Coromandel Visakhapatnam At a Glance -...

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Coromandel – Visakhapatnam – At a Glance

Commissioned in 1967

1.0 / 0.185 / 0.6 / 0.025 MMTPA Complex

Fertiliser / Phos Acid / Sulf Acid /

Speciality Nutrients Plants respectively

5 MW Turbo Generator from Waste Steam

20 LIGPD Max Water from Tatipudi &

Meghadrigedda Reservoirs

Connected Load 14.3 MVA

Energy cost 2.19% of Mfg Cost

Turnover 2496 Crore Rupees 2016-17

Employees incl Contract Tech – 1567

Brand – Gromor

An ISO9001, ISO 14001 & OHSAS 18001 Certified & PSMS Compliant Company

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Manufacturing Process

Sulphuric acid Plant – I

DCDA Process - 1400 MTPD

Sulphuric acid Plant – II

DCDA Process - 300 MTPD

Sulphur SulphurWater Air Water Air

Sulphuric Acid

Phosphoric acid Plant

Dihydrate Process - 600 MTPD

Water

Rock

Phosphate

By Product Gypsum

Evaporation

& Fluorine Recovery

NP/NPK

Preneutraliser & Pipe

Reactor Process

Granulation Plant

1050 MTPD x 2

1800 MTPD X 1

By Product

Hydrofluorosilicic

Acid

28-28-0

14-35-14

10-26-26

18-46-0

28% P2O5 Acid

48% P2O5 Acid

20-20-0-13

Products

Steam

Steam

Steam

Ammonia

Urea

Potash

24-24-0-8SBought out Sulf Acid

Auxillary Boiler

48 MTPH

LSHS

Diesel Generators

2 nos x 4 MW

1 nos X 6 MW

LSHS

Turbo Generator

1 nos X 5 MW

Bought out Phos Acid 20-20-0-13S


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Major Energy Saving Measures Implemented-2014-15

S. No Title of Project

Annual

Electrical

Saving (kWh)

Annual

Electrical

Cost Saving

(Rs million)

Investment

Made (Rs

million)

Payback

(Months)

1Modernization of 11 KV

Circuit Breakers243769 1.19 12.5 126

2

Optimization of

Mechanical design of

Plate Heat Exchanger -

Sulphuric acid Plant - I

258467 1.27 8 76

3

Optimisation of Thermal

Design of Turbo

Generator Surface

Condenser

2142857 10.5 37.25 43

4

Deployment of Low

pressure steam

Extraction from Turbo

Generator

106931 0.52 0.01 0


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Major Energy Saving Measures Implemented 2015-16

S.No Title of Project

Annual

Electrical

Saving

(kWh)

Annual

Savings

(million

INR)

Investment

(million

INR)

Payback

(Months)

1 LED Retrofit of HPSV Street Lighting 91265 0.49 3.11 76

2Installation of Variable Frequency

Drives on variable power loads119516 0.64 1.4 26

3Conversion of Mercury Vapor Lamps

to Metal Halide Lamps297292 1.60 8.78 66

4

Reducing precooling time by design

change in Ammonia pre-cooling

pipeline (5.2km) from wharf to AAST

17600 0.09 10.58 -

5

Separation of variable and

common lighting loads in

Bagging Plant

35186 0.19 0.1 6

6Replacement of old rewound motors

by modern energy efficient motors150912 0.81 6.7 99

7

Stoppage of Building air-

conditioning power loads during

night time in winter season

70000 0.38 0.01 1


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Annual

Electrical

Saving

(kWh)

Annual

Savings

(million

INR)

Investment

(million

INR)

Payback

(Months)

8

Power Tie up with Rain CII Carbon

(Vizag) Ltd for avoiding high cost

fuel oil fired diesel generator power

0 0.51 0.05 1

9Renewable Energy Power Tie up

with Sagar Power Limited0 1.19 0.05 1

10Optimization of HP steam

consumption in Dryer of C Train1838994 9.90 0.1 1

11Integrated pumping system for

effluent recovery in AB Trains72000 0.39 0.2 6

12

Independent pumping system,

for effluent recovery in

Phosphoric acid plant

24143 0.13 0.1 9

13Combining multiple Conveyors

in Bagging Plant29700 0.16 0.1 8

14Reduction of Instrument Air piping

system pressure drop127334 0.69 0.2 4


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Annual

Electrical

Saving

(kWh)

Annual

Savings

(million

INR)

Investment

(million

INR)

Payback

(Months)

1Higher Capacity SAP Economizer

System4942000 26.1 89 41

2

Reducing the catalyst striking

temperature at 410 deg C in SAP1853250 9.6 - -

3

Reducing ETP Operations in

Acid Plant by implementing best

water balancing practices

113933 0.60 0 -

4

Installing sieve tray condenser

in PAP evaporation section

thereby stopping a 75KW

vacuum pump

483883 2.08 0.5 3

5Installation of New Turbo

Generator Stator60922 0.32 34.2 -

6Installed Steam Driven Ejector

for Open pit dewatering1980 0.01 0.005 6



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Major Energy Saving Measures Committed

S No Title of Project Year Status

1 Higher Capacity SAP – I Economiser System 2016-2017 Implemented

2 Installation of New Turbo Generator Stator 2016-2017 Implemented

3 Installed Steam Driven Ejector for Open pit dewatering 2016-2017 Implemented

S No Title of Project Year

Annual

Electrical

Saving

kWh

Annual

Thermal

Saving

million kcal

Status

1 Sieve Tray Condenser 2017-18 540000 Implemented

2

Supply Chain – Install 30000 MT

Rock Phosphate storage godown &

avoid diesel fuel oil consumption due

to multiple handling

2017-18 1078Under

construction

3

Supply Chain – Deploy 28 MT

capacity trucks replacing 17 MT

trucks for Sulphuric acid transport &

avoid diesel consumption due to

multiple handling

2017-18 458 Implemented

4 Install Variable frequency drive 2017-18 23900 1078Under

proposal

5 Modernised lighting 2017-18 332412 In progress


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Road map for energy conservationParameters 2017-18 2018-19 2019-20

Capacity utilisation

100% 105% 110%

Widen base raw material

Establish usage of alternative raw materials

Maximise production run with alternative raw materials

Sustain the improvements

Minimize Unplanned downtime

17% 15% 14%

Encon projects

1) Install sieve tray condenser

2) Install variable frequency drives

3) Supply chain - Install 30000 MT Raw material godown & avoid material handling diesel costs due to multiple handling

4) Supply chain - Deployment of higher capacity trucks for Sulfuric acid transportation

5) Modernise lighting

1) Conversion to energy efficient lighting

2) Replace age old motors by energy efficient motors

3) Install Sulf acid tanks at wharf & transfer via pipeline thereby avoid material handling diesel costs

Incorporate energy efficient plant layout in plant expansion

Monitoring & Reporting

Blueprint of automation

Energy Consumption tracking via INSIS

Centralization of process plant control monitoring & reporting through DCS

Sustain the improvement


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% Capacity Utilisation

0%

50%

100%

150%

% U

tilisati

on

% Cap Utilisation 82% 88% 90% 88% 100% 105% 110%

Capacity 100% 100% 100% 100% 100% 100% 100%

2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

% Rock Phosphate utilisation

0%

20%

40%

60%

80%%

Uti

lisati

on

Hi grade 54% 60% 67% 51% 36% 35% 35%

Low grade 46% 40% 33% 49% 64% 65% 65%

2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Machine Downtime % Breakdown

0%

10%

20%

30%

40%

% D

ow

nti

me

% Unplanned BD 29% 19% 19% 17% 17% 15% 14%

2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Roadmap on Strategy

• Reduce unplanned stoppages by improving equipment reliability

• Under Long Term Strategy, we operate various sources of rock phosphates (Low & medium grades)


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Excellence in Energy ManagementParameters

2013 -2014

2014 -2015

2015 -2016

2016 -2017

Annual Electrical Energy Consumption million kWh 85 86 93 90

Annual Cost of Electricity Consumed million INR 336 406 393 379

Annual Consumption of Fuel LSHS Metric Ton 501 426 452 484

Annual Consumption of Fuel Light Diesel Oil Kilo Litres 1.5 2.3

Annual Consumption of Kerosene oil (SKO) Kilo Litres 86 71 87 54

Annual Total Cost of Fuel million INR 31 24 19 18

Thermal Energy Consumption million kcal / Year 5716 4840 5217 5250

Production MT 862795 921592 949236 925056

Specific Electrical Energy Consumption , kWh / Ton of production 99.00 93.08 97.72 97.0

Specific Thermal Energy Consumption, kJ / kg of Production 27.74 21.99 23.01 23.76

13

13.5

14

14.5

15

15.5

16

16.5

Sp Power Consumption, KWh / MT - SAP - I

KWh/MT 16.1 14.2 14.3

2014-15 2015-16 2016-1770

75

80

85

90

95

Sp Power Consumption, KWh / MT - Evap acid

KWh/MT 92.6 88.2 80.3

2014-15 2015-16 2016-1735

35.5

36

36.5

37

37.5

Sp Power Consumption, KWh / MT - Complex

KWh/MT 37.1 36.7 35.8

2014-15 2015-16 2016-17



Unit wise Power consumption & Operation trends

Imported Vs Evap Acid, MT

20000

40000

60000

80000

100000

0%

10%

20%

30%

40%

Evap Acid 59975 53131 73011 80134

Imported 55754 79820 58908 56655

% Imported 27% 35% 26% 26%

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

% Consumption on overall Power consumed

SAP-1, 8%SAP-2, 8%

PAP, 37%

Complex A,

15%

Complex B,

13%

Complex C,

19%

• PAP (Phosphoric Acid Plant contributes 37% on the total power consumption

• Captive generation of Acid increasing against reducing imports which consumes additional power



Energy Benchmarking- Detailed Roadmap

Parameter BenchmarkActuals 2016-

17Action Plan Target

Phosphoric acid (kWh/MT P2O5)

150 161

Improve the evaporation efficiency by 6th

Evaporator2017-18

Capacity enhancement of PA Plant thereby improve the SEC

2019-20

Complex (kWh/MT) 32 36

Increase Capacity utilisation of Complex A & B train by 30%

2017-18

Overall Unit (kWh/MT Complex) 93 97.4

Maximising capacity utilisation & improve onstream hours of all units

2017-18

As we are an integrated manufacturing facility, Plant units’ capacity, products vary from industry to industry hence benchmark not comparable with other manufacturing units



Bench Marking for energy Spec



Innovation Project- SAP Economizer system

Brief Description: Replacement of old economizers by higher capacity economizers, cooling Inter Absorption tower inlet gases up to 165 degC from earlier 200 degC.

Type of Innovation – New concept

(risks taken/self driven/beyond OEM)

New EconomizersOld Economizers

Increased surface area & Duct redesigning

Trend of Gas Temperature before & after modification

0

50

100

150

200

250

300

6.Feb 12.Feb 18.Feb 24.Feb 6.May 12.May18.May24.MayBefore & After SD

Gas T

em

pera

ture

Inlet temperature

Outlet TemperatureBefore After

Trend of Gas Temperature before & after modification

0.0

100.0

200.0

300.0

400.0

500.0

6.Feb 12.Feb 18.Feb 24.Feb 6.May 12.May18.May24.May

Before & After SD

Gas T

em

pera

ture

Eco II inlet

Outlet Temperature

BeforeAfter

SAP-1 Economizer-1 SAP-1 Economizer-2



Cost Benefit Analysis:

Specific Steam Generation

1.04

1.08

1.18

1.21

1.171.19 1.19

1.20

0.95

1.00

1.05

1.10

1.15

1.20

1.25

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

MT st

eam

/MT

of H

2SO4

SAP 1

SAP 2

Benefits:

• Additional Turbo Power generation

from additional steam generated

• Reduction in heat lost to cooling

tower & water makeup

• Acid coolers cooling water outlet

temperature limited to 50oC max

minimizing water side scaling

InvestmentRs. 891 Lakhs INR

Annual Power saving 4941603 KWH

Annual savingsRs. 261 Lakhs INR

Pay Back 41 Months

Innovation Project- SAP Economizer system



Weak

washReturn

acid

Product

TankProductWASH

TANK

WASH

WATER

ETP Operations

Spillages &

waste water

Clean water

separation via

sumps

Separation of low quality

water in ETP storage

&treat

Reuse back to

the Process

Shutdown water

due to non-

operations

Innovation Project- ETP Operations Optimization




Type of Innovation : Elimination/Substitution of an activity by making

changes in the process

Brief Description: Effluent Treatment Plant (ETP) operates with the

effluent generated from the process, during maintenance, scrubbing &

breakdowns.

The treated water is taken back to the process

Break through Innovation:

The generation of effluent was identified to be inversely proportional

to the operating hours of the plant. Also at higher utilization of the plant,

system requires more water due to the process conditions.

Operations team brainstormed & worked on this phenomena &

analyzed the complete water balance of the process, arrived at conclusions

on reducing the power consumption from ETP sector by reducing its

operating hours.




Steps taken:

1. Consistent operation of plant above

85% of the max load always

2. Segregation of effluent based on its

impurities

3. Reuse into the process as per the

quality of water

Benefits:

1. Lesser operation of ETP plant thereby saving power (as illustrated

above)

2. Reduced water consumption due to reuse of the process water



Innovation Project- Evaporator operations

Type of Innovation – Elimination/Substitution of an activity by making

changes in the process

Brief Description of Process: Strong Phosphoric acid is produced from

the Evaporators by evaporating the water from the weak phosphoric acid

produced from the process & enriching its concentration from 26% to 48%

levels. Evaporation is by process of heat through Heat exchangers &

steam under Vacuum

Break through Innovation:

The overall power consumption of the unit PMT of complex was

identified to be increasing based on captive generation of Phosphoric acid

(Strong Acid). Team was focusing on reducing the power consumption

from the Evaporator sector by either increasing the throughput or by

reducing the operation of equipment or both.

Benchmarking was one of the tool used to identify the gap where

team worked on reducing the power consumed in the vacuum section by

redesigning the vacuum pump to Sieve tray condensor model.



Innovation Project- Evaporator operations

Description of Change– Earlier the

vacuum pump (75 KW motor driven) was

used to apply vacuum in the condenser.

Instead of normal open condenser, sieve

tray has been installed in the condenser to

give additional surface area for the vapors

to condense.

Benefits:

Elimination of one vacuum pump thereby

reducing the energy consumption by 5.4

Lakh KWhr

Investment:

Negligible(as in-house fabricated sieve tray

installed)

Cold

Well

HOTWELL

1 2

Vacuum

Pump-

600mm

Hg Abs

3

Cold

Well

HOTWELL

1 2

Strong

Acid

Strong

Acid

No

Vacuum

Pump-

600mm

Hg Abs

3

BEFORE

AFTER

1. Flash Chamber

2. Heat Exchanger

3. Condensor

4. Condensor

5. Sieve Tray Condensor



Carbon Emission Reductions

Scope Emission Sources Considered

Scope 1 Emissions

LSHS Fuel of for process heating, Diesel for Power Generation, Kerosene oil for furnace firing, Diesel for company owned internal transport & LPG for Ammonia

Tank flare stack

Scope 2 Emissions

Bought out Electrical Power

Scope 3 Emissions

Employees commuting and Business travel

Year Scope 1

emissions

Scope 2

emissions

Scope 3

emissions

Total % Reduction in

emission

CO2e (MT) CO2e (MT) CO2e (MT) CO2e

MT *

intensity since

baseline year

study

2013-14 2287 51777 3177 57241 Baseline year

2014-15 1870 58571 3177 63618 -11.14%

2015-16 1902 54991 3177 60070 -4.94%

2016-17 1915 51494 3221 56630 1.07%



Efficiency Improvement & GHG reduction

Rock Efficiency & Rock / MT P2O5

93%

94%

94%

95%

95%

3.05

3.1

3.15

3.2

3.25

3.3

Rock Efficiency 93.63% 94.74% 94.60%

Rock / MT P2O5 3.26 3.17 3.15

2014-15 2015-16 2016-17

Complex P2O5 Efficiency & P2O5 Bought out

reduction / MT P2O5

97%

97%

98%

98%

99%

99%

1

1.01

1.02

1.03

1.04

P2O5 Efficiency 97.25% 97.37% 98.60%

P2O5 / MT P2O5 1.03 1.03 1.01

2014-15 2015-16 2016-17

Phosphoric Acid Plant:

Improved efficiency of the process

thereby reducing the raw materials

purchased & the carbon footprint

Complex Plant:

Improved efficiency of the process

thereby reducing the raw materials

purchased & the carbon footprint


Corporate level Mfg. Plant LevelMCM Review | Operational Review BEST | Core Committee | Process

Facilitation, Resource, R&R Deployment, R&R, Cutomization

23

5S Visual Factory – Management by walk around

IdeaTap creative potential of employees

kaizenSimple why-why Analysis

SGAProblem solving - 7QC Tools

LSSLean & SQC Tools

InnovationEntrepreneurship

Focus AreasCommunication

Outcomes of

• Internal

Performance

levels

• Operational

Imperatives

• Market

Feedbacks

• Sense of

purpose visit

• Service Level

Agreements

Total Employee Involvement (TEI)

Employee Empowerment : Structural | Informational | Knowledge

Training | Hands-on exp. | OPLs | TQM – How to Guide | Best Practices sharing platforms

Mgmt .

Review

Breakthrough

Incremental

Small

Continual Improvement

in PQDCSM

Continual Improvement

TQM FrameworkBuilding Culture of Excellence

“Company-wide integrated & quantitative continual improvement of processes, products and services with total empowered employee involvement and aiming at stakeholders’ delight to help improve business results”


Employee Involvement

85%

90%

95%

100%

Employee Involvement

Overall 93.78% 100.00% 100.00%

NM 90.40% 100% 100%

Target 100% 100% 100%

2014-15 2015-16 2016-17

82%

84%

86%

88%

90%

92%

%TQM Score Card Achieved

Actual 87.40% 89.20% 90.30%

Target 85% 85% 85%

2014-15 2015-16 2016-17

0

100

200

300

400

TQM Projects Implemented

SGA & Six Sigma 15 18 20

Kaizen 300 305 310

Ideas 61 56 50

2014-15 2015-16 2016-17

0%

1000%

2000%

3000%

4000%

Energy Related Projects

No of Projects 25 30 40

2014-15 2015-16 2016-17



Employee InvolvementDescription Project - 1 Project - 2 Project - 3 Project - 4 Project - 5

Source of En-Con Idea Workmen Engineer Middle Management Senior Management Top Management

Name of the Project

Stoppage of Building airconditioning power loads during night time in winter season

Installation of Variable Frequency Drives on variable power loads

Install Sieve Tray Condenser

Power Tie up with Sagar Power Ltd for renewable Hydro power for avoiding high cost fuel oil fired diesel generator power

Installation of Higher Capacity Economiser

Idea Originated in Year 2015 2015 2016 2015 2015

Whether Idea

ImplementedYes Yes Yes Yes Yes

Details of Members in

the Implementation

Team / Core Group

(Nos, & Designation)

Small Group consisting of Plant Technicians - 5 Members

Small Group consisting of Managers, Supervisors and Plant Technicians - 5 Members

5 member team comprising Sr Manager Tech Services, Manager Operations, Manager Maintenance & Technicians

5 member P & I Team comprising GM - P& I, DGM Finance, Manager - Power, DGM - Legal

5 member Senior Management Team comprising Unit Head, AVP, Sr GM P & I, Asst GM Projects & Sr Mgr Tech Services

Expected or Actual

Date of ImplementationApr-2015 Apr-2015 Mar-2017 Apr-2015 Apr-2016

Constraints

encountered during

implementation of idea

Locations of equipment far & wide. Regular visit during night times for checking requirement of air conditioning very low

Replacement requires shutdown of plant

Lack of knowledge on working of Sieve Tray Condenser

Lack of Knowledge on Trade terms to plant teams

Allocation of funds, Lack of techno commercial talent in implementation team

Methodology adopted

to overcome the

constraints

Routine checks on individual equipment performance being practiced

Replaced during planned shutdown

Sharing of Literature

Technical & Legal team Inter department Knowledge sharing

Estimation of replacement, Knowledge sharing, Selection of experienced fabricator



Team workOPERATIONS IMPROVEMENT TEAM

Managing

Director

Executive Vice President &

Head - Manufacturing

Vice President -

Manufacturing

Sr Manager

Tech Services

Associate Vice President

Operations

Sr GM

EngineeringSr GM – Power,

Inst. & Projects

Asst GM Safety

& Environment

Section Heads

Process Plants &

Facilities

Section Heads

Engineering Units

Dy GM – Process

Plant Operations

Dy GM –Bagging &

product handlingGM –E & I

DGM / AGM –

Mech Maintenance



Employee Team work Monitoring & Reporting format

TQM Score Card 2016-17 as on Mar-17 end

S No.Simpli5

MeasureTarge

tWeight

age Actual ScoreWeighted

Score

15S external audit score (Target: score of lowest scoring zone)

Score (1K points)

600 5 620 100 5

Klic 15

1 Kaizens implemented No./Emp 1 9 0.54 54 5

Sparks 15

1 Overall Ideas implemented in a yearNo./NM Emp

0.5 2 0.14 28 1

2 No Of Ideas received No./Emp 3 2 3.05 100 2

Small Group Activity 10

1No. of projects completed before Dec-16 No.

15 6 15 100 6

2 Avg cycle time of projects completion Months 6 2 6.00 100 2

Six Sigma

1 No. of projects completed by Mar 2016 No. 5 5 5 100 5

Take One

1 One Point learning Implemented No / Emp 1.5 7 1.51 100 7

Overall

Employee Involvement % 100 8 100 100 8

Reward & Recognition % 40 8 41.12 100 8

Employee given training % 90 6 90.25 100 6

Others 45

Total Score 100 90.3



Management Certifications

Management system Certification Valid Up to

Environmental Management system

ISO 14001:2004 28/Jul/2018

Occupation Health & Safety

OHSAS 18001:2007 28/Jul/2018

Quality Management System

ISO 9001:2008 28/Jul/2018

Process Safety Management

Process Safety Management System

Level 4 / 4

Training ISO 10015+:1999

We have initiated implementation of ISO 50001 in 2017-18



Investment in Encon

2014-15 2015-16 2016-17

Investment in Encon Rs Crore

6 4 12

Turnover Rs Crore 2759 2871 2496

% Investment for Encon on Turnover

0.20% 0.13% 0.49%

Savings Rs Million 14 18 26

0

5

10

15

20

25

30

Encon Savings Rs Million

Savings Rs Million 14 18 26

2014-15 2015-16 2016-17

0

2

4

6

8

10

12

Encon Investment Rs Million

Investment Rs

Million

6 4 12

2014-15 2015-16 2016-17

0.00%

0.10%

0.20%

0.30%

0.40%

0.50%

% Investment for Encon on Turnover

% Investment on

Turnover

0.20% 0.13% 0.49%

2014-15 2015-16 2016-17



Energy Monitoring & ReportingHourly Monthly

Online Plant DCS & SCADA Report Monthly Plant Performance Report

By Engineers & Managers of Operations & Technical Services

By Top Management

Power variable cost – Rs 5.29/kWh; Fuel – Rs 3003/million kcal



Energy Monitoring - Steam / Condensate Balance

All figure in MT/HR

Air Blower

Turbine37

4 Vent

1

27 15

30 0.5 0.5 0 9.5 2 HP to LP 0.5

make up

5 MW

Turbo

Generator Vent

37 30 0 9.5 0 1

0.5 0.5 0.5 1 25 0.5

6 0.5 0.75 0.75

21 21 77 0.75 0.75

Process / Losses 1

Condensate Header

SAP-I WHB

HP generation

68 MT

HP steam Header 32 ata ,350 0 C

Melters &

jacketing

SAP-II WHB

HP generation

15 MT

DM Water

Make up

LP steam Header 3.0 ata , Saturated

Sulphuric Acid Plants- Waste Heat Steam Generation Units

Water Soluble

Fertiliser Plant

Dearator

Fuel Oil

Heater&

Tracing

Vapour

Absorption

Refrigiration

AAST

Ammonia

Heater

Granulation

Plant

Air Preheaters

Sulphur

Bentonite

Plant

Complex Plant

Sparging /

Flushing

Bagging

Air

Handling

CafeteriaWork

shop

Turbo Power

Generation

Complex

Sulphur Pit

Insulation &

Trap Losses

Evaporated

Phos acid

Complex

dedusting



Encon Implementation Methodology

Mapping Energy

Consumption

External Energy Audits

Best Practices / Benchmarks

New Technologies

Training

Targets

Achieved

Daily review by HoD’s & Unit

Head & through Daily Prodn

report & Daily Energy Balance

Monthly review by Executive

Vice President & MD through

conversion cost report

No

Identify Thermal &

Power Energy Losses

Formulation of Encon

Projects

Prioritisation of Encon

Projects

Implementation

Check & Reviews

Reward & Recognition

Horizontal Deployment

Updation of Knowledge Management Portal

Training

Yes



Environment - Renewable Energy Utilisation

Renewable energy certificates purchase:

Solar – 0.25% of purchased power

Non Solar – 4.75% of purchased power

Renewable Energy Tie-up: Coromandel International Ltd entering into a renewable

energy tie up for around 20 Lakh KWH per annum with Mini Hydel Plant for

meeting its renewable energy obligations

Replacement of

Electrical Energy with

Renewable Energy

Installed

Capacity

Annual

Energy

Generated in

2014-15

%

Share

Annual

Energy

Generate

d in 2015-

16

%

Share

Annual

Energy

Generate

d in

2016-17

%

Share

(Million kWh) (Million

kWh)

(Million

kWh)

Solar Photovoltaic (PV) 0 34000 0.04% 40000 0.04% 39006 0.04%

Small Hydro Plant 0 0 0 871179 0.94% 116802 0.13%

Others 0 641000 0.75% 0 0.00% 606263 0.68%



Raising Public awareness

Showing consumers the many ways to conserve energy & water and congratulates them on their energy &

water saving efforts

Reporting to all consumers budgeted and actual monthly / periodic specific energy & water consumptions

Encouraging all plant workmen in generating ideas for energy & water conservation and providing

necessary human and financial resources for effective implementation

An idea mela is conducted once in a year and all plant personnel are encouraged to put up their water and

energy conservation ideas.

Sharing knowledge on need to conserve energy & water through handouts, booklets etc in plant,

residential colony and local community

6. Knowledge dissemination to all on a. Where our energy / water comes from; b. How we are utilizing

c. The value of energy & water; d. How much we actually need and how much has gone wasted

e. Necessity to conserve energy & water

World Environment Day Cycling Simhachalam to shirdi

spreading environment awarenesss

World Water day – Walkathon on the beach



Utilisation of waste heat-Turbo Power Generation

The heat from the Sulphur Gases after melting is recovered as steam energy, which is used for driving the turbine of SAP blower & Power generation in TG. The remaining steam is reused in process.

Various initiatives been taken to improve the TG performances on availability & full utilisation.

The graph shows significant reduction in the Power consumption from the GRID, contributed by the TG performance & Power

0

200

400

600

800

TG Vs GRID Power, Lakh kWh

TG 150 265 277

GRID 715 671 628

2014-15 2015-16 2016-17

55

60

65

70

75

Grid Power withdrawal trend

Grid Power

KWH/MT of

Complex

74 66 64

2014-15 2015-16 2016-17



Green Supply Chain Management

a.Projects

ImplementedProjects Evaluated

We take up green purchase initiatives in all dealings with vendors

1) Constructed Temporary sheds to store product & avoid plant stoppage

b.Supplier

EvaluationSuppliers evaluated based on

1) fuel efficiency of transport

2) Lowest cost

c.Benefits

AchievedBenefits Achieved

1) Lower cost of product

2) Lower specific energy consumption

3) Support to our industry from all stake holders

d. Replication Improvements achieved are replicated at all sister locations within the

business group



AccoladesAward Awarded By Year

SAFETY & ENVIRONMENT

“One of the Top 10 Greenest Companies in India” TERI & Business Today 2001

Safety, Health & Environment Performance Award CII - SR 2003, 2004

Environment Protection Award FAI 1996, 2009

5 Star Rating British Safety Council 1999, 2011

Safety Award National Safety Council 1998

WATER & ENERGY CONSERVATION

Excellence in Energy Conservation & Management CII 2000,2001,2002,2014,2015,2016,2017

Certificate of Merit BEE 2002-03, 2003-04, 2005-06 & 2006-07, 2011-12

Excellence in Energy Conservation NREDCAP – Govt of AP 2009-10,2011-12,2012-13

Excellence in Energy Conservation AP Productivity council 2006-07

Excellence in Water Management CII 2009-10, 2010-11, 2011-12

PRODUCTION

Best overall performance of Fertiliser Plant FAI 1994-95

Best Operating Phosphoric Acid Plant FAI 1994-95,1995-96,1996-97,1997-98,2000-

01,2001-02,2003-04,2004-05,2005-06,2006-

07,2009-10, 2011-12,2013-14,2014-15,2015-16

INDUSTRIAL RELATIONS

Best Management Award Labour Dept – AP Govt 2005, 2013, 2015,2016,2017



For further information please contact

[email protected]

Vice President - Manufacturing


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