25-03-2013

RESPONSE TO CLIMATE CHANGE

TATA MOTORS LTD. PANTNAGAR

COMPANY PROFILE
Established in Over

1945, Tata Motors' presence cuts across the length and breadth of India.
Tata vehicles ply on Indian roads, since the first rolled out in 1954

7.5 million

India's largest automobile company, with consolidated revenues 12. Leader in commercial vehicles in each segment, and vehicles The

USD 32.5 bn

in 2011-

among the top in passenger

world's fourth largest truck and bus manufacturer.

Presence in

Europe, Africa, the Middle East, SE Asia, South Asia, South America and Russia
Over

55,000 employees are guided by the mission employability, education, health and
2

Working on four thrust areas -

environment

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Geographical Plant Location of TATA Motors

Uttarakhand Pantnagar - 2007
Uttar Pradesh Lucknow - 1992

Gujarat Sanand- 2009

Jharkhand Jamshedpur - 1945

Maharashtra Pune - 1966

In Uttarakhand State (Northern part of India) 250 kms NorthEast of Delhi 7419 Employees
3

Karnataka Dharwad - 2011

Present Models

ACE 0.75 Ton

Super ACE

Magic IRIS Magic

Ace ZIP Venture

ACE CNG

ACE -Fuel Efficient

Magic CNG 4

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Concern for the Environment

10,00,000th Vehicle

27th Oct 2012

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8,00,000th Vehicle - Mar 2012 5,00,000th Vehicle - Apr 2011 8 2,00,000th Vehicle - Oct 2009 1,00,000th Vehicle- Feb 2009 Export Started - May 16, 2008 4 3 2 1 6 7

5 Trial production started - April 2007

Construction completed - Feb 2007 Construction started - April 2006

6

Bhumi Poojan - March 30, 2006

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Environment Policy

EMS / ISO 14001

OHSAS : 18001

Climate Change Policy

Audit done & Recommended for ISO 50001 - EnMS by BVC

Env Procurement Policy

Water Policy

ISO 50001

Energy Policy

Facilitating and Maximizing Reduction in Carbon Footprint through Value Chain

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Strategy - To Reduce Environmental Footprint

Infrastructure
Actions :
To reduce 30% Steel for building structure Modular concept To reduce heat load on ventilation by installing Double insulated side and roof walls . To reduce illumination load by installing Sky light sheets To install energy efficient motors for blowers, conveyors To install Screw chillers for AC system VFD for Compressor and all High powered motors Servo controller for Compressed Air Supply . Fan less cooling towers for compressor Propane for process heating, instead of conventional fuel e.g. HSD/LDO/FO Use of natural resource Artisan wells CFL Lamps, Solar Lamps, Wind Ventilators Lakes & Rain water harvesting

Manufacturing
Actions :
Efficient Washing Machines Inter Shop Conveyor Friction roller conveyor Wet on Wet Painting process Process Optimization Power & Free Conveyor Electrified Monorail System CNC Machines Reuse, Recycle, Reduce process waste

Logistics
Actions :
Vendor park near the mother plant to reduce inbound transportation Out bound Transportation Transportation internal & employee transport

New Product Introduction

Actions :
CNG Vehicle Fuel Efficient Vehicle with Start-Stop arrangement Adherence to emission norms

STRATEGY

Reducing Environmental Foot print

New Products
CNG vehicles BS III & IV

Infrastructure
Integrated Manufacturing Modular concept Innovative construction Less Cement & Steel Efficient Facilities Water conservation

Manufacturing Logistics
Vendor Park Near Mother Plant Transportation Recyclable bins , pallets System Process Ramp up plan Continuous Improvement

. towards green plant10

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Background

TML Vendor Park

Total area TML Plant Area

953 Acres 616 Acres

Roads length Vendor Park area

~ -

15 km 337 Acres

Effluent Treatment Plant (Largest ETP in SIDCUL Industrial Estate, Udham Singh Nagar, Uttarakhand).
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Utility

Plant layout

Air, Water, Power, Fuel

ETP,STP

Training

Service

Vehicle Assy 2A, 2B TCF 1E

BIW 1A

BIW 1B

& Gear Box

Inter shop Conveyor Weld shops to Paint to Assy Lines 1.5 Km long

Ready WIP

Paint Shop
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BIW 1C

BIW 1E

TCF 1D

TCF 1A

TCF 1B

TCF 1C

Engine

Weld Shop 2A

BIW 1D

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Inter shop Conveyor for Fast, Safe & Efficient Body movement

Floor Conveyor - FRC

Employee Buses run up to Floor Conveyor with Dolly 1. 2. 3. 40 Km from Plant On 9 Routes 70 Buses

Transportation Facilities
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Carbon Footprint - tCO2 / Eq Ace Veh

Specific GHG Emisisons (Electricity + Fuel)

0.35 tC O 2/ E qA c eV e h ic le 0.30

0.32

0.24 0.25 0.20 0.15 0.10 0.05 0.00 2008-09 2009-10

0.23 0.21

45 %

2010-11

2011-12

Specific emissions (Scope I + Scope II)

Direct Emissions - Fuel
Indirect Emissions - UPCL Power

2011-12

0.06

2011-12

0.15

2010-11

0.08

2010-11

0.15

Year

2009-10

0.08

Fuel (HSD + Propane)

Yea r

UPCL Electrical
2009-10

0.15

2008-09

0.07

2008-09

0.25

0.00

0.02

0.04

0.06

0.08

0.10

0.00

0.05

0.10

0.15

0.20

0.25

0.30

T C O2/ Eq Ace Vehicle

T CO2 / Eq Ace Vehicle

Scope I (Fuel) emissions

Scope II (Electricity) emissions

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Use of Environmentally Sustainable Technologies Minimize Waste Generation and Enhance Recycling and Recovery

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Reducing Waste Generation

Recycling of Paint sludge into Industrial Reusable Primer

With help of Robots and Efficient

Painting guns, the wastage is reduced

20-25% Use of Eco

by

Friendly (Water Based)

Incineration Recycling

Paints

Total Paint Sludge Recycled : 100 MT (i.e. 200 KL Fresh Paint Saved)

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Effluent & Sewage Treatment Plant

Re- Utilization of ETP Sludge as a raw material into Paver Blocks

Modular Concept
ETP : 1300 + 1300 KLD STP : 600 + 600 KLD
MT

ETP Sludge utilization for Pavement Tiles

490 420 350 280 218 210 140 70 9 0 FY 08 -09 FY 09 -10 FY 10 -11 FY 11 -12 120 410

Approved by CBRI

CUMSUM Utilization of ETP Sludge

Total ETP Sludge Reused : 400 MT (i.e. 4 Lakhs Bricks Manufactured)

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Eco - friendly activities

Objective : Use of Zero Ozone depletion potential refrigerant in HVAC system - R 410A Objective : Use of Recycled materials such as AAC bricks, made of Ash content.

Objective : Recycling of E Waste

Objectives : Low VOC Paints, Adhesives, Sealants No TOBACCO / NO SMOKING premises Reserved car parking for car pooling users

Proactively initiated along with draft proposal in March 2011

Electric charging station for electric vehicles

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Total E waste Recycled : 15 MT

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Offset Carbon Footprint

Tree Transplantation

250 tCO2 Reduction per Year

Total 40, 000 Trees Planted till date

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Select, Purchase and Use Appropriate Energy Efficient Equipments, Services and EcoFriendly Technologies

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Efficient Facilities
Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification

CFLs

Screw Compressor With VFD Savings 250 MWH/Yr

Servo Control Valve

Patent

22% Energy saved Fan less cooling tower 21

Renewable Energy
Wind Ventilators Solar Water Heating System

Main Features:
Used for Hot water requirement Total system capacity 5000 Litre / Day Max water Temperature 900 C

1, 25, 000 KWH saved per year 1.05 Lakh tCO2 per year

More than 1280 nos installed and saved 2.9 Million Units.

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Green Building LEED INDIA GOLD RATING

220 KV Switch Yard & Open Access

Main Features
Energy efficient building Use of eco friendly and recycled building materials such as AAC Blocks Zero VOC paint and materials Automatic control of lighting Zero ODP HFC refrigerant
20 15 10 5 0 16

220 KV Switch Yard Hence Power Quality Improvements 2011 3

P owe r Fa i lur e

2012

500 0
tCO
2

5 0
Ov er / Unde r Volt a ge

4 0
Fluc t ua t ion

50 % Reduction in Direct Emissions

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Energy conservation activities

Objective : Energy Conservation in ventilation Objective : Energy saving in lighting load
Use of DALI (Digital addressable light interface) Ballast 75% reduction in energy consumption Maximize comfort and reducing strain / glare.

Objective : Energy saving on air conditioning

Day Light Sensor / LDR for Street Lights

Use of Low U Value (thermal transmittance) Glass. Double jacket glass to reduce thermal loss. Tinted Glass to save reduce energy consumption in Air conditioning

Total Annual Saving = 1 Lakh KWH

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Insulation of Washing Machine

Timer Based Switch (On/Off)

Insulated the Washing machine

Benefits:
Energy Saving of 0.91Lakhs KWH PA

Benefits:
Energy Saving of 0.135 Lakhs KWH PA

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Reduction in baking time & Fuel Savings

2C-2B SYSTEM

Waste Heat Recovery

The waste heat of exhaust flue gases from ED oven RTO is recovered to raise the water temperature of Hot Water Generator system used in paint Shop.

BASE PRIMER

BAKING OVEN SANDING

BAKING OVEN

TOP COAT (RUBY RED)

2C-1B SYSTEM

BASE PRIMER

TOP COAT (RUBY RED)

BAKING OVEN

168 MT fuel saved PA Benefits: Saving of 1403 Million Kcal PA 1 Cr INR saved PA 505 tCO2 saved PA
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Green Drive at Suppliers

Green Drive at Dealers

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Specific Energy Consumption

32 %

Power Consumption KWH / Vehicle

Fuel Consumption M KCal / Vehicle

32 %

28

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Select, Purchase and Use of Appropriate Water Efficient Processes, Equipments, Services and Technologies for Treatment, Reduction and Recycling

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Efficient Facilities Water conservation

Daily 500 KL/Day

treated water is used for gardening purpose

Eco Friendly Lake water harvesting

It saves 150 KWH per day

One of artesian well is Supplying Raw water to WTP with out power

Total Rain Water Harvested

78, 000 KL
Reduce the energy consumption for water pumps for WTP

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Recycling of Treated Industrial Effluent by Reverse Osmosis (RO) Technique and Reusing in Paint Shop Process Main Features: Recovery Capacity - 95% and unique system in recovery point of view. All the equipments are placed above the tank, hence looks compact & less space required Good quality of inlet water for paint shop and huge reduction in Ground water extraction. Stand by options with existing process water supply system. Reduction in 40% Ground Water withdrawal.
Reduction in Ground Water

One Lakh KL

R.O. Recovery started.

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Water conservation activities

Objective : Water efficiency in Gardening Water reuse- 100% STP water for landscaping Use of Shrubs and trees which needs less water. Gardening design so that minimum water should flow out of the spaces. Objective : Prevent loss of soil and storm water during construction due to rain

Objective : Reduce consumption of water Use of water efficient fixtures Saves approx 30% water

Objective : To harvest and recharge Total we have 5 no. of water bodies Total Rain Water Harvested 78, 000 KL

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PH & DO VALUE MONITORING SYSTEM LAYOUT

PH Meter

RS 232

PLC Input

Annunciator Panel

GSM Modem

PLC

SMS Format pH: High (> 9) / Low (<5) DO : High (>4) / Low (<2) DO Data Logger
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Power Supply

Specific Water Consumption

47 %

Water Consumption KL / Vehicle

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Suggestion Scheme Launched on Climate change & Environment Theme

Reducing environmental foot print. . towards green plant

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To generate awareness STICKERS are developed

Awareness

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National Energy Conservation Awards 2009 & 2010

CII Awards

State Energy Conservation Awards 2010 & 2011

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