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Best Energy Efficient Case Study

Indo Count Industries Ltd


Team Leader : Mr.S.K.Mohanty (Senior VP Operations),
Team Member : Mr.Gurpal Singh ( Head Utility & Engg)

Email : smohanty@indocount.com, gsingh@indocount.com


2nd CII National Energy Efficiency Circle Competition 1
About the Organisation
At Indo Count we are driven by a culture of continuous Innovation and Sustainability across
value chain towards common goal of excellence. Indo Count is recognized as one of India’s
fastest growing companies.

We are specialists, not generalists, and have chosen to only work towards creating the best sleep
experience imaginable products. Indo Count has acquired multiple brands, patents and
trademarks across the globe spreading its horizons in all directions.

Within a short span of time Indo Count ‘s presence in International market has risen successfully
to new heights. We export to almost 54 Countries spread across 6 Continents with interests in -
Sheet Sets, Fashion Bedding, Utility Bedding, Institutional Bedding etc.

Indo Count is accredited with numerous awards in Sustainability, Compliances, Best Capability
etc viz - STeP (Sustainable Textile Processing by Hohenstein), Made In Green, LEED Green
Building US, OEKOTEX by Shirley Institute UK, GOTS (Organic Production) , SEDEX, BSCI, ISO
9001:2015, Texprocil - Highest Exporter Award and many more ++

• . 2nd CII National Energy Efficiency Circle Competition 2


Energy Mapping

Thermic Fluid Heat utilization

5
10 Finishing
Dying
15

Printing
70
Curing

2nd CII National Energy Efficiency Circle Competition 3


E Fibre Insulation on Thermic fluid line

E fibre (Hitlin) Insulation


Hitlin Insulation :- Density 200 kg/m3
Life :- 20 years
Low radiation loss

LRB(Light Resin Bonded) Rock wool Insulation


LRB Insulation :- Density 140 kg/m3
Life :- 4-5 years
High radiation loss after expiry of life

2nd CII National Energy Efficiency Circle Competition 4


Data collection
Parameter Old Rock Wool Insulation (Jun- E Glass Fiber Pipe Sections (Mar- Impact
2007) 2017)

Pipe Line Details 272 oC Thermic Fluid Line, 10” NB, 1420 meter Length ( Supply & return headers)
Thermal Insulation Rockwool 125 mm, 10 Years E Glass Fiber Pipe Sections 70 Surface Area Reduced by 21%
Old Installation mm
Surface Temperature Ambient + 35 oC Ambient + 15 oC Guaranteed, Improved Indoor Environment as No
on Insulation Ambient + 12 oC Actual Air Circulation Between Hot Pipe &
Insulation
Thermic Fluid 272 oC at Generation Point, 250 oC at Generation Point, At
Temperature At end of 750 Mtr – 245 oC end of 750 Mtr - 245 oC
Reduction in 27oC 5 oC Reduction in specific coal
Temperature Drop in consumption for Thermic Fluid from
Insulated Line 0.51 to 0.36 post insulation
replacement
Coal Consumption 30 to 32 MT/Day 23 to 25 MT/Day Saved 5-6 MT/day
Specific Coal 0.51 Kg/Kg Coal for Thermic 0.36 Kg/Kg Coal for Thermic Reduction of ~ 30% in Specific
Consumption Application Application Consumption
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Analysis and basic principal

Measure temperature difference


between Generation and User end as
well as Surface Temperature of Insulated
Lines.
Found huge difference than
recommended because of completion of
life cycle of LRB ( Light resin bonded
Insulation of Rock wooll
Proposed to re insulate the LRB
insulation with E Fibre (Hitlin) Insulation
of high density ( 200 Kg/m3) and more
compact and better life cycle as
compared to LRB (140 kg/m3). nd
2 CII National Energy Efficiency Circle Competition 6
Results Achieved
After replacement of insulation , the
temperature difbference between
Generation point and User End reduced to
5 degree as compared to 22 degree Earlier

Genernation set point reduced to


temperature 250 degree from 272 degree
centigrade and plant inlet 245 degree C
of Air Compressor by HOC Dryer. Saving of 850 KWH/Day
Resulting into fuel ( Imported Coal) saving
of 7 Tons / day

2nd CII National Energy Efficiency Circle Competition 7


• Uniqueness of the project
DESIGN PHASE INSTALLATION PHASE OPERATION PHASE DISPOSAL PHASE
• LOWER THICKNESS • EASY & SAFE INSTALLATION – EVEN • LONG LIFE OF MORE THAN 20 YEARS WITH SAME • COMPELETELY REUSABLE EVEN IF
(~40~50%) ON LIVE LINES WITH 500 oC FLUID PERFORMANCE REQUIRED TO BE OPENED FOR
• THINNER RACK SPACE TEMP • NO DEGRADATION WITH PASSAGE OF TIME, WALKING OF MAINTENANCE
• FASTER TURNAROUND TIME WORKERS ON INSULATION OR ATMOSPHERIC EFFECTS • NOT REQUIRED TO BE REPLACED
• INDIVIDUAL LABOR SKILLS LESS INCLUDING ACIDIC AND ALKALINE CONDITIONS DURING PLANT LIFE AS IT OUTLASTS
IMPORTANT • HOLDS HOT FLUID PIPE IN AIR TIGHT MANNER FOR LIFE PLANT LIFE
• NO REQUIREMENT OF SS FOIL FOR TIME WHICH HELPS TO PREVENT • EVEN IF REQUIRED TO BE DISPOSED –
INSULATION ON SS PIPES • MOISTURE INGRESS USED AS REINFORCEMENT AGENT IN
• MITRE ELBOWS, INSPECTION PLUG • WATER INGRESS CONCRETE
HOLE • AIR CIRCULATION BETWEEN HOT PIPE & • NO DUSTING AT THE TIME OF
• PROPERLY COVERED SUPPORT ATMOSPHERE REMOVAL
• PROVISION OF EXPANSION JOINTS • CORROSION UNDER INSULATION
• MATERIAL PROPERTIES, SS STRAPS • GOOD ASTHETICS, SLICK INSULATION
& TIGHTENING TOOL TO PROVIDE • NO VARIATIONS IN TEMPERATURES AT END EQUIPMENTS
AIR TIGHT INSTALLATION WITH IN DIFFERENT SEASONS – NOT EVEN WHILE RAINING TO
HOT PIPE FOR LIFE TIME PROVIDE STABLE PARAMETERS FOR PROCESS
• INSPECTION PLUG HOLES CAN BE PROVIDED FOR
ELBOW/PIPE THCIKNESS INSULATION
• FUEL/STEAM SAVINGS OF 10~30% COMPARED TO
CONVENTIONAL INSULATION IN SATURATED/PROCESS
STEAM LINES FOR LIFE TIME – RECOVERS MORE THAN 10
TIMES THE INVESTMENT
• NO MAINTENANCE FOR INSULATION REQUIRED

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2nd CII National Energy Efficiency Circle Competition
Fuel Saving

Per day coal consumption


Avg Per day coal 40000
Month consumption in 35000
thermopack
Aug-16 37940 30000
Sep-16 35919 25000
Oct-16 30602
Nov-16 29556 20000
Dec-16 28338
Jan-17 35746
15000 Per day coal
Feb-17 29699 10000 consumption
March 17 28709
April 17 22789 5000
May 17 31270
June 17 33577
0

April 17
Aug-16
Oct-16
Dec-16

June 17
Aug 17
Oct 17
Dec 17
Feb-17

Feb 18
July 17 34110
Aug 17 24231
Sept 17 25492
Oct 17 22137
Nov 17 22828
Dec 17 23873
Jan 18 23936
Feb 18 25967 Coal Saving 2160 Ton of Coal per Annum
March 18 25487
Amount saved Rupees 141 lakh per Annum
2nd CII National Energy Efficiency Circle Competition 9
Thank you !

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