Presented By :

Vijayant Gupta (Chief Manager - Engineering)Kushal Trivedi (Sr. Manager – Engineering)

19th National Award for Excellence in Energy Management 2018: 29, 30 & 31 August 2018

Introduction1

Textile – Process Flow2

Road map to achieve the benchmark

3

Projects implemented

4

Case studies

5

Renewable Energy

6

Sp. Energy Consumption & benchmark

7

Waste Utilization 8

GHG Reduction9

10

Contents

Green Supply Chain11 Team Work, Employee involvement & Monitor

Introduction

$1.3Bn Indian conglomerate

Interests in Textiles, Retail, Advanced materials,

Environmental solutions

and Real estate

Founded in 1931 during Swadeshi

movement

Among Global top 5 organized Denim

manufactures and pioneers of Denim in India

Every 2 secondsan Arvind manged brand apparel is sold in India

Our fabric can go around the

earth

~6 times

Own or manage

30 brands (International and domestic) in India

1 lac acres of farmland under organic cultivation

22 global patents

for environmental solutions

Largest Fire Protection

Fabric Producer in India

Raw Material

Spinning

Yarn Dyeing

Weaving /Knitting

Processing Finishing

Inspection

Textile – Process Flow

Sp. Energy Consumption in last 3 years & Internal Benchmark

6262 5626 5182

2015-16 2016-17 2017-18

Sp. Electrical Energy kWH/ Ton of Production

65627

5968655850

2015-16 2016-17 2017-18

Sp. Thermal Energy in KJ/KG

17% Reduction in Sp. Electrical Energy

15% Reduction in Sp. Thermal Energy

Internal benchmark for Composite Textile Unit

Area Spinning Weaving Knitting Dyeing

UOM kWh/kg of Yarn kWh/Meter kWh/ kg kWh/kg kg of steam/kg of Fabric

National Benchmark*

3 to 3.5 2.9 to 3.1 0.09 to 0.2 0.04 to 0.15 4 to 9

Arvind, Gandhinagar**

2.90 2.45 0.15 0.12 7.92

* Data from Shakti foundation

Link : http://shaktifoundation.in/wp-content/uploads/2014/02/textile.pdf

**Data from FY 2017- 18

Arvind’s road map to achieve the benchmark

Water One of the largest

Zero Liquid Discharge plant in

Asia at Gandhinagar

Use of Sewage water from nearby

communities as process water

Energy

Chemicals

100% process water from

recycled water

India’s most energy efficient textile unit, awarded three years in a row

largest solar roof-top plant in World - 18

MW

Specific energy consumption

reduced by 20% over last four years

Robust quality check established

for incoming chemicals

In house state of the art IQC

lab

Globally first textile mill to sign a

pact towards zero discharge of hazardous

chemicals

No. of Projects : 31

Total Amount Invested : Rs. 261 Million

Cost Saving Achieved : Rs. 425 Million

Reduction in GHG emissions : 69886 Tons of CO2

Thermal Energy Saved : 19885 Tons of coal

Electrical Energy Saved : 271 Lacs kWh

Encon Projects Implemented in the years 2015-16, 2016-17& 2017 -18

S.

No.Title of Project

Annual

Savings,

(Rs. million)

Investment

(Rs million)

1Installed right Capciy pumps set (300 M3/Hr & 50 Head) inplace

of (300 M3/Hr & 85 Meter Head)21.8 15

2Installed Heat Recovery Unit at 7500 CFM air compressor &

recovered heat from Hot Air discharge from Each Stages ( 3

Stages)

26 25

3Rejected RO evaporation through Mechanical Vapour Re

compression Evaporation (MVRE)34.6 25

4 Steam Condensate transfer Pump 1.27 3.8

5Installed Residual Moisture Measurement of Fabric at Stenter at

Outlet14.6 8.5

6Installed Air Gun inplace of Hose pipes for cleaning air

application1.5 0.3

7 Installed Heatless Air dryers in place of Refrigerated Air Dryers 6.1 5.05

8Higher automization of water particle so that water vapor mix

with air & desired RH maintained10.4 11.5

9Replaced 3700 CFM Screw Compressor with 2900 CFM

Energy Efficient Air Compressor in Shirting Air Distribution21.4 6.5

10 Iinstalled 150 KVA voltage stabilixer for Loomshed lighting load 1.3 0.8

11Replaced 70 numbers of 400 W X2 nos. of Mercury Vapor flood

lights with 150 Watts LED Flood Lights1.5 0.4

Total 140 101

Projects Year 2017 - 18

Projects Year 2016 – 17

S.

No.Title of Project

Annual

Savings,

(Rs.

million)

Investment

(Rs. million)

1Installed PNLD on Air dryer drains (Qnty -12) & reused Condensed

water to cooling tower makeup 23.12 12.1

2 Installed APH in 20 LkCal & 15 Lkcal Thermic fluid Heater 27.1 50.1

3 Installed natural Draft CT for air Compressors 18.2 6.1

4 Insulation Improvement in steams lines 5.9 5.1

5 Installed PPPU Pumps for Sizing Condensate (80 KL / day) 9.9 6.8

6Installed 450 CFM low pressure 4.5 barg air compressor for

Cleaning application 5.7 1.3

7 Conversion of negative Suction Effluent pumps to positive Suction 0.7 1.2

8Replaced of forced draft cooling tower to natural draft CT in air

compressors 1.2 0.5

9 Installed of Heat recovery Unit in thermic Fluid stenters Exhaust air 21.3 6.9

10 Installed of 175 kW sloar panels in shirting office area 7.6 4.7

Total 138.8 94.7

Projects Year 2015 – 16

S.

No.Title of Project

Annual

Savings,

(Rs.

million)

Investment

(Rs. million)

1Replaced of 36 Watt TFL by 18 Watt LED lamps in Loom shed,

spinning & Ware house shed 24.3 19.5

2Optimized Compressed air System i.e. reduction in pressure drop &

increase Pipe Size with close loop for entire generation & User End 40.0 7.5

3

Replaced of old air dryers with High size new Refrigerant Air dryer

(Large size SS Pre cooler) to avoid line loss & replaced Demister

pad of old ref. dryer with New SS Mess

18.2 6.4

4 Replaced of Raw water pump with right capacity & Head EE pumps 5.9 5.1

5Replaced of 6 nos. of Cooling Water Pumps & Process Water

Pumps with 2 nos. of right Size EE pumps in Shirting Pump House6.0 3.1

6Installed of PNLD in Air compressors & dryers drain & drain water

Diverted to Cooling tower make up5.7 1.3

7Installed of day light sheet/ Translucent Sheet in Bottom & Knit

Process House 0.7 1.2

8 Insulation improved in 20 & 30 TPH boilers 1.2 0.5

9 Installed of Economizer in 30 TPH boiler 21.3 6.9

10 Replaced of faulty Steam Trap in Khakhi division 7.6 4.7

11 Heat Recovery from process effluent water @ 85 C Effluent 15.4 9.9

Total 146.4 66.1

Project 1 : Utilize Recovered brine in dyeing process instead of salt

ETP RO

EvoparationSalt ProductionProcess Diagram - ZLD Plant

Before

ROReuse in Process

& Utilities

Evaporation

Recovered Salt

Process Dyeing

ETP

Feed Permeate

Reject

Concentrate

17000 KL 16309 KL691 KL

345 KL

518 KL

57 Tons Salts

Energy Cost : Rs 231 /KL

ROReuse in Process

& Utilities

Evaporation

Recovered Salt

Process Dyeing

ETP

Feed Permeate

Reject

Concentrate

17000 KL 16309 KL691 KL

123 KL

518 KL

40 Tons Salts

100 KL Brine ~ 17 Tons

After

Energy Cost : Rs 231 /KL

Energy Cost : Rs 170 /KL

Project Duration : 2017-18Annual Electrical Saving : 7.92 Lakhs kWhAnnual Steam Saving : 15300 Tons of

SteamWater saving : Avg. 100 KL per

dayProject Cost : Rs. 3 millionAnnual Saving :Rs. 25 million

• Saving on Maintenace Cost is not included in above table : - Rs. 20 Lacs annually

This Project Can be Replicated in Composite textile industry which can generate salt (by product of ETP) can be used dyeing process house

Project 2 : Foam Coating in place of paste coating in fabric

Chemical Foam Coating in place of paste coating in fabric

Coating : We have GASTON foam coating Technology which implies foam as media to apply chemicals at low weight pick up . Less moisture to evaporate so approx. 60% less energy consumption compared to conventional knife coating technique

Types :1.Paste coating 2. Foam Coating

Advantage of Foam coating :1.Foam as a medium extends the surface area of the chemical system to more closely match the surface area of the fibres, leading to tremendous reductions in required liquor2.Reduced water uptake results in commensurate reductions in energy requirements for evaporation3. Reduction in WPUs of 8- 80% on weight of substance. 4. 7 times Pressurized Air required to create 1 liter Foam Which can create a thin layer when applied to fabrics5. Finished fabrics carry Only 4 -5 % of moisture after applying foam so very less energy required for drying.

Chemical Foam coating system

Liquid metering

Mixer Air metering

Controller

Foam coating Slot Chemical Mix

Compressed Air supply

Foam

Before Coating

After Coating

Gaston Machine Spraying system

Project Duration : 2017-18Annual Thermal Saving : 346 Million kCalProject Cost : Rs. 1.5 millionAnnual Saving :Rs. 1.4 million

Project 3 : VFD in ring frame machine in Spinning area

At Present R/F Pnemafil Fan Motor Running On Constant Speed & Constant Suction Pressure. VFD control speed of suction fan motor through transducer and maintain suction pressure Pascal as per require. This machine has 1632 pneumatic spindles

Ring Frame machine Suction tubeVFD Pressure transducer

SR NO DETAILES BEFORE AFTER

1 Suction 800-1000 400-600

2 Frequency Hz 50 40

3 Actual Total 10.09 8

4 Power Consumption Kwh/day 200 160

5 Power saving KWH/day 40

6 Annual saving for 25 m/c/year 24.02 Lacs

Project Duration :2017-18Annual Electrical Saving :3.65 Lakhs kWhProject Cost :Rs. 13.5 millionAnnual Saving :Rs. 24.0 million

Utilisation of renewable energy sources

200kW X 14 Nos. Wind mill @

Costal Area of Saurastra, Gujarat

World Largest Solar Roof top ~18 MWTo be commisioned by Dec.'2018

Installed Day Light sheets at Process Shed

a) Foam Coating – We have GASTON foam coating Technology which implies foam as media to apply chemicals at low weight pick up . Less moisture to evaporate so approx 60% less energy consumption compared to conventional knife coating techniqueb) PFC free Durable water finish – We have developed PFC free durable water repellent finish free from PFOA & PFOS which are persistant bio-accumulative & toxic .Needs 40% less drying in drier due spray rating of 90 to100 (Water repellency). Extended life of cloth due to less staining form water based stains so less wash.c) Formaldehyde free wrinkle free finish : Formaldehyde is comes under category of carcinogen & must essential for wrinkle free finish .We have developed Zero Formaldehyde wrinkle free finish system where formaldehyde content is not all detected .Due wrinkle free finish we save on ironing time /energy in post-consumer use.d) Natural Softener form Plant Extracts : We have worked on sustainable finish systems based on products which are finished with bio-oil based softeners replacing regular silicones/PU & acrylic acid derivatives such as Bio-soft ELS from Midori based on plant seed oils.e) Recycled Material : We have GRS certification for claiming the recycled material use in products we have developed various products from recycled cotton as well as recycled polyester with recycled content as high as 30 to 40%. Recycling of 1 ton of PES saves 4.7barelles of oil equivalent. Production of 1 Ton baled cotton fibers demands 46 GJ of energy (range from 36 to 55) , 5 730 m³of water and emits 2.0 t CO2 equivalents ( Fiber Recycling: Potential for Saving Energy and Resources -Andreas Bartle, Vienna University of Technology)f) SORONA : We have worked on various innovative products based which exploit the property of SORONA with respect to the NYLON & POLYESTER at 63% reduced carbon foot prints in comparison to Nylon. Soronais a co-polymer of 1-3 propane diol & TPA out of which 1-3 propane diol is a fermentation product of waste harvest feed stock that way SORONA contains 37% renewably sourced polymer.

Arvind’s Most innovative Technique

Waste Management

20 TPH AFBC Boiler

Central Kitchen

Bio – Sludge from ZLD plant

Agro Waste - DOC

Bio gas plant

GHG Reduction

13.2 12.310.9 10.1

2014-15 2015-16 2016-17 2017-18

Ton of Co2/ Ton of production

Green Supply Chain

Cotton

BCI

Organic

Other Fibers

Recycled Fibers

Chemicals

Chemicals

“ Cotton is crucial for our sourcing so we promote responsible farming techniques likeOrganic farming & BCI ”

“ ARVIND initiated first BCI approved project in India so far this has resulted in 27% lesswater consumption & 29% more yield. We have build complete infrastructure of Green Sourcing”

“ We help farmers & create awareness of organic farming by forming SHGs –Self Help Groups& create self sustainable ,mutual support system . ”

“ We have innovative product portfolio based on various sustainable fibers from Lenzing ,Grasim , Dupont such as Tencel , Modal , Sorona which contributes to greener production &reduced carbon footprints”

“ Our product portfolio also contains GRS certified raw materials – Global RecyclingStandards which uses recycled material such as recycled cotton from process as well as fromPCW- Post Consumer Waste & recycled polyester from PET bottle recycling”

“ We have our own chemical management policy where we ensure all Dyes & chemicalswhich are being used at our side are in -line with ZDHC / REACH /Oekotex norms ”

“ We select vendors which comply with highest level of eco standards likewise Blue sign/GOTS such as HUNTSMAN / CRODA/ARCHROMA/DYSTAR / TANATEX / Midori ..etc”

Customers

“ Our majority of customers are also equally aligned with Green Chain such asLEVIS/GAP/C&A / H&M/ INDITEX/ VF so by default our entire value chain becomessustainable

2014 2015

2016

MOST INNOVATIVE ENVIRONMENTAL PROJECT

Highest number of ECertsin Textiles Sector –

PAT 1

Awards, Acknowledgement

Energy Committee –Chaired by Head

(Engineering )

Energy Team -Shirting

Energy Team Bottom weight

Energy Team -Knit

Ene

rgy aud

it Te

am

Energy Conservation Organogram

Sr No

. List Of Training Program

Organized Year Days Attendees

1 Promote Energy Efficiency in Utilities BEE & KEP March -18 2 24

2 Energy Efficiency Financing NPC Dec - 17 1 5

3 5 days Training Programme for certification of Energy Manager & Auditors

BEE - NPC June -17 5 2

4Knowledge Exchange Platform - Best practise in Energy Efficiency in textile Sector

Arvind- BEE Aug-16 2 120

5 Energy Efficiency in Utility BEE Apr-16 5 4

6 Advance Training of Energy Management Program CS May-16 3 4

7 Training On SAP IBM Aug-16 30 7

8Training of Efficient Operation & Maintenance of Thermic Fluid Heater

Thermex Nov-16 5 12

9 Energy Efficient Air Compressor IR Sep-16 2 2

10 Training of Open Access & Trading Mittal Sep-16 3 4

11 Steam Boiler Forbe Marshall

Nov-16 2 5

12 Energy Efficiency in Pumping System Kirloskar Apr-16 2 4

Energy efficiency / awareness training program

ISO 14001 SA 8000 ISO 9001 ISO 50001 BS OHSAS 18001

Textile – Certification

SMALL GROUP ACTIVITY KAISEN @

Thank You