Lala Lakshmipat Singhania ( 1910 1976 )

A Visionary & Key of JK Organisation

Presentation By

JK Tyre & Industries Ltd.

D R PAI

General Manager Engineering & Project Kankroli Tyre Plant (KTP) A unit of ) Kankroli ( Rajasthan JK TYRE & INDUSTRIES LIMITED ( TS-16949 , ISO-9001, OHSAS & ISO-14001 Plant )

KTP

11th National Award for Excellence in Energy Management-2010

Lala Lakshmipat Singhania ( 1910 1976 )

Presentation By

A Visionary & Key of JK Organisation

Kankroli Tyre Plant (KTP) A unit of JK TYRE & INDUSTRIES LIMITED

( TS-16949 ,OHSAS, ISO-9001 & ISO-14001 Plant )

Team Members D.R. Pai A.K. Pamecha M.K. Sharma

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KTP

An Overview of JK Tyre & Industries Ltd.

Lala Lakshmipat Singhania ( 1910 1976 )

A Visionary & Key of JK Organisation

KTP

VISION
To be amongst the most admired companies in India
Lala Lakshmipat Singhania ( 1910 1976 )

Committed to Excellence.

A Visionary & Key of JK Organisation

MISSION

Be a Customer Obsessed Company-Customer first 24x7 No.1 Tyre Brand In India Most profitable Tyre company in India Motivated and committed team for excellence in performance Be a green company Deliver enhanced value to all stakeholders Leverage & Enhance global presence through Acquisition / JV
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KTP

Manufacturing Process Flow Diagram

Lala Lakshmipat Singhania ( 1910 1976 )

A Visionary & Key of JK Organisation

KTP

Energy Policy
We at J.K.Tyres are Committed to Conserve Natural Resources & Energy by
Lala Lakshmipat Singhania ( 1910 1976 )

A Visionary & Key of JK Organisation

Enhancing Equipment Efficiency Minimizing Waste & idle run Technology & Innovation Periodic Reviews and Skill Upgradation People Involvement
We will continuously Benchmark & Improve Energy Performance in our endeavor to be the Worlds Best Bias Tyre Plant By 2010.

KTP

Focus areas for

Lala Lakshmipat Singhania ( 1910 1976 )

Energy conservation
Fuel conservation Resource conservation Reduction of green house gases Reduction in consumption of petroleum products Elimination of ozone depleting substances

A Visionary & Key of JK Organisation

KTP

POWER
Lala Lakshmipat Singhania ( 1910 1976 )

Actions: Optimization of Blowers and pumps Process Optimization Energy Efficient Lighting Use of renewable energy Efficient compressed air generation Extensive use of VFDs Energy Monitoring.

A Visionary & Key of JK Organisation

KTP

Plant Specific Power Consumption ( Kwh/Kg.)

0.816
Lala Lakshmipat Singhania ( 1910 1976 )

0.795

A Visionary & Key of JK Organisation

0.776

0.748

0.712
2004-05 2005-06 2006-07 2007-09 2009-10

KTP

STEAM
Lala Lakshmipat Singhania ( 1910 1976 )

A Visionary & Key of JK Organisation

Actions:
Optimization of Usage Pressure Elimination of redundant lines Process improvements Waste heat recovery Switching to alternate economic energy forms Heat recovery and reuse

KTP

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Plant Specific Steam Consumption ( Kg./Kg.)

2.634
Lala Lakshmipat Singhania ( 1910 1976 )

2.593

2.516

A Visionary & Key of JK Organisation

2.385

2.125
2004-05 2005-06 2006-07 2007-09 2009-10

KTP

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Saving Realization
Year Annual Energy consumption Prodn. in Specific Energy tons or Consumption any other unit of prodn. Electrical Thermal KWH / Ton tons or kL or unit of per ton or prodn unit of prodn
71795 779 0.483 0.01 72203 766 0.453 0.01 69089 749 0.419 0.01 53711 740 0.403 0.01 1.22 2.22 1.67

Lala Lakshmipat Singhania ( 1910 1976 )

Redn. in Specific Energy consn. Over previous year ** Electrical Thermal

(April March)

Electrical

Thermal

A Visionary & Key of JK Organisation

KWH * Million
200607 55.918

Rs Million
218.65

Type of Tons/KL fuel

Coal LDO/LSHS 34670 731 32866 759 28946 734 21696** 596**

Rs Million
101.12 3.04 116.3 7.29 120.82 5.31 96.44 2.47

3.23

-5.69 9.1 6.21 0 7.51 0 3.82 0

200708

55.293

243.72

Coal LDO/LSHS

200809

51.725

222.53

Coal LDO/LSHS

2009-10

39.747**

170.91

Coal LDO/LSHS

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Power Consumption ( Million Kwh ) Coal Consumption ( MT )

56.08

Lala Lakshmipat Singhania ( 1910 1976 )

39.75

Savings 815 Lacs

31824

21696

A Visionary & Key of JK Organisation

01/01/1900

02/01/1900

2005-06

2009-10

LDO/LSHS ( KL )
788

596

2005-06

2009-10

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Plant Energy Data Review

Plant Power Consuming Loads
Lala Lakshmipat Singhania ( 1910 1976 )

Power Consumption
Utilities = 38% , Mixing = 36%. Extruders = 7%, Air Washer = 5%, Calendaring = 4% Tyre Curing = 4%, Tyre Building = 2%, Lighting = 2%.
Ty re C urin g 4 Ca lend arin g, 4 A ir W a s he r, 5 U tilit ies , 38 E x tru ders , 7 , Ty re B uild ing 2 ,

A Visionary & Key of JK Organisation

L ight ing, 2

M ix in g , 3 6

Utilities & Mixing Consume Maximum Power

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Banbury # 4 Single Stage Mixing

INNOVATION: Concept of conversion of three stages mixing in to two stages mixing is innovative itself. Which have an added advantage of improvement in productivity, reduction in power consumption, low man-hour cost. The complete concept of conversion of three stages mixing in to two stage mixing was new and developed in-house. The design of required equipment and schemes was done locally including selection of process requirement. Benefit:After implementation of this project we generate extra 150 min/day for mixing which is equivalent to 10500 KG master compound per day or equivalent to 35000 Rs/day.

Lala Lakshmipat Singhania ( 1910 1976 )

A Visionary & Key of JK Organisation

KTP

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AIR WASHER
Lala Lakshmipat Singhania ( 1910 1976 )

Band Building Air Washer Metallic Blades replaced by FRP Blades. Horizontal Deployment to be done on All AHU
AIR FLOW (CFM) AIR FLOW DELIVERED VIS A-VIS POWER CONSUMED TOTAL Pump Conversion 18KW to 3.7 KW ALUMINIUM ENCON POWER (KW) ALUMINIUM ENCON

A Visionary & Key of JK Organisation

140000

140000 13.7 KW

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SAVING SAVING PER DAY Per AHU SAVING PER DAY 13 AHU SAVING (Rs.)/Year (250 Days)

11 KW 264 KWH 7800 KWH 2.73 LACS/Annum

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ENERGY SAVER Batch Off Mill BANBURY # 2

Lala Lakshmipat Singhania ( 1910 1976 )

WORKING PRINCIPLE Variable Triggered Voltage (Thyristor Control) with respect to variable load. Approximately 300 KWH saving per day. Energy Saver Cost 2.25 Lacs For 200 KW Motor. Pay Back 8 Months

A Visionary & Key of JK Organisation

KTP

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Industry Benchmark & Road Map

Utility
Lala Lakshmipat Singhania ( 1910 1976 )

Steam (Kg/ Kg ) 1.98 Reduction of fossil fuels Insulation improvement on hot steam lines Waste Heat recovery Reduction in flash steam losses Hot water recovery in curing presses Using optimum solution for process heating

Power (Kwh/Kg) 0.710 q Replacement of inefficient pumps. q Strengthen power monitoring system. q On line Energy management qVFD installation on Higher HP Mills qOptimization of Blower on air washers

JK - KTP

A Visionary & Key of JK Organisation

Future Plans to Challenge THE BEST

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Daily Monitoring Key Parameters

Review Mechanisms
Lala Lakshmipat Singhania ( 1910 1976 )

Daily Review of Process Scrape Parameters

P a rt i c u l a r s U n it K gs % K gs % K gs % K % K % K % K % K % K % K % K % K % V % K % K % K % V % gs gs gs gs gs gs gs gs gs a lu e gs gs gs a lu e P la n 17 0 .0 1 0 1 57 0 .0 9 0 C o m p o u n d S c ra p C B C B C T o m U 1 o m U 2 o m o ta pou nd Lu m pypou nd Lu m pypou nd Lu m pyl T oday A c tu a l 0 0 .0 0 0 0 0 .0 0 0 0 0 .0 0 0 0 0 .0 0 0 46 0 .0 6 4 38 2 0 .5 2 8 42 8 0 .5 9 1 19 0 .8 4 3 21 0 .2 0 5 20 0 .0 1 0 37 0 .0 1 9 52 5 0 .2 6 9 598 30 0 .3 4 7 13 0 1 .4 2 4 12 0 .8 0 3 66 7 0 .3 2 4 738 98 0 .4 0 4 D i ff 17 0 .0 1 0 1 5 6 .5 0 .0 9 0 Pla n 47 7 0 .0 1 0 4 291 0 .0 9 0 0 .0 0 0 4 291 0 .0 9 0 1 127 0 .0 6 0 7 512 0 .4 0 0 8 639 0 .4 6 0 50 9 0 .7 2 0 75 9 0 .2 7 0 54 1 0 .0 1 0 2 632 0 .0 5 0 142 15 0 .2 7 0 1 532 735 0 .3 3 4 3 456 1 .3 6 3 48 4 1 .2 0 0 227 36 0 .4 0 9 2 304 291 0 .4 9 4 M TD A c tu a l 4 32 0 .0 0 9 210 3 0 .0 4 4 5 04 0 .0 1 1 260 7 0 .0 5 5 182 2 0 .0 9 7 10 082 0 .5 3 7 11 904 0 .6 3 4 7 21 1 .0 2 1 7 78 0 .2 7 7 6 26 0 .0 1 2 348 0 0 .0 6 6 18 655 0 .3 5 4 194 884 5 0 .4 1 8 257 7 1 .0 1 6 3 47 0 .8 6 1 25 403 0 .4 5 7 253 809 5 0 .5 1 3 D if f 45 0 .0 0 1 2 1 8 7 .6 0 .0 4 6

Daily capturing of energy parameters, their analysis and investigate for deviations by section and functional heads Comparison within similar equipment

F a b r i c S c ra p -B U 1 F a b r i c S c ra p -B U 2 F a b r i c S c ra p -T o t a l S q W o v en F a b r ic I n su la te d B e ad

A Visionary & Key of JK Organisation

Daily reporting and threadbare discussions in management review meeting Review of energy projects by unit head for progress and employee participation

G r e e n T y re C u re d T y re T o ta l Pr o c e ss S cr a p T yre T o ta l Pr o c e ss S cr a p T yre C u re d T u b e C u re d F l a p T o ta l Pr o c e ss S cr a p T o ta l Pr o c e ss S cr a p

1 57 0 .0 9 0 43 0 .0 6 0 2 90 0 .4 0 0 3 33 0 .4 6 0 16 0 .7 2 0 28 0 .2 7 0 19 0 .0 1 0 98 0 .0 5 0 5 27 0 .2 7 0 56 772 0 .3 3 4 1 24 1 .3 6 3 18 1 .2 0 0 8 41 0 .4 0 9 85 241 0 .4 9 4

-3 -0 . 0 0 4 -92 -0 . 1 2 8 -95 -0 . 1 3 1 -3 -0 . 1 2 3 7 0 .0 6 5 -1 0 .0 0 0 61 0 .0 3 1 2 0 .0 0 1 -3 0 5 9 -0 . 0 1 3 -6 -0 . 0 6 1 6 0 .3 9 7 17 4 0 .0 8 5 11 343 0 .0 9 0

-6 9 5 -0 . 0 3 7 -2 5 7 0 -0 . 1 3 7 -3 2 6 5 -0 . 1 7 4 -2 1 2 -0 . 3 0 1 -19 -0 . 0 0 7 -85 -0 . 0 0 2 -8 4 8 -0 . 0 1 6 -4 4 4 0 -0 . 0 8 4 -4 1 6 1 1 0 -0 . 0 8 4 8 79 0 .3 4 7 1 37 0 .3 3 9 -2 6 6 8 -0 . 0 4 8 -2 3 3 8 0 4 -0 . 0 1 9

Daily Review of utility Parameters

Particulars Building Tyre Curing Tyre Tube Flap Total Utility Power Coal Unit MT MT MT MT MT KWH/Kg MT Kg/Kg Kg/MT MT Kg/Kg Kg/Kg M3/Kg Ltr/Kg Ltr/Kg Ltr/MT Plan 192.51 192.51 8.89 1.51 202.91 0.750 86.366 0.420 153.0 534.646 2.600 2.450 0.675 5.750 6.550 12.00 Today Actual 192.42 195.01 9.13 1.49 205.63 0.787 77.30 0.376 162.05 477.00 2.32 2.31 0.597 3.676 4.678 14.97 Diff -0.09 2.50 0.24 -0.01 2.73 -0.04 9.07 0.04 -9.05 57.65 0.28 0.14 0.08 2.074 1.872 -2.97 Plan 191.56 191.56 8.87 1.51 201.9 0.750 83.382 0.420 153.0 516.176 2.600 2.450 0.675 5.750 6.550 12.00 MTD Actual 193.17 188.03 9.06 1.44 198.53 0.813 92.03 0.464 183.60 501.24 2.52 2.41 0.637 4.162 5.170 12.73 Diff 1.61 -3.53 0.18 -0.07 -3.42 -0.06 -8.65 -0.04 -30.60 14.94 0.08 0.04 0.04 1.588 1.380 -0.73

Daily Review of equipment power

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Equipment BANBURY # 1 BANBURY#2 BANBURY#3 BANBURY#4 TOTAL BANBURIES DIP UNIT 3 ROLL CALENDER 4 ROLL CALENDER DUAL EXTRUDER MP EXTRUDER TUBE EXTRUDER TOTAL BUILDING TOTAL CURING PCI AIR PLANT AIR TOTAL AIR COOLING TOWER BOILER OTHER UTILITY TOTAL UTILITY LIGHTING TOTAL AIR WASHERS TOTAL REST METERED LOAD TOTAL UNMETERED NET PLANT CONSUM RSEB Unit Kgs. Kgs. Kgs. Kgs. Kgs. KM Eq.Rolls KM Eq.Trk.Tread Eq S/W Eq.Trk. Tube MT MT M3 M3 M3 MT MT MT MT MT MT MT MT MT Eq. Prodn. 47710 45323 44967 44220 182220 28299 1549 50292 5121 10504 5270 192.42 205.63 64650 58029 122679 205633 205633 205633 205633 205633 205633 205633 205633 205633 205633 To-Day Power Consumption ( Kwh.) per Unit 9803 0.205 12336 0.272 10101 0.225 11509 0.260 43749 0.240 2691 0.095 3543 2.287 7798 0.155 14299 2.792 3671 0.349 3688 0.700 3273 17.010 11764 57.209 8979 0.139 10011 0.173 18990 0.155 9106 0.044 3483 0.017 5102 0.025 43510 0.212 3827 0.019 11827 0.058 1467 0.007 6666 0.032 161773 0.787 164000 0.798 MTD Power Consumption ( Kwh.) per Unit 9337 0.203 11352 0.267 11128 0.267 11344 0.250 43161 0.246 2911 0.075 3822 2.915 7610 0.162 13011 2.670 3259 0.359 3769 0.747 3129 16.200 11282 56.827 10962 0.170 8924 0.154 19886 0.162 9122 0.046 3716 0.019 4779 0.024 45965 0.232 3553 0.018 11584 0.058 2078 0.010 6280 0.032 161413 0.813 164554 0.829

Steam(G) Steam(S) Air Water-Ex Water-Inc Naphtha

KTP

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Energy Conservation Structure

Lala Lakshmipat Singhania ( 1910 1976 )

A Visionary & Key of JK Organisation

KTP

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Proposed Project for Energy and Fuel Conservation

Location Key Projects Plan Project Cost Saving Remarks

Lala Lakshmipat Singhania ( 1910 1976 )

A Visionary & Key of JK Organisation

Township Street light to be replaced with LED Halogen lights of lamp. 30 Nos. 250W to be replaced with LED lights BU#1 MP F/mill drive - race sent to H.O . Trial Taken BU#3 BU#3 G,H line lightining to be linked with Circuit modification to press. be done curing lights to be linked with lighting Transformer available transformer. to be taken in line AHU pump replacement Relacement of Pump

20000 per piece 13 lacs Rs. 5000 10000.00

Rs. 7000 PA

Rs. 70000 per annum saving per uint

11 Lacs PA Awaited For Race approval 25000 PA approx.25000 per annum saving 1.25 Lacs PA 2.73 Lacs

Plant Plant BU#1

1.5 Lacs 1.2 Lacs 4 Lacs

BU#1

AHU filter replacememnt Relacement of Filter MP cooling conveyor D.C motor Conversion Of Dc replaced with A.C motor . Motor with Ac Motor VFD BB#2 Reconditioning in 27 lacs BB#2 Reconditioning instead of 1.1 corers. (17lacs/year to be continued for 6 years)

3.5 Lacs

Technology Upgradation

27 Lacs

17 lacs PA 17 lacs per year for for Six years next six years.

Contd .

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Proposed Project for Energy and Fuel Conservation

Locatio n Key Proje cts Plan Projec t Cost Saving Re marks

Utility

Bio fuel to be used in boiler. Boiler blow down control Steam reduction by installation of electrical heater (4-roll calander,T.C.U ,hot can,Dil. heating) Rs. 24 lacs to be saved under W /shop reconditioning Ecoventilater to be fixed - 200 Nos. BB V.F.D

Lala Lakshmipat Singhania ( 1910 1976 )

Utility BU#1

Usage of biomass instead of coal Process Optimization Conversion of steam to electric heater 9 Lacs

To Be evaluated. 0 Top Be evaluated 15 Lacs

A Visionary & Key of JK Organisation

SSU#1

SSU#1 BU#1

In House spare development with spares. Ecoventillaters to be provided over roof To Be Evaluated

No Cost

24 Lacs

24 lacs will be saved by development of in house spares.

5000/- per piece 1 Carore

to be evaluated To Be Evaluated 4 Lacs

Approx Rs. 60 to 70 Lacs per year saving expected

Utility

power saving in ACFC +cooling tower by VFD

Common VFD to be provided or switchng On & OFF of AC motors as per temperature Tecnology Upgradation Process Optimization Old Low Efficeint AC to be replaced with new efficient AC Process Optimization

2.5 Lacs

BU#3 BU#2 Utility SSU#1

CBD pump vertical to horizontal. slitter D.C motor replaced with A.C motor + drive Dome drain + Condensate recovery old age A.C to be replaced by star A.C

1 Lacs

1.5 Lacs Per Annum

To Be evaluated. To Be evaluated.

22000 per unit

To be evaluated

Utility

Air and water Pr. Drop study in drop line

To Be evaluated.

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Accolades- Present Glory-2009

Lala Lakshmipat Singhania ( 1910 1976 )

A Visionary & Key of JK Organisation

CII Excellent Energy Efficient Unit

CII Excellent Water Efficient Unit

National Energy Conservation BEE Award

Rajasthan Energy Conservation Award

KTP

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Lala Lakshmipat Singhania ( 1910 1976 )

A Visionary & Key of JK Organisation

Thank You

KTP

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