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Project Details: :

SRF is a multi-business manufacturing entity and one of the leading manufacturers of fluorochemicals, specialty chemicals, technical textiles, engineering plastics and packaging films. With 12 manufacturing plants in India, 2 in Thailand and 2 in South Africa, SRF caters to customers spread across 75 countries. The Tyre Cord Fabrics Business manufacturing is based in Gummidipoondi, Chennai. With a turnover of more than Rs. 5100 crores (US$ 790 Million), they are the market leaders in most of their businesses in India.

SRF contacted Statkraft BLP to set up a solar power plant in their campus for 5 MW to meet their energy demand. Being a manufacturing company consuming millions of units of grid power, SRF wanted to reduce their dependence on expensive grid energy and at the same time contribute to carbon footprint reduction. The power expenditure also had a huge impact on the costs of their product.

Challenges Faced :

  • The plant load consists of critical sections like polymerization, spinning, dipping and coating lines for which reliable power supply source is essential. We used Centralized Monitoring Systems and an onsite team to manage this.
  • Special controller implementation had to be designed to prevent reverse power from flowing into the grid. This controller ensures that in case a significant amount of current flows into the grid the inverter is shut down.
  • As the campus water collection flows into the proposed solar plant, designing the drain was a big challenge.
  • Shadows from adjacent transmission line towers also posed a challenge.

Key Highlights :

  • This project is one of the largest in-campus projects in the country.
  • Water table was very high in SRF. To overcome that we explored a series of options and used the pile encasing method.
  • Liquid cooled, state of the art inverters are used in this project which would effectively regulate the heat/ cooling mechanism and thereby increase the efficiency of the inverter. The liquid cooled mechanism also improves the life cycles of the IGBTs.
  • A special controller has been designed for this project to prevent the reverse flow of power into the grid.
  • The completed project would now generate 7.59 million units of energy per year and save close to 6000 tonnes in carbon emissions in its first year of operation.