Limited highlighted the energy efficiency gains achieved by optimizing the compressed air systems, optimizing the air dryer systems, installation of pressure reducing valve for cleaning air application which led to an annual electrical power saving of 0.048 CFM per kW, 23.1 Lakhs kWh and 1.10 Lakhs kWh respectively. The presentation by Banswara Syntex Limited explained the energy efficiency initiatives taken by installing inverter in humidification plant, replacing ordinary tube rod with LED tube rod, installing VFD and variator belt drive with direct coupling on LR 6/s ,G5/1 and Texmeco ring frames and replacing the low efficiency motors with IE3 energy efficient motors. The presentation by Raymond Limited explained the journey towards implementing ISO 50001, road map followed and benefits achieved at every step ranging from awareness, documentation, commitment from top management and regular monitoring. The presentation by RSWM Limited highlighted the energy initiatives taken by replacing all the three stenter machines  to new and improved technology ones, replacing 10 energy efficient pumps in place of traditional type monoblock pump in the process plant and by using heat exchanger at F.D fan of thermopac (20 lacs kCal per hour) in inlet air, which led to daily energy savings of 1000 kWh, 500 kWh and 300 kg pet coke respectively. The presentation by Indo Count Industries Limited highlighted energy efficiency gains achieved by replacing old LRB insulation by e-fibre insulation of thermic fluid & balance steam lines, replacing 2 screw compressors by 1 energy efficient centrifugal compressor, replacing refrigerant type dryer of existing 4000 CFM centrifugal compressor  by heat of compression type, improving hot water temperature of CRP hot water recovery and distribution by installing 50 KL SS 304  hot water tank for collection of hot water and supply to machines, which led to daily savings of 300 tons of coal, 2400 kWh, 850 kWh and 10 tonnes of steam respectively. The presentation by Kirloskar Brothers Limited highlighted the strategies which can be adopted in the pumping system which would help to bring down the pumping costs and avenues in energy efficiency in pumping systems.

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Shri Vinod Padmanabhan with the panelists of the second technical session

The third technical session was focused on energy efficient technologies for textile sector, was Chaired by Shri Harvinder Rathee, Head-Engineering, Arvind Limited. 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 processes in textile sector viz. technological solutions for spinning section by Voltas, Mumbai, technological improvement in reduction of Air Consumption in Air Jet Looms by Arvind Limited, technological solutions for finishing section by Voltas, Mumbai, humidification system for textile sector by DRAFT-AIR (I) Pvt. Limited, energy conservation in compressed air systems for textile industry by Atlas Copco, energy efficient technology in RO reject handling by Arvind Pvt. Limited and energy information management and analytics system for the textile sector by E-CUBE Energy Trading Pvt. Ltd.

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Shri Harvinder Rathee with the panelists of the third technical session (Part – A)

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Shri Harvinder Rathee with the panelists of the third technical session (Part B)

Technical sessions was followed by a panel discussion on technology gap assessment in which the panelist shared their thoughts and views on the need for mapping the present status of textile industry in terms of energy efficiency technology deployment and the need of technological advancement in order to achieve the targets set under the 2nd cycle of PAT. Shri R. S. Patel, Head – Engineering, Arvind Limited, mentioned that the textile industry has lagged behind in adopting energy efficient technology and practices because investment typically required for modernization of the industry is high and the payback period is generally not viable. He mentioned that because of poor modernization, energy efficiency gain in the textile sector is not as high. Even with modernization, new machinery will need skilled labour, availability of which is still an issue in the textile industry. Although scheme like “learn and earn” are there and are affective in the southern states but it is not effective in the northern region. He also pointed out that some of the  normalization factors, such as fuel substitution, under the PAT scheme, have not helped the textile industry, as application of the same has led to increase in Specific Energy Consumption (SEC). This has demotivated the industry from investing in fuel substitution. On the financing aspect, Shri Patel suggested that government has sanctioned INR 6,000 crore under TUFF, which should be made available to the textile industry.

Shri Vinod Padmanabhan, Works Director, Raymond Ltd. mentioned that energy efficiency is the need of hour as all international manufacturers are now investing in energy efficiency and to remain globally competitive, Indian industry will have to follow the suit. However, just technology upgradation would not be sufficient in textile industry because the sector lacks good engineering talent. BEE should provide more help on the soft component (Technical Competent) for implementation of energy efficiency. Shri Rakesh Arya, Senior Project Executive-GEDA mentioned that renewable energy component is missing in industry efforts of promoting energy efficiency. He suggested that renewable energy could offer good solution in areas such as process heat, boiling of water etc.

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Panelists in the Panel discussion on Technology Gap Assessment

On behalf of Bureau of Energy Efficiency, Institute for Industrial Productivity, Shri K. K. Chakarvarti thanked the top management of Arvind Limited, in particular, Shri Susheel Kaul, CEO- Lifestyle Fabrics (Shirting, Khaki & Knitwear), Arvind Limited, Shri Harvinder Rathee, Head-Engineering, Arvind Limited, Shri Kushal Trivedi, Senior Manager- Engineering, Arvind Limited and the entire team of  Arvind Limited for extending their earnest support to the KEP initiative and pulling through an event of this scale. He also 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 130 distinguished speakers, eminent textile industry leaders, Government agencies, Gujarat Energy Development Agency, Ahmedabad Textile Industry’s Research Association (ATIRA), The Textile Association (India) Ahmedabad Unit, technology providers, energy managers and auditors, and senior Industry professionals amongst many others.

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Participants at the 2nd Textile sector Workshop under Knowledge Exchange Platform initiative

2nd WORKSHOP ON
BEST PRACTICES IN ENERGY EFFICIENCY IN TEXTILE SECTOR
INAUGURAL SESSION (9.30 AM- 10.15 AM)
Lighting of Lamp
Welcome Address, introduction and strategies for the next phase of KEP initiativeMs. Ritu Bharadwaj, Institute for Industrial Productivity
Special AddressShri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Special AddressShri Girja Shankar, Assistant Energy Economist, Bureau of Energy Efficiency
Special Address Shri Rakesh Arya, Sr. Project Executive, Gujarat Energy Development Agency
Inaugural AddressShri. Susheel Kaul, CEO- Lifestyle Fabrics (Shirting, Khaki & Knitwear), Arvind Limited
Vote of ThanksShri Harvinder Rathee, Head-Engineering, Arvind Limited
TEA BREAK (10.15 AM -10.30 AM)
TECHNICAL SESSION I (10.30 AM - 11.30 PM): PAT and Intended Nationally Determined Contributions (INDCs)
ChairmanShri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Success stories from PAT 1 Cycle by Bureau of Energy Efficiency Shri Ajitesh Upadhyay, Textile Sector Expert
Trading of Energy Saving Certificates (ESCerts) by Bureau of Energy EfficiencyShri Girja Shankar, Assistant Energy Economist
Introduction to PAT Cycle 2 by MCJ Energy Engineers Pvt. Ltd.Shri M C Jain, Director
Intended Nationally Determined Contributions (INDCs) – India by Bureau of Energy Efficiency Shri K. K. Chakarvarti, Expert Consultant
TECHNICAL SESSION II (11.30 AM - 1.00 PM): Best Practice Presentation by Industry Representatives
ChairmanShri Vinod Padmanabhan, Works Director, Raymond Limited
PART A: Sharing of Best Practices from Textile sector and experiences of ISO 50001 certified industries
Best Practices in Energy Efficiency in Arvind LimitedShri Kushal Trivedi, Senior Manager- Engineering
Best Practices in Energy Efficiency in Banswara Syntex LimitedShri Ayush Modi, Supervisor
Implementation of ISO 50001 by Raymond Limited Shri Jayant Joshi, General Manager (Engineering)
Best Practices in Energy Efficiency in RSWM LimitedShri Bhupendra Pratap Singh, Depty. Chief Engineer
Best Practices in Energy Efficiency in Indo Count Industries LimitedShri Gurpal Singh, Head - Utility & Engg
PART B: Sharing of Best practices by Energy Auditors
Energy Efficiency Practices in Textile Sector by Kirloskar Brothers LimitedShri Bhagvatdan Gadhavi, Associate Manager
Upgradation kit to convert Shuttle loom to Rapier Loom in Textiles by Shreenidhi Green ServicesShri Ravinder Vannam, Director
LUNCH BREAK (1.00PM – 2.00PM)
TECHNICAL SESSION- III (2.00PM – 3.45 PM) : Energy Efficient Technologies for Textile Sector
ChairmanShri Harvinder Rathee, Head-Engineering, Arvind Limited
PART A
Technological solutions for spinning section by Voltas, Mumbai Shri M. Mohanraj, Service Manage ( Product & service)
Technological improvement in reduction of Air Consumption in Air Jet Looms by Arvind Limited Shri Debkumar Goswami, Chief Manager – Weaving
Technological solutions for finishing section by Voltas MumbaiShri V. Vinod Kumar, Sales Manager
PART B
Humidification system for textile sector by DRAFT-AIR (I) Pvt. LimitedShri G. D Panchal, CMD
Energy Conservation in Compressed Air Systems - Textile Industry by Atlas CopcoShri Milind Mehta, Business Marketing Manager
Energy Efficient technology in RO reject handling by Arvind Envisol Pvt. LimitedShri Chandan Kumar, Head – Technology
Energy Information Management & Analytics System for the Textile Sector by E-CUBE Energy Trading Pvt LtdShri Umesh Bhutoria, Founder & CEO
TEA BREAK (3.45 PM -4.00 PM)
PANEL DISCUSSION (4.00 PM - 5.00 PM) : Technology Gap Assessment- Mapping the present status of textile industry in terms of EE technology deployment and the need of technological advancement in order to achieve the targets set under the 2nd cycle of PAT.
CONCLUDING REMARKS (5.00 PM - 5.10 PM)
Shri Harvinder Rathee, Head-Engineering, Arvind Limited
Ms. Ritu Bharadwaj, Institute for Industrial Productivity
Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency

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