1St Factory of ITCGreen Building

Platinum ratingISO 14001 Certified

Highlights

HVAC- ATCS, Energy Saver, VRV

FAN- BLDC, Backward Curve

Energy efficient Burner

National Energy Conservation Day

World Environment Day

Smart Utility– Industry 4.0

8 % Reduction in Units/MNC

17 % Reduction in KL/MNC

95 Solar Street Light Under

Greenovation

Open Access 2 MwP

5Mw offsite solar

Engineering

Sustainability

Digitalization

Awareness Building

Technical Interventions

Electrical Supervisor

Branch Engineer

Energy Manager

I/C Electrical

MFG Executive

HR Executive

E.H.S Manager

Commercial Executive

ESP Member

Central Management Committee

The Energy Management Committee consists of Management, non-Management and Service Providers who actively takes part in the meeting

Environment Management organization Chart

TECHNOLOGY

Feasibility

Viability

BUSINESS

Usability, Desirability

HUMAN VALUES

DESIGN &

INTERACTIVITY

ORGANIZATION

BEHAVIOR

MANUFACTURING

Design

Innovation

Energy/MNC

Thermal Energy (FO & LPG)

LPG

Electrical Energy

EnCon Projects/Practices: Technology Map for last 3 Years

4

• Hot Condensate Recovery system including SOPTs

• Process heat recovery• Economizers• Air-fuel ratio optimization to

1.5-2.5%• Steam Trap monitoring

Steam generated (Tobacco Processing)

• Substitution of LPG with Biogasgenerated from Tobacco Waste

LPG / Biogasconsumption

• LED lighting for shop floor

• LED street lights for compound lighting

• Light Pipe

Lighting

• Screw compressors for better efficiency

• Industry 4.0 demand measurement system

• Auto-cut off valves

Compressed Air

• Chilled condensate recycling system

• Energy Saver for Admin Cooling

• Auto Tube Cleaning System

• VRV system

HVAC

• Interlocks for to prevent idle losses on compressed air and DRF lines

• IE4 Motors

• Compressed air leakage audits by production teams on shop floor

Motors/Rotating parts on Shop floor (Cigarette manufacturing)

Solar 1 MWpBiogas: 19 m3/dayWind 2 MWp Open Access

Energy Management Trends

Energy Audits-Expert

Internal Brain Storming

& Learning

Awareness Building

Bench Marking

Innovations

Approach

744732

670

640

2015-16 2016-17 2017-18 2018-19(Target)

kWh/Million No Cigarette

670

835

940920

MGR SRE PUN BLR

kWh/MNC

28512629 2729

2565.26

2015-16 2016-17 2017-18 2018-19(Target)

0

1000

2000

3000

Thermal kJ/Kg

Light Pipes & Natural lights use

Energy Management - Electrical

Energy savings with ATCS

Periodic cleaning each 6 months

Periodic cleaning

Every 1*F increase in Condenser approach increasespower consumption by 1.5%

Automatic Tube Cleaning System

Energy Management - Electrical

More Quiet Motor OperationLonger Life ExpectancyAccept input voltages of 100~240 VAC• Save up to 60% power consumption than

traditional AC Motor ceiling fanPotential Savings of 18 Mwh

Energy Management - Electrical

BLDC FAN Backward Curved Centrifugal Fan with IE4 motor

• Highest static efficiency• Non Overloading characteristics• Blade design efficiency >82%• Reduces Motor size Potential Savings of 150 Mwh

Electronically commuted Motors for AHU

• Direct Coupling, FRP blades• Power Consumption reduction by 45 % of AHU-2

Technical Interventions for Performance ImprovementBoiler Performance

SCADA system to study trend

Plan

Energy Management: Thermal

12.36

13.213.4

13.7

15-16 16-17 17-18 18-19

EVR

Waste Heat recovery system for Hauni Tunnel

Bulk Tank Heating System

100% Condensate RecoveryRevamp of HVAC system to increase humidification through air washers

Reducing Losses:Monitoring steam traps & Plug leakages

Demand Side

Minimize losses:Arresting leakage, focus on increasing condensate recovery

Optimizing Consumption:PRV for Admoist

530

242200

50

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

HVAC Steam (Tons)

No Title of ProjectAnnual Electrical Saving (kWh)

Annual Thermal Saving,

Million kcal

Total Annual Savings (Rs million)

Investment Made (Rsmillion)

1Commissioned Rooftop Solar Plant -663 kWp (In addition to existing 400 kWp commissioned in June'14)

352000 0 2.362 52.04

2Increasing hot condensate recovery for maximising Boiler efficiency

0 3.5 0.03 0

3Auto-cutoff Furnace Oil heating system for Optimizing Air-fuel ratio in Boiler

0 10.5 0.03 0.25

4Installtion of SOPTs (Steam Operated Pumping traps)

0 4.23 0.01 0.7

5Elimination of redundant water pumping

1418 0 0 0.07

6EnCon in HVAC (Cooling Coil replacement, Air filter replacement & Chilled condensate for Air washer)

14400 0 0.096 0.87

7Compressed Air Leakage Audits on Shopfloor and areesting the same

48000 0 0.322 0

8PLC controlled cut-off valve for CDRF line

7800 0 0.052 0.15

9 Automatic compressed air cutoff valve 11700 0 0.078 0.2

Total 435318 2.98 54.28

Energy Saving Projects 2015-16

Energy Saving Projects 2016-17

No Title of ProjectAnnual Electrical Saving (kWh)

Annual Thermal Saving (In GJ)

Total Annual Savings (Rs million)

Investment Made (Rs million)

1TPM pilot project: Energy reduction route for savings in production ancillaries

50000 0 0 1

2Improvement in solar 1MW plant performance by 1% through effective solar panel cleaning initiatives

13000 0 0.09 0.8

3Increasing hot condensate recovery for boiler feed-water (from 34% to 45%)

0 106 0.08 0

4Cost-effective Economizer coil replacement for improved boiler efficiency

0 327 0.24 1.5

5Reduction in Excess air in furnace oil-fired boilers to 10-15% (from 50%)

0 285 0.21 0

6Biogas: from tobacco waste to replace LPG in canteen

0 98.8 0 1.2

7RUPS shutdown to reduce fixed losses during zero production days

0.02 0 0.14 0

8Replacement of old split/window ACs with VRVs for comfort cooling

0.02 0 0.14 0.7

9 Auto-tube cleaning system for chillers 0.04 0 0.28 0.9

Total 63000.08 1.18 6.1

Energy Saving Projects 2017-18

No Title of ProjectAnnual Electrical Saving (kWh)

Annual Thermal Saving (In GJ)

Total Annual Savings (Rs million)

Investment Made (Rs million)

1Energy Efficient Airconditioning System(VRV) for Administrative buildings

79392 0 0.595 2.028

2Extended ATCS system for conndensertube cleaning of chillers

86733 0 0.65 0.9

3 HT Heat Recovery System 0 106 0.297 0.791

4Electrocoupling Fan blower system for AHU

41832 0 0 0.874

Total 207957 1.542 4.593

Innovative Project- Industry 4.0Smart Utility- Compressed Air

• Maintenance Alerts by Compressor

• Run Hours & machine health ( Smartlink)

• Compressed Air Demand Measurement

• Loss Measurement

• Performance Dashboard• Benchmarking among Focke/Loga M/C• Email Alert on Deviations/reports

• Reduction in Machine Demand

• Efficient Compressor Run

Key Features

43%

12%

34%

11%

Energy Consumption of Services at Production Floor of Munger

Factory

Compressed air

DRFs & Fans

HVAC

Lighting

Compressors are enabled with Smartlink capable of sending run hour and maintenance alerts on configurable emails.

Real time Consumption is monitored Line wise/Machine wise and recorded in Database capable to send email alerts on defined frequency.

Capabilities of SystemCompressors Consumption Points

The Dashboard indicates issues in Machine no 30 & 33 compared to

other machines.

Maintenance team digs the issue on specific Machine

Highlighted in Daily reports to Maintenance I/Cs

Operator’s interface

Innovative Project- Industry 4.0

Uniform heat Across the Heat pot

Higher Thermal efficiency

Low gas consumption (27% reduction)

Energy Efficient Burner

The Agnisumukh devices are built on low gas pressure platform. Each device is fitted with a step down regulator

No emission Carbon Soot

Potential Savings of 3.7 Ton LPG

Utilization of Renewable Energy: Solar

Focus on continuous replacement of conventional energy with renewable energy Commissioned 1.063 MW of Rooftop Solar Plant in Sep’15

16

Sustainability: Solar 2017-18

Interstate wheeling of Power from Telengana

14%24% 22%

58%70%

10% 13% 10%

25% 30%

2015-16 2016-17 2017-18 2018-19 2019-20

Renewable Energy substitution

Solar-Electrical Energy substitution Total Renewable Energy

To Increase Green Energy

Offsite Solar System

Interstate wheeling of 2 MW capacity from PSPD- Approved by SLDC & DISCOM already received and Metering system installed- Target Sept 18

Off Site Solar System- 5.2 MWp capacity for ITD, PPB & FBD demand in Munger- Approval in progress- Target March 19

Renewable Energy Plan 2018-19

938

1235 1206

326

835 815

2015-16 2016-17 2017-18

Solar Impact

Units generated (inMwh) GHG Reduction (in Tonnes)

Off-Site Solar Power Plant

1818

EPC Regulatory Framework

Off-site Solar Project Investment 18-19

Land- 5 Cr, EPC 33 Cr IRR – 15.7%

Wheeling of Power using BSPTCL

network

Local Discom SBPDCLSolar Power Plant

Stepping Up - 440V to 33KV

Feeding power to the nearest substation of SBPDCL

Power scheduling by

SLDC

ITC Munger

Renewable Policy 17-18

• Transmission and distribution (T&D) losses ~ NIL

• T&D charges NIL

• Representations made to Principle Secy BREDA for allowing banking in peak hours

Project Viability

• 5 MWp Fixed Tilt

• PLF- 16 %, 70 Lac/Annum Generation

• Land Parcels at Gaya

• Power Tariff increasing at 7 % CAGR

Project Status

• Understanding of Regulatory Approvals process – completed

• Offers including land and EPC-Completed

• Detailed Proposal in progress

Plan 18-19

• Final negotiations with vendors – Aug’18

• CMC approval (EPC) for solar project – Aug’18

• LOI and advance to vendor –Nov’18

Waste to Energy – Innovative Approach

GHG Inventorisation

0

0.1

0.2

0.3

2014 15 2015 16 2016 17 2017 18

Scope 1

0.4

0.42

0.44

0.46

0.48

0.5

0.52

2014 15 2015 16 2016 17 2017 18

Scope 2

0

0.02

0.04

0.06

0.08

0.1

0.12

2014 15 2015 16 2016 17 2017 18

Scope 3

New Product launched last year which increased scope 3 emissions.

Disclosure part of ITC Sustainability reporting as per GRI standards

Green Supply ChainAll ITC Units continue to pursue efficient use of raw materials through focused efforts on waste elimination/reduction. Moreover, as most of ITC’s Businesses are vertically integrated, this provides the Company unique opportunities for exercising greater control over optimum utilisation of raw materials, recycling/reuse of wastes as well as efficient logistics.

Munger Printing Factory Supplies Major Raw Material (HLP) implemented following energy conservation project

No Title of Project Year

1 Replacement of window AC by central AC (with FCU) 2015-16

2 Turbo ventilator fixing in godowns 2015-16

3 Advance cool portable chiller installation 2015-16

4Steam shut up valve conneceted with m/c power for auto cut in m/c

stoppage 2016-17

5 500 nos LED lights 40 w fitting replacing 80w light 2016-17

6 VSD installation for Fan of SR plant 2016-17

7 Occupancy sensor fitting in officers toilet, meeting room and lab 2016-17

8 50 Nos old Fans Replacement 2016-17

Encon Task Forces: Employee Engagement-TPM

Employee Engagement

Water Management

• AHU Condensed water(4-5KL Avg) reuses at Cooling Tower

• In house Rain Water Storage & Treatment System

• Recycling & reuse RO Reject and MGF/IRF backwash from Boiler softener

Major Interventions

5.22

4.22

3.353.20

15-16 16-17 17-18 18-19

KL/MNC100

8379

75

15-16 16-17 17-18 18-19

KLD

Sustainable Society

Sustainable Society

LED street Lamp with Solar system

95 no’s Solar LED lights provided for community

Sustainable Society

28

1.Energy ManagementUnits/MNC-640 (2018-19)Units/MNC-590(2018-21)

2.Renewable Energy5Mw Offsite Solar plant-2019

3.Water ManagementKL/MNC-2017-18 3.35Kl/MNC-2018-21: 2.86

4.Waste Management

Upgradation of Bio gas to 100m3 -2020

8.Environ friendly MaterialsExploring Environment friendly Materials-

Biodegradable plastics, filters , led free pain etc.

7.Greening the supply chainStandarisation of vendor selection

criteria based on green parameters and provide support

6.Regulatory FrameworkScan regulatory framework

continuously and frame suitable strategies

5.Green RecognitionsIGBC platinum Certification renewed-2017

Exploring and applying various national and international Green award.

Greenovation– Roadmap of Green Journey 2017-20

1

2

3

4

5

6

7

8

Greenovation

Awards & Accolades-2017