Shailendra Arora · 2018-09-13 · Mr. Shailendra Arora Chairman Mr. Vimal Rai Mr. Rajat Mathur...

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Presenting Team

Shailendra Arora

(VP – Manufacturing)

Mukesh Mahbubani

(Head-Energy Cell)

Anurag Varshney(General Manager)

Brief introduction on Company/Unit

❖ Established in 1978 and Commercial production started in 1981.

❖ Total Area – 463 Acre approx.

❖ Total Employees – 882

❖ Self sustaining Employee housing facility.

❖ Strategically located in the sugarcane belt of UP

❖ Fully integrated renewable biomass based chemical products

❖ Backward and forward integrated portfolio of products

❖ Self sufficient with captive power and cogeneration of steam 3

Jubilant Life Sciences Limited ,Gajraula

Advanced Intermediate Business Fine Ingredients (Pharma & Others) Business

Ethanol Business LifeScience Chemicals (Acetyls) Business

Biogas

Beta Picoline

Pyr

idin

e

Pyr

idin

e

Bio

gas

Ammonia (Purchase)

Methanol (Purchase)

Molasses (Purchase) Acetic Acid (Purchase)

FC Products

3 CPBeta PicolinePyridine

CO2

EA

SALESA

lco

ho

l (P

urc

ha

se)

AC2O

Advance Intermediates & Nutritional Products Specialty Ingredients & Life Science Chemicals

Anhydrous Alcohol

Alcohol (Purchase)

4

Product Integration

Sp. Energy Consumption in last 3 years

Reduction in SEC of last 3 Yrs

6

(KWH/MT)

1390

1211 1204

2015-16 2016-17 2017-18

H

2149

1961

1804

2015-16 2016-17 2017-18

I

2542

2287 2278

2015-16 2016-17 2017-18

J

10007

9534 9529

2015-16 2016-17 2017-18

G

Continual effort towards energy conservation by taking energy intensive initiative

Global Leadership

Leadership Positions – Globally……Life Sciences Ingredients

8

Advance Intermediate

Nutrition Ingredients

Fine Ingredient

Acetyl

No. 4 in Ethyl Acetate &

No.7 in Acetic Anhydride

No.2 in Niacinamide (Vitamin B3)

No.1 in11 Pyridine Derivatives

No.1 in Pyridine

Leadership Positions – Globally……Pharmaceuticals

• No.1 in 4 APIs, Ranked among Top 3 in 3 APIs

Active Pharma Ingredients

• No.1 in 3 Nuclear Medicine products in North America

Radiopharmaceuticals

• No.1 in 3 generic products among Top 3 in 5 products

Generics

• Ranked among Top 3 suppliers in North America

Allergy Immunotherapy

• Ranked among Top 5 Contract Manufacturers in North America in Sterile Injectables

Contract Manufacturing

Strong relationship with 19 out of the top 20 global Pharma companies and 7 of the top 10 global agrochemical companies.

Energy Saving projects implemented in last 3 years

Energy Saving projects implemented & Achievement in FY 2015-16

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Project DescriptionPower

Lacs KWHCoal MT

F.Oil/LDO/HSD

KL

Total fuel (MTOE)

Total fuel (MMKcal)

Saving(Rs Lacs/ Annum )

One time Investment (Rs. Lacs)

To reduce steam consumption in A Process from 11.90 to 11.35 MT/MT (AI)

Nil 982 Nil 391 3909 271.9 22.1

To reduce Steam Consumption Norm in J(LSC)

Nil 314 Nil 125 1250 52.8 1.0

To reduce steam distribution losses (Utilities)

Nil 1657 Nil 660 6601 229.7 20.3

To increase utilization of Extraction Steam in I plant.(in place of 21 kg/cm2 steam supply) (LSC)

Nil 914 Nil 364 3641 111.5 0.0

Maximisation of biogas and reduction of E furnaces (FI)

Nil Nil 18 18 181 126.8 1.0

Reduction of Coal Consumption due to fines losses + Reduction of Coal Consumption due to fuel additives (Utilities)

Nil 2593 Nil 1033 10329 145.8 299.3

Total No of projects : 21

Saving : Rs 1248 Lacs

Investment : Rs 385 Lacs


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Lacs KWHCoal MT

Total fuel (MTOE)

Total fuel (MMKcal)



To reduce steam consumption in A Process from 11.78 to 11.25 MT/MT (AI)

Nil 2874 1141 11408 148.0 -

To reduce steam consumption in G Process from 11.44 to 10.69 MT/MT (AI)

Nil 2371 941 9411 122.1 -

Reduction in Furnace Heat losses Nil 1580 627 6274 81.4 35.0

Optimisation of energy cost of I by replacing Existing/Proposed VAHP by screw compressor. (LSC)

Nil 1310 520 5200 67.5 136.5

Steam saving through RO reject preheating before degasser by L raffinate (Ethanol)

Nil 2760 1096 10958 142.2 -

Increase the efficiency of 90TPH-1 boiler (Utilities)

Nil 4765 1892 18917 245.4 -


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Lacs KWHCoal MT

Total fuel (MTOE)

Total fuel (MMKcal)



To increase steam generation norms from 0.437 to 0.504 MT/MT in F Plant

Nil 877 381 3812 54.9 0.0

Reduction in steam norm from 12.32 to 11.67 MT/MT in A plant

Nil 3718 1617 16168 232.8 10.0

Reduction in steam norms from 0.16 to 0.11 MT/KL in reffinate distillation column

Nil 2715 1181 11807 170.0 40.0

Reduction in Power norm from 328 to 289 KWH/MT in I Plant Nil 830 361 3609 52.0 10.0

Power norm reduction from 21.23 to 20.25 KWH/MT in 90 TPH-2 boiler / Power norm reduction in 90 TPH-1 boiler ID,FD & PA- 2 no's each Fan.

16 136 1358 60.0 100.0

Steam loss reduction from 3.85 to 3.25% by reducing the loss from distribution traps, vents, safety valves and surface.

Nil 2124 843 8434 109.4 35.0


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Lacs KWHCoal MT

Total fuel (MTOE)

Total fuel (MMKcal)



Reduction in steam norm from 12.32 to 11.67 MT/MT in A Plant

Nil 5495 2389 23892 315.0 10.0

Reduction in steam norm from 11.67 to 11.47 MT/MT in A Plant

Nil 1116 485 4854 64.0 25.0

To reduce steam norm from 11.24 to 10.69 MT/MT by heat recovery from R6 reactor top.

Nil 3070 1335 13348 176.0 -

Steam norm reduction from 0.19 to 0.16 MT/MT at MEE by feed preheating by using Distillery vapors

Nil 1581 687 6872 90.6 60.0

Reduction in Power norm from 345 to 278 KWH/MT in I Plant

22 186 1856 89.8 113.3

To reduce Coal norm from 0.2484 to 0.2439 MT/MT by Increasing the efficiency of 90TPH-2 boiler.

5253 2284 22841 248.8 45.0

Innovative Projects implemented

16

Waste Heat recovery

Process change by preheating the feed

Innovation by adopting new equipment

Pinch Analysis

Changing the current practices

Energy Conservation Through Innovation

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Project :- To reduce steam consumption in “G” Process from 11.44 to 10.69 MT/MT

Vent

R

e

b

o

i

l

e

r

Feed Line

Distillation

Column

Reflux Hot

Condenser

Cooling Water

Product

Steam

Condensate

Bottom Product

Newly installed HE

From

Feed

Tank

Feed Preheating

Norm Reduction by :-• Feed preheating in

distillation column using Bottom product stream

• Feed preheating in continuous Residue distillation column using Bottom product stream.

• Feed preheating in process recovery and Product column using Bottom product stream

Annualized Savings: Rs. 125 LacsInvestment: Rs 25 Lacs

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Project :- Reduction in Heat furnace losses by installing air preheater in Incinerator-2

S

T

A

C

K

Incinerator-2

Organic reffinate

Heating by Flash Steam

To Boiler

Condensate

Residue

Biogas

Flue Gas 250˚ C

Water InWaste Heat Recovery Chamber

Flue Gas 950˚ C

Solid Ash

Flue Gas 210˚ C

ID FanHot Air

Feed Air for Combustion

Steam Out

Steam for Atomization

Inside

Brick lining

in place of

casting

Air preheater

Installed

Fresh Air

Air preheater installed. Refractory changed & Chocked pipes replaced.


Project:- To reduce VC of Pyridine Derivative by steam, Power, HSD & Raffinate norm reduction.

R-4 & R-4A

Column

V-1 V-2

CondenserCondenser

Reboiler

Dry Vacuum

Pump

Installed in

place of

Steam Ejector

Product

Steam

@8.0Bar

Pressure

PSV

PRV 8.0

to 4.0Bar Steam

@4.0Bar

Pressure

Steam Condensate

Switching

of Hot oil

to Steam

Steam & Raffinate norms reduction by installation of dry vacuum pump in place of ejector.


From V-1 (2.5KL,MSGLR)

Dry Vacuum pump setup

Project:- To reduce the variable cost of FI Product by steam & Effluent Norms reduction & yield improvement

➢ Reduction of Raffinate & Steam by using dry vacuum pump in place of ejector.

➢ Product yield increased by applying high vacuum from dry vacuum pump, as product degrades at high temperature.


Project :- To reduce the Steam consumption from 1.326 to 1.248 MT/MT in “H” Product

To EQ. – 6A/B/C/D

Absorption Column

Wash Column

Inter Cooler

AA B

B

To be Replaced with higher capacity

From Chiller

Fresh Alcohol

Distillation Column

CWR

CWS

Distillation Feed Pump

Feed Pump

Existing PHE-3 and PHE -14 replaced with higher capacity Heat Exchanger. Steam saving of 9 TPD


Utilization of renewable energy sources

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Renewable Energy Generation and utilization

DISTILLERYPLANT

Spent Wash to Biogas Plant

ETHANOL & CO2

BIOGAS PLANT

RO PERMEATE

RO REJECT

RO

MULTI EFFECT EVAPORATOR

Recycled to Distillery

Recycled to Distillery

INCINERATORAC2O PLANT PYRIDINE PLANT

FINE INGREDIENTS

PLANT

Biogas to CONSUMERS

Effluent to RO

Biogas generation increased resulting in reduction of 4720 MT of Liquid fuel consumption.

Utilization of waste

Utilization of Waste material

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Liquid ResidueIncinerator

As Fuel

Steam

(95 MM KCal/Day)

Waste (Input) Energy (Output)

3CP/Pyridine Vent Gases

Thermal OxidizerSteam

(22 MM KCal/Day)

Distillery Spent Wash

Slop Fired BoilerSteam

(04 MM KCal/Day)

Bio – GasBio Gas

(11 MM KCal/Day)

Total 133 MMKCalenergy generated by utilizing waste as a

fuel to replaced 4485 MT of Liquid fuel

GHG Inventorisation

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In producing alcohol from Molasses the waste from Distillery is used to produce Biogas and also the concentrated RSW is used to produce medium pressure steam for process use thereby conserving conventional fuel and reduction in emission of green house gases.

Carbon Footprint of Jubilant

989

916

852

FY'15 FY'16 FY'17

GHG 1000 tCO2e

Carbon Footprint of Major Products

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11

12

13

14

15

16

17

18

19

Ethanol Route (tCO2)

Petro Route (tCO2)

GHG emission savings (tCO2)

tCO2

/tonn

e of 3

-cya

nopy

ridine

20% benefit

15.38

18.47 3.09

Saves ~3.25MT CO2 per tonne of Pyridine & Beta Picoline, by using ethanol instead of petro feedstock as a starting raw material

Saves ~3.09MT CO2 per tonne of 3-Cyano Pyridine, by using ethanol instead of petro feedstock as a starting raw material

Using products produced by Jubilant will help you to make your supply chain greener

*Estimation of Carbon foot print through Cradle-to-gate approach, adopted as per PAS 2050 & GHG protocols

Green Supply Chain System

Green supply chain Initiatives

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Started Mechanized unloading of Coal – use of Poklane machines.

Started major raw material movement by Rail instead of road – mechanized handling through REACH stacker.

Installed mass flow meters in FG dispatch loading points – elimination of manual handling & exposure to fumes.

Started handling hazardous chemicals (THF, DMF etc.) in tanks instead of drums - handling in closed loop.

Agreement with Cement Company & NHAI for disposal of Fly ash.

Enhanced material handling trolley size – more material is being shifted in the same trolley thus reducing the number of trips.

Reverse logistics initiated, empty tankers are used for transporting the other products.

Green supply chain Initiatives photographs

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Team work, Employee Involvement & Monitoring

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Energy Cell

Mr. Shailendra Arora

Chairman

Mr. Vimal Rai

Mr. Rajat MathurEnergy Audit/

Excellence Team

Mr. A Varshney

Mr. A Prabhakar

Operational Team

Mr. D K Binjola

Mr. S Chauhan

Engineering Team

Mr. A Jain

Mr. R Rastogi

Utility Team

Mr. Rajesh Sharma G

Mr. R A Mishra

Six Sigma Cell

Mr. Mukesh Mahbubani

Energy Cell & BE Co-ordinator

A systematic approach towards energy management is kept in place by creating an Energy management team consisting of Production head as a Chairman of the team and the organization is shown as below

Company Energy Scenario FY 17-18

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Type Energy (Mkcal)

Thermal (Coal) 1212105

Electrical 126047

Renewable 46183

Thermal (Liquid Fuel) 156451

Total 1220337

Strategic Process for Energy Excellence

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Daily Review : Daily report of production / energy of all plants, Review of norms - plan vsactual & Identify gaps & Analysis /corrective action by Energy cell/ Technical cell

Monthly Review : Plant performance review (PPR) with top management/EC/Six sigma, Review of Norms/Opportunity for improvement & Identify Energy improvement Project.

Business Excellence & Six Sigma: The team identifies major cost drivers and prepared Loss cost matrix. Based on identified gaps, continual improvement projects are executed.

Employee Participation @ TPM : System Titled SANAKLP is developed open for 100 % of the employee for communicating their suggestions.

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Review System…….. Utility deviation reportDaily Review / Date-15.07.18

S.no Parameter UOMBudget-Jun'18

Plan Actual Deviation

1AFBC boiler Steam Generation TPH 128 116 116

WHRB Steam Generation +SLOP TPH 29 18 27

1a Coal Norms MT/MT 0.244 0.244 0.244

1b Steam Losses % 3 3 2.8

1c Power KWH/MT 20 21.5 21.3 Due to High demand

2 Power Generation MW 20.42 16.4 17.14

2a Extraction TPH 107 86 99

2b Condensing TPH 30 22 22

3 Coal Price Rs/MT 4239 5765 5765

4a Steam - Variable cost Rs/MT 1291 1684 1680Gain due to low losses

4b Steam - Transfer cost Rs/MT 1365 1779 1775

5a Power - Variable cost Rs/KWH 3.58 4.40 4.39

5b Power - Transfer cost Rs/KWH 4.32 5.34 5.33

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Review System through QlikviewMonthly Review

Achieving the Target through the Monthly review

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S.No Initiative UOM Base line Target

1To reduce steam norm from 12.32 to 11.67 MT/MT in “G” product.

MT/MT 12.32 11.67

2Power norm reduction from 22.21 to 21.23 KWH/MT in 90 TPH-1 boiler PA- 2 nos. Fan; Motor - 75 KW

KWH/MT 22.21 21.23

Boiler Furnace

ID Fan

VFD

VFD

VFD

APH

PA Fan

ID Fan

Air box

Chimney

Energy Efficient system

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• A software “Smart Sense” is installed to monitor and analyze the equipment wise power consumption

Real time monitoring of power consumption

• A systematic energy conservation approach was adopted from design stage to ensure energy efficient devices are installed for energy intensive fans.

VFDs for Energy intensive Air fans in power plant

• An integrated system is designed for continuously monitoring of operating loads of drives of rotating equipment and ensure optimum loading of motors at their best efficiencies. The driven machine efficiencies are also monitored at regular intervals and ensured the machines operate at optimum efficiency if not replaced with correct size of machines.

Operation of drives at highest efficiency

• Adopting LED light fittings replacing conventional lightings and change of design specifications for future installations. Automatic lighting switching systems to utilize natural light. Replacement of roof sheets to translucent sheets to avoid day time energy consumption.

Energy conservation in Lighting

• Solar lights are to be installed in Shahbazpur for lighting and camera

Solar Power

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Screen Shot- SMART SENSE

Take“Sankalp” Make “Shop Floors dry” – Campaign : 2017-18

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Leakages.

Pump, Pipelines, Tanks, Vessels, Containers etc.

Chemicals, Water, Steam, Oil etc

Spillage

(Modify Material loading and unloading areas, Sample points, Improve Material transfer etc)

Steam Loss

(Condensate arresting / Traps modification / Elimination etc)

Water Loss

(Traps modification / Drains or line modification, Condensate, Chilled Water, DM Water etc)

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The company encourages efforts of teams and individuals who excelled in achieving energy conservation besides others, such as STAR OF THE MONTH, OUT STANDING TEAM AWARD and annually there are awards from Corporate for outstanding achievers.

Reward & Recognition

Implementation of ISO 50001/Green Co/IGBC rating

Certifications & Accreditations

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RC-14001:2013 (Responsible Care)

American Chemistry Council.

NABL for Quality Control Laboratory

Certified by Kosher (STAR-K KOSHER CERTIFICATION)

Certified by ISO 22000:2005 (Food Safety System)

Certified by ISO 9001:2015, ISO 14001:2015(Quality & Environment System)

Certified by BS OHSAS 18001:2007 (Occupational health Safety System)

Certified by HALAL (HALAL Certification Authority)

GMP approval from Indian FDA

ISO 50001 certification under progress, Stage-2 Audit completed.

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Jubilant –Policies

47

Jubilant –Certificates

ISO 9001:2015 ISO 14001:2015 OHSAS 18001:2007 RC 14001:2013 & ISO 14001:2004

Reduction of Energy Through Environment Project-Effluent norms

Plant Initiative Description Rs Lacs

EthanolEffluent norm reduction in Ethanol from 9.62 to 9.5 M3/KBL (by increasing Ethanol content)

791

Fine Chemicals

To Reduce the Inorganic Raffinate Norms from 0.020 to 0.012 Kl/Kg in fine chemical product A

25

Fine Chemicals

To Reduce the Organic Raffinate Norms from 525KL/Month to 275KL/Month in finechemical plant-1

68

Pyridine derivative I

To Reduce the Organic Raffinate Norms from 6.13 to 3.13 Lt/Kg in Pyridine derivative I & from 2.745 Lt/Kg to 2.53 Lt/Kg in Pyridine derivative II

15

Total Saving (Rs Lacs) 899

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Summary at a Glance

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Tree Plantation at various places

Any other relevant information

Year Category Award

2015 Green tech Award“Environment Green tech Award” by Green tech foundation India .Award was presented at Kolkata.

2015 FICCI AwardsNational Quality Award in Large Scale Industries for Quality Systems Excellence Awards for Manufacturing by FICCI

2015Environment Green tech Award

Gold Category winner in “ Chemicals sector “ for our continuous efforts towards environment improvement initiatives .

2016Excellent energy efficient unit

National Award for Excellence in Energy Award by CII

2016FICCI Chemicals & Petrochemicals Awards

Sustainability Award for “Best Green Process” in “Chemical sector”: FICCI Chemicals & Petrochemicals Awards, 2016 on 1st Sep’16.

2016 ICC certificateAwarded ICC certificate of merit for the continuous efforts of “water resources management in chemical industries “. ICC Awards for the year 2015.

2017 FICCI Award Awarded FICCI chemical award in Efficiency in Energy usage (Chemicals)

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Award and Felicitation

Shailendra Arora · 2018-09-13 · Mr. Shailendra Arora Chairman Mr. Vimal Rai Mr. Rajat Mathur...

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