8/8/2019 Energy Saving in Appolo
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1 ID: 97 Title of measure Sector:
2 Survey Year: 2006 Energy Efficient Temperature Control Technology: Control Systems
3 Name of the Company :
4 Agency that executed the project : In-house
5 Year of Implementation : 2005
6 Apollo Tyres Ltd., is a US$ 1.07 billion annual turnover company with its manufacturing plants atPerambra & Kalamassery in Kerala, Vadodara in Gujarat and Pune in Maharashtra. Apollo Tyres isengaged in production of Bias and Radial tyres for all types of vehicles.
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Tyre industry uses a large number of temperature control units (TCU's) for maintaining constanttemperature in its machinery. In the original system, tempered water at controlled temperature iscirculated through the machinery using a pump. This water is heated using steam and cooled usingcold water in heat exchanger as and when required, by using a single point pneumatic temperaturecontrol.
The plant has developed an innovative energy efficient temperature control unit, which incorporates acompact energy efficient TCU which uses electricity for heating and radiator for cooling. Since the unitis very small it can be placed very close to the machine saving in pumping energy and reducedradiation losses. Heating and cooling controls made through electronic controllers avoid the valvesand pneumatic systems making it accurate and energy efficient.
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9 Total investment per unit: 1,250 US$
10 First year energy cost savings: per unit 17,500 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh 63
13 Annual electricity consumption after, MWh 27
14 First year electricity savings, MWh 36
15 Annual oil consumption before, kl 30
16 Annual oil consumption after, kl 0
17 First year oil savings, kl 30
18 First year tons of CO mitigated 1262
19 Assumed sustainability, years 10
20 Expected tons of CO mitigated throughout life cycle 1,2602
Tyre Industry
Apollo Tyres Ltd., Kerala, INDIA
Unit Profile:
Description of Energy Conservation Measure:-
Picture Before Modification Picture After Modification
Pump
Load
Steam
Heat
Cold Water
Heat
Pump
Load
ElectricHeater
Radiator
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8/8/2019 Energy Saving in Appolo
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1 ID: 98 Title of measure Sector:
2 Survey Year: 2006 Plant Lighting Technology: Lighting System
3 Name of the Company :
4 Agency that executed the project : In-house
5 Year of Implementation : 2004
6Perambra plant is known as the mother plant of Apollo tyres Ltd., and was incorporated in 1975. Theproduct range of this plant includes bias tyres for trucks, light commercial vehicles, passenger cars,front & rear tyres for tractors and radial tyres for various farm sizes.
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The shop-floor was illuminated with 3500 Nos. of 40 watts twin tube lights (each consuming 106watts) with electromagnetic ballasts. This has been replaced with
1) 1500 twin tube sets with electronic ballast and T8 tube lights (each consuming 80 watts) andaluminum reflectors.
2) 1800 single tube sets of 28 W T5 lamps with electronic ballast (each consuming 28 watts).
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3500 tube light set with 2X40 watts T13 lamps 1500 nos of 2X40 watts T8 tube lightswith electromagnetic ballasts with electronic ballasts
1800 nos of 28 W, T5 tube lights
9 Total investment: 62,500 US$
10 First year energy cost savings: 147,500 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh 3,200
13 Annual electricity consumption after, MWh 1,500
14 First year electricity savings, MWh 1,700
15 First year tons of CO mitigated 1,7002
16 Assumed sustainability, years 3
17 Expected tons of CO mitigated throughout life cycle 5,1002
Tyre Industry
Apollo Tyres Ltd., Perambra, Kerala, INDIA
Unit Profile:
Description of Energy Conservation Measure:-
Picture Before Modification Picture After Modification
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1 ID: 99 Title of measure Sector:
2 Survey Year: 2006 Replacement of reciprocating Technology: Chillers
compressors with screw compressor
in chillers
3 Name of the Company :
4 Agency that executed the project : In-house
5 Year of Implementation : 2005
6Perambra plant is known as the mother plant of Apollo tyres Ltd., and was incorporated in 1975. Theproduct range of this plant includes bias tyres for trucks, light commercial vehicles, passenger cars,
front & rear tyres for tractors and radial tyres for various farm sizes.
7 Chilled water at a temperature of 14 degrees Celsius was used in the process of tyre production4Nos. of 120 ton reciprocating compressor chillers were installed in 1990 and had an efficiency of 0.8 kWh/ton of refrigeration. This has been replaced with 2 Nos. of 215 ton screw type chillers withan efficiency of 0.45 kWh/tons of refrigeration.
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9 Total investment: 125,000 US$
10 First year energy cost savings: 78,750 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual electricity consumption before, MWh 2,800
13 Annual electricity consumption after, MWh 1,900
14 First year electricity savings, MWh 900
15 First year tons of CO mitigated 9002
16 Assumed sustainability, years 10
17 Expected tons of CO mitigated throughout life cycle 9,0002
Tyre Industry
Apollo Tyres Ltd., Perambr, Kerala, INDIA
Unit Profile:
Description of Energy Conservation Measure:-
Apollo Tyres Limited Picture After Modification
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screw compressor chillers
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1 ID: 100 Title of measure Sector:
2 Survey Year: 2007 Optimization of Energy on Technology: Cooling Towers
Cooling towers
3 Name of the Company :
4 Agency that executed the project : In-house
5 Year of Implementation : 2006-07
6J K Tyre & Industry Ltd. (Formerly known as J K Industries Limited), is the flagship company under theumbrella of JK Organization. J K Tyre manufactures entire range of tyres for all four-wheeler vehiclesbeing manufactured in India. J K Tyres have pioneered Radial tyre technology in India in 1977 and stillhas largest market share. J KTyre has largest share of business with Maruti and Tata Motors, the
largest vehicle manufacturers in India.J K Tyre also provides compete range of technical services for tyre care. The annual turnover of theunit for the year 2006-07 is US$ 0.25 billion.
7 In tyre plants CT are used to remove process heat. In the original system, the unit 's two different plantssections in the same premises, were having separate cooling towers for catering to the processcooling demand. Both these CT's were under-utilized. The process heat was required to be removedat particular pressure & flow.
This is an innovative idea of the in-house team to optimize the plants energy consumption. In thisregard, pressure of one of cooling tower water was measured near another plant. Based upon study,one inline pump was incorporated to increase the pumps pressure, so that same cooling tower could also
cater another plants. This measure resulted in elimination of cooling towers.
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9 Total investment: 2,500 US$
10 First year energy cost savings: 162,910 US$
11 First year additional savings beyond energy (i.e. water, raw materials etc.): Nil
12 Annual energy consumption before, MWh 3,411
13 Annual energy consumption after, MWh 1,899
14 First year electricity savings, MWh 1,51215 First year tons of CO mitigated 1,5122
16 Assumed sustainability, years 10
17 Expected tons of CO mitigated throughout life cycle 15,1202
Tyre Industry
M/s J K Tyre & Industry Ltd., Rajasthan, INDIA
Unit Profile:
Description of Energy Conservation Measure:-
Picture/ sketch/ drawing Before Modification Picture/ sketch/ drawing After Modification
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