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Kansai Nerolac
The Story Till Date
Energy
GRI Standards
| GRI 302: Energy | Sections/Comments | |
|---|---|---|
| GRI 103-1 | Management approach: Explanation of the material topic and its boundary | |
| GRI 103-2 | Management approach: The management approach and its components | |
| GRI 103-3 | Management approach: Evaluation of the management approach | |
| GRI 302-1 | Energy consumption within the organization | Energy Consumption |
| GRI 302-3 | Energy intensity | Energy Intensity: 1.34 GJ/KL of FG Sp. Power Consumption: Manufacturing Facilities 186 KWH/KL of FG Sp. Fuel consumption: Manufacturing Facilities 47 Lt/MT of Resin production |
| GRI 302-4 | Reduction of energy consumption | Sp. Power Consumption: Manufacturing Facilities 186 KWH/KL of FG Sp. Fuel consumption: Manufacturing Facilities 47 Lt/MT of Resin production |
| GRI 302-5 | Reductions in energy requirements of products and services | KNPL actively explores and adopts environmentally friendly options like renewable energy sources like solar and wind power. By integrating renewable energy into its operations, KNPL decreases its reliance on fossil fuels and contributes to the overall decarbonisation of the energy sector |
Planning for the Future
Going ahead, we have an action plan in place for energy efficiency improvement:
- Full-fledged implementation of EMS at Hosur was completed in FY 2022-23. Going forward, horizontal deployment of EMS implementation is planned at Jainpur and Bawal.
- Incorporation of new age additive in diesel consuming forklifts for optimizing the fuel consumption by enhancing fuel effficiency and better combustion.
- Implementation of new age product for use in chillers for cooling efficiency enhancement by lubricity improvement, reduced fouling and reduction in compressor runtime.
- Installation of an intelligent air flow controller to optimise the compressor load by reducing artificial demand through the air demand management system.
ENERGY CONSUMPTION
At KNPL, progress in energy management is measured through key indicators of specific power consumption, specific fuel consumption and percentage of renewable energy.
| FY 22-23 | |
|---|---|
| From Renewable Sources | |
| A. Electricity consumption – Renewable Sources | 74,631 GJ |
| B. Fuel consumption – Renewable Sources | 33,932 GJ |
| C. Energy consumption through other sources (Biomass / Briquettes) | 1,34,835 GJ |
| Total energy consumed from renewable sources (A+B+C) | 2,43,398 GJ |
| From Non-Renewable Sources | |
| D. Electricity consumption – Non-renewable Sources | 1,80,990 GJ |
| E. Fuel consumption – Non-renewable Sources | 76,356 GJ |
| Total energy consumed from Non-Renewable sources (D+E) | 2,57,346 GJ |
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Energy is also used in the form of steam and heat in our manufacturing processes. Most of the steam and heat requirements are being met through bio fuel and biomass based solid fuel boiler.
Specific Power Consumption
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Method of Calculation:
Specific Power Consumption is ratio of Electricity Consumed (from all sources) at Plants to Total Production of Finished
Goods during Specified Period. Electricity consumption is sum of electricity received from grid (i.e. state electricity board), electricity generated
from DG set and electricity from renewable energy sources at respective manufacturing facilities.
Specific Fuel Consumption
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METHOD OF CALCULATION- Specific Fuel Consumption is ratio of Fuel Consumption in Boilers at Plants to Total Resin Production during a Specified Period.
Energy Intensity
In FY 2022-23, we consumed 5,00,744 GJ of energy within the organisation while our overall energy intensity was 1.34 GJ/ KL of FG.
Method of Calculation:
Energy Intensity is ratio of Total energy (Fuel + Power + Heat and Steam) consumed within factory premises organisation-wide (Manufacturing facilities, R&D centre and Head Office) to Total Production of Finished Goods during specified period.
Reduction of energy consumption
At KNPL we have focussed approach and consistent work along the lines of “Energy security” theme has helped us reduce our energy cost Y-o-Y; at the same time adopt environment-friendly technologies thereby reducing our Carbon footprint. In the current year, our focus was to improve the efficiency of systems at plants.
Replacement of conventional pumps/ motors with energy efficient options, conversion of motors starters to star / delta based on loading pattern, installation of cyclic timers on mixers, descaling of water jackets were undertaken thereby reducing overall power consumption which led to improvement of energy efficiency.
Diversification of Energy-mix
Solar Capacity augmentation
Exploring installation of greenfield solar capacity to meet power demand across factories.
Installation of new technology - ‘Solar tree’ - across locations, which consumes lesser space and can be put up in open spaces.
Captive Wind Power augmentation
Installation of 2.1 MW capacity wind turbine at Sayakha to meet power requirements and increase our renewable footprint.
By FY 2023-24, we aim to source 41% of our total power consumption through renewable energy sources.
Renewable Energy:
We constantly search for alternate sources to increase our share of green energy and accordingly plan our initiatives based on feasibility and applicability. This, in turn, allows our facilities to be increasingly self-reliant in their energy needs and thereby reduce the carbon footprint.
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Heat & Steam generation through Biomass based Boiler
| Heat & steam generation through a biomass-based boiler | |
|---|---|
| Total steam consumption | 19,347 MT |
| Total heat consumption | 1,97,213.6 Lakhs Kcal |
Other Initiatives
Incorporation of new age additive in diesel consuming forklifts for optimizing the fuel consumption by enhancing fuel effficiency and better combustion.
Implementation of new age product for use in chillers for cooling efficiency enhancement by lubricity improvement, reduced fouling and reduction in compressor runtime.
Installation of an intelligent air flow controller to optimise the compressor load by reducing artificial demand through the air demand management system.
Energy Management system at Hosur
Energy cost is a major contributor in an overall operating cost of a manufacturing plant. For optimal operations, it is essential to monitor, track and analyse real-time energy consumption data of equipment. Monitoring and trending of the data helps identify opportunities for optimising the consumption and save upon energy costs. In line with this objective, full fledged implementation of energy management system was undertaken at our Hosur facility. EMS software is a key component in any power monitoring and energy efficiency strategy, which helps in delivering intelligence required to get the most out of energy management across the plants. Through this initiative, we have already achieved energy cost reduction of ₹7 Lakhs and further aim to achieve a cost savings of ₹19 Lakhs.
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