my home industries private limited. mellacheruvu cement works … · 0.03 1.2 0.5 25 14 avoided...
TRANSCRIPT
19th National Award for Excellence in Energy Management -2018
My Home Industries Private Limited.
Mellacheruvu Cement Works
❖ My Home Industries Pvt Ltd (MHIPL) is established in the year 1998 with an installedcapacity of 0.2 mtpa and rose to 10.0 mtpa.
❖ MHIPL entered into a Joint Venture with CRH Plc, Ireland in 2008 an internationallyreputed group having the business in cement and building materials in 35 countries.
❖ Other core businesses of the group are Construction & Real Estate, Power, Transport,Power Consultancy and Education.
❖ MHIPL-MCW is an ISO 9001:2015, ISO 14001:2015, OHSAS 18001:2007,ISO 50001:2011certified company.
❖ MHIPL-MCW received CII Green Co GOLD Rating in June’2017
❖ MHIPL is the members of CSI (Cement Sustainability Initiative ) and also have theroad map for sustainability.
Company Profile
MY HOME INDUSTRIES PVT LIMITEDMCW
MY HOME GROUP
Company Profile
Cement Process Flow Diagram
Sl. No. Projects 2015-16 2016-17 2017-18
Achieved
Total Annual Savings
(Rs in Lakhs)
Co2 Reduction MT
1 No Investment 7 5 4 116 2350
2 Investment 12 10 12 4704 98156
Total 19 15 16 4820 100506
Energy Saving Initiatives Takenfrom 2015-18
Total investment made in last three years -148.43 Crores
Sl. No
Title of Project
Annual Electrical
(Million kWh/MT Coal)
Total Annual Savings
(Rs. lakhs)
Investment Made
(Rs Lakhs)
Co2 Reduction
MT
No Investment
1Modification of Unit-3 Cooler fan-8,9 suctionsilencers
0.16 8.3 0 166
2 Modification of Unit-3 Cooler fan-2 outlet duct 0.05 2.3 0 48
3Reduced pressure drop across cement mills CAfan damper
0.25 12.3 0 252
4Avoided damper loss across Cooler ESP fan(Line 3)
0.05 2.6 0 53
5Reduced Pressure Drop across Damper in RABHfan (Line-3)
0.15 7.4 0 150
6 Avoided compressed air leakage in the plant 0.48 24 0 480
7Optimization of Unit-2&3 RABH RAL on/off toreduce power consumption
0.1 4.7 0 96
Investment
8Modified the Unit-3 preheater fan inlet duct toreduce pressure drop.
0.4 4 3 396
9 VFD for Coal mill-3 Booster fan 0.14 6.1 3 140
10 VFD for Unit-1 RABH RA fan 0.03 2.2 3 34
Energy saving projects implemented during 2015-16
Sl. No
Title of Project
Annual Electrical
(Million kWh/MT Coal)
Total Annual Savings
(Rs. lakhs)
Investment Made
(Rs Lakhs)
Co2 Reduction
MT
Investment
11Optimization of Coal firing blowers volume –Kiln & PC in (Line-1)
0.08 4 0.1 76
12Optimization the operation of packing plantbag filter
0.11 5.4 0.6 111
13Avoided damper loss across identifiedauxiliary bag filter- Raw mill section
0.03 1.2 0.5 25
14Avoided pressure drop across identifiedauxiliary bag filter- Kiln section
0.03 1.2 0.5 25
15Lighting circuit distributed and separateswitch provided for minimum lighting ,whennot in use.
0.05 2.6 0.9 53
16141no's of 70w HPSV lamps are replaced with35w LED lights in critical areas
0.03 1.4 6.2 29
17Thermal savings with Increase of PH Topcyclone efficiency and reduce the Dust lossfrom Pre-heater system (Line-2)
437 17 100 795
18Kiln-1 inlet riser duct modified to reducepressure drop.
0.48 23.2 100 475
19Avoided damper loss across auxiliary bagfilter- kiln section
0.04 1.9 1.5 40
Energy saving projects implemented during 2015-16
Energy saving projects implemented during 2016-17
Sl. No
Title of Project
Annual Electrical
(Million kWh/MT of coal)
Total Annual Savings
(Rs. lakhs)
Investment Made
(Rs Lakhs)
Co2 Reduction
MT
No Investment
1Convert identified Motors From delta to starConnection
0.03 1.6 0 33
2Reduced pressure drop across silencer incooler fan no 6 in line-2
0.11 5.5 0 113
3Avoided Bag filter pressure drop acrossauxiliary Bag Filter- Cement mill section
0.025 1.2 0 25
4Mill vent BF product diverted to final productin CM-2
0.36 17.6 0 360
5Modification VRM-3 Mill feed chute to reducemain drive power
0.195 9.555 0 195
Investment
6 Reduce false air in Pre heater (Line-1) 0.075 4 0.1 75
7 Reduce false air in Raw mill Circuit (Line-1) 0.05 2.3 0.3 47
8 Reduce false air in Raw mill Circuit (Line-3) 0.0325 1.6 0.3 32.5
Energy saving projects implemented during 2016-17
Sl. No
Title of Project
Annual Electrical
(Million kWh/MT Coal)
Total Annual Savings
(Rs. lakhs)
Investment Made
(Rs Lakhs)
Co2 Reduction
MT
Investment
9Optimize cooler loss in line-3 by modifyingStatic and 1st grate of the cooler
2887 172.27 606 6593
10Optimize Lighting Voltage in Plant byproviding energy savers
0.02 1 1.58 20.76
11 Replaced Identified Faulty Capacitors 0.028 1.4 1.27 28
12 Replaced HPSV/MV lamps with LEDs 0.04 1.7 7.5 35
13Turbo Blower installed in Unit-3 kilnprimary air to reduce primary air %.
0.396 19.404 50 396
14Vrm-3 Recirculation modified to increase %of recirculation air
0.3465 16.9785 5 346.5
15Installed waste heat recovery system 12.5MW
87.5 4375 14000 87500
Energy saving projects implemented during 2017-18
Sl. No
Title of Project
Annual Electrical
(Million kWh/MT Coal)
Total Annual Savings
(Rs. lakhs)
Investment Made
(Rs Lakhs)
Co2 Reduction
MT
No Investment
1Increased the OFF time of RABH RAL's in kiln-1,2,3 to reduce power consumption
0.03 1.58 0 32
2Reduced pressure drop across the damper inClinker Extraction Bag Filter Fan by interchangechange fan and motor pulley
0.06 3.00 0 60
3Unit-2 RABH DP intervals optimized to reduceRABH fan power consumption
0.24 11.88 0 238
4Air lift system installed in place of Pneumaticpump system for cement bag branding toavoid packer stoppages
0.05 2.5 0 50
Investment
5Reduce pressure drop across the damper in U-3LS crusher bag filter fan(VFD provided)
0.10 4.86 4 97.2
6Reduce pressure drop across the damper inCM-1A Extraction Bag Filter fan by reducing fanRPM reduced from 1920 to 1450
0.02 0.9 0.05 18
7Excess venting reduced in unit-3 swirl airblower
0.02 1.19 0.05 24
Energy saving projects implemented during 2017-18
Sl. No
Title of Project
Annual Electrical
(Million kWh/MT Coal)
Total Annual Savings
(Rs. lakhs)
Investment Made
(Rs Lakhs)
Co2 Reduction
MT
Investment
8Avoided higher capacity Compressor (GA-75) forbulk loading operation by providing airline fromother compressor
0.05 2.25 0.05 45
950 No's of 70w HPSV lamps are replaced with 35wLED lights in critical area
0.00875 0.44 1.8 9
10150 no's 36 watts tube lights replaced with 18WLED tube lights
0.0144 0.72 1.26 14
11Reduced pressure drop across the damper in CM-4hopper top bag filter fan (VFD provided)
0.12 6 1.75 120
12Reduced false air in Cement mill-2 by providingnew expansion joints and arrested cycloneleakages
0.15 7.5 0.2 150
13 CM silo -2 areation blower volume optimization 0.0030 0.15 0.1 3
14 Reduced pressure drop cross coal mill-3 outlet duct 0.10 4.95 1.6 99
15Installed new TAD damper in Kiln-1 to reduce falseair entry
132.00 7.92 10 264.95
16Modification of kiln feed bag filter ducting and eliminate one bag filter
0.04 1.98 0.2 40
Specific thermal energy Consumption Reduction Kcal/Kg Clinker
Power consumption up to clinkerisationkWh/Ton of clinker
Energy Performance in Last 3 Years
2015-16 2016-17 2017-18
718.2
710.8
713.0
2015-16 2016-17 2017-18
49.5
47.747.9
Remarks: In 2017-18 kiln-1 is running continuously compared to 2016-17(Kiln -1 Power & Fuel Consumption high due to 5stage PH)
Reduction of Specific Power ConsumptionkWh/Ton of Cement
Energy Performance in Last 3 Years
2015-16 2016-17 2017-18
79.35 78.76 78.48
32.228.9
25.1
SEC per Ton of Cement %PPC Production
Benchmarking with National Performance
Benchmarking with National Performance
Top 10 plants MHIPL-Line-1,2,3
65.20
78.48
Overall Electrical SEC kWh/Ton of Cement
Top 10 plants
MHIPL
703
713.0Thermal Energy kCal/kg Clinker
Energy benchmarking for Cement Industry 2018 Version 3.0
Top10 MCW Line-1,2,3
49.20
47.90
Electrical SEC. Up to Clinkerisation kWh/Ton of Clinker
Electrical SEC. Up to Clinkerisation kWh/Ton of Clinker
NATIONAL BENCH MARKING
Energy benchmarking for Cement Industry 2018 Version 3.0
Top10 MCW Line-1 MCW Line-2 MCW Line-3 MCW Line-1,2,3
49.20
52.68
43.95
49.0047.90
NATIONAL BENCH MARKING Specific Heat Consumption kCal/kg Clinker
Top10 MCWLine-2
MCWLine-3
678
709708
Thermal SEC in 6 Stage Preheater(kcal/kg clinker)
Top10 MCW Line-1
721
731
Thermal SEC in 5 Stage Preheater(kcal/kg clinker)
Energy benchmarking for Cement Industry 2018 Version 3.0
National Benchmarking
Sr.No Section Electrical Energy Consumption(kWh/MT Material)
Bench Mark Unit-1Achieved
Unit-2Achieved
Unit-3Achieved
1 Raw mill 11.10 11.52 10.48 12.97
Raw mill-2 Electrical SEC is Lower than the National Bench marking.
Energy benchmarking for Cement Industry 2018 Version 3.0
Sl.No
Proposed Major Energy Saving projects(2018-2021)
Investment Rs. Lakhs
Saving Kw/hr(or)
kcal/kgclinker
Co2 Reduction
Tons/Annum
1Install new high efficiency fan for line 1PH fan
50 60 kW/hr 848
2Increase the Efficiency of PH Top cycloneand reduce the Dust loss from Pre-heatersystem (Line-1)
2005
kcal/kgclinker1256
3Improve heat transfer in identified pre-heater cyclone (Line-1)
3505
kcal/kgclinker1250
4Increase the Efficiency of PH Top cycloneand reduce the Dust loss from Pre-heatersystem (Line-3)
2002
kcal/kgclinker 880
5Replacement of shell cooling fan bladeswith FRP(Fiber Re-enforced plastic)blades
14 30 kW/hr 163
6Replacement of 1000 No’s HPSV lampswith LED lights
30 35 kW/hr 153
Road map to achieve National benchmark
Observation :❖ High pressure drop across the coal mill-3 outlet duct.
Analysis:❖ Inadequate Mill outlet duct area (OEM Design)❖ High pressure drop across the mill outlet duct (60 mmwg)
Action taken:❖ Mill outlet duct modified with In-house design
Parameter Units Before After
Mill outlet
pressure
mmwc -340 -290
Fan power Kw/hr 210 195
Savings Rs-Lakhs/Annum 4.0
Project: Reduction of power consumption in Coal mill-3
Case Study-1
Benefits:
Project: Reduction of power consumption in Coal mill-3
Case Study-1
Before After
Observation:
RABH fan power high
Analysis:
The power consumption of the bag housefan is varying significantly during differentoperating conditions like direct mode andcompound operation.
Project: Reduction of Specific power consumption in Unit-2 RABH fan
Case Study-2
Operating condition
DP RABH fan Power
Compound Mode 100-110 300
Direct Mode 120 314
Action taken :➢ Operate with different RABH DP settings of – 90 mmWC, – 100
mmWC, –110 mmWC by increase the reverse-air fan flow rate, whichwill reduce the DP across the bag house.
➢ Monitor the total power consumption of the BH fan and RA fan.➢ Optimized the operation of reverse air fan based on the optimum ‘DP’
across the bag house and Fix the ‘DP’ setting, which gives the lowesttotal power consumption.
➢ Bag house DP settings changed from 120-100 to 110-90 mmwc.
Benefits Achieved:Power saving -30 kW/hrAnnual saving -10.80 Lakhs/Annum
Project: Reduction of Specific power consumption in RABH fan
Case Study-2
Project: Optimization of Unit-1,2&3 RABH RAL’s
Observation:❖ After commissioning of WHR project ,
as per observation dust collection inRABH-1,RABH-2,RABH-3 is reduceddrastically.
Action taken:❖ Increased the off time interval from
30 min to 45 min.❖ As a precautionary measure continue
running of RAL given whenever anyhopper high level sensor acts.
Benefits Achieved:Total saving per day – 97 kWh/DayPower saving:Rs.1.60 Lakhs/annum
Case Study-3
Observation:❖ Two separate bag filters in operation
for kiln feed bin & kiln feed solid flowmeter.
Analysis:❖ Both the bag filters operating with
50% damper causing power loss.
Action taken :❖ Modified the ducting and avoided
one bag filter totally.
Benefits:❖ One bag filter totally stopped.❖ Power saving -5 kW/hr
Project: Modification of kiln feed bag filter ducting
Case Study-4
Project: Reduction of Power consumption in packing plant
Observation:❖ Packer stoppages due to Failure of cement bag branding machine pump
Analysis:❖ Frequent failure of piston & O-rings.
Action taken :❖ Air lift system installed in place of Pneumatic pump system
Benefits:❖ No packer stoppages due to bag branding machine pump problem.❖ Power saving-5 kW/hr
Case Study-5
v v
INK
PRINT HEAD
PUMP
BELTCONVEYOR
Problem area
AIR + INK
COMPRESSED AIR
FRL
INK CONTAINER
OPERATION OF BRANDING MACHINE
DRYER
INK
PRINT HEAD
BELTCONVEYOR
AIR + INKCOMPRESSED AIR (15 PSI)
FRL
OPERATION OF AIR LIFT SYSTEM (BOTTLE SYSTEM)
Compressed air goes to the ink Bottle. Due to air pressure acting on ink, the ink moves to print head through pipe line for printing.
INK BOTTLE
DRYER
RENEWABLE ENERGY SOURCES
Solar Plant
Sl.No Capacity Annual kWh Generation % Consumption
1 1.2 MW 18.43 Lakhs 0.86%
2 12.7Kw 4148 (5Months) ---
RENEWABLE ENERGY SOURCES
12 Kwp Solar Plant at Mines (Nov-17)1.2 MW Solar Plant
RENEWABLE ENERGY SOURCES2x 500 LPD ROOF TOP SOLAR HEATER AT GUEST HOUSE
Commissioned in Nov-2016 -(Units saved @3000Units/Annum)
RENEWABLE ENERGY SOURCES SOLAR FENCING AT MINES MAGZINE
Solar Fencing
Waste Management System
Waste Management System
❖ Well developed technology steps like Waste Heat Recovery power plant (12.5MW) incorporated in process.
❖ Usage of alternative fuels (pharmaceutical waste) 1.90 % (TSR) in kiln’s to reduce usage of natural resources.
❖ Fly ash addition in cement is 30.8%
❖ Slag addition in raw meal is 0.57%
❖ Fly ash addition in raw meal is 0.59%
❖ Shale consumption in raw meal is 0.36%
❖ Internally generated wastes like cotton waste , waste bags, grease are also being fired in kiln.
❖ STP water (200 KLD) is being used for plantation .
WHR system Installation at MHIPL
❖MHIPL-MCW installed and commissioned 12.5MW Waste Heat RecoverySystem in Jan’2017 with a capital expenditure of about Rs 140 croresand started utilizing waste heat from preheater and cooler of all thelines for power generation.
❖ Waste Heat Recovery System was installed by M/s LNVT/SINOMAEnergy Conservation Ltd and achieving PLF of 85% an average.
Suspension Preheater Boiler Air-Quenching Boiler (AQC) Turbine -Generator
WHRPP – 12.5MW
CO2 Emission reduced by 75440 MT/Annum in 2017-18
Fool proof AFR firing system for firing hazardous waste in kilns with the
technological support from FLSmidth,Denmark.
Utilization of AFR Consumption for Pyro Processing
Scrubber system for odour control
2015-16 2016-17 2017-18
2.48 2.58
1.9
Alternative Fuels (TSR)%
*In 2017-18 low TSR % due to non availability of solvent with specified quality .
Utilization of AFR Consumption for Pyro Processing
GHG INVENTORISATIONCo2 (Kg Co2/Ton of clinker)
GHG reduction due to Encon Projects,Installation of 12.5 MW WHR,and Thermal saving in Unit-3 Cooler upgradation.
2015-16 2016-17 2017-18
1087
1024
937
GHG Emission Reduction
YearScope-1
emissionsScope-2
emissionsScope-3
emissions TotalKg Co2/MT of Clinker
2015-16 1080.70 0.78 5.65 1087
2016-17 1013.87 3.64 6.37 1024
2017-18 929.40 0.77 7.21 937
Scope Emission Sources Considered
Scope 1 EmissionsCement process-Calcination, Fuel Burning in Kiln & HAG, CPP -Coal Consumption etc.
Scope 2 Emissions Electricity Consumption from Grid
Scope 3 EmissionsRaw material Transport, Cement dispatch through rail & Road, Employee commute etc.
Best Practices Implemented on Energy front inGreen Supply Chain
❖ Training critical vendors on green initiatives like waterconservation, wastage and energy Consumption.
❖ Visual aids-training for better understanding on greeninitiatives.
❖ Display of posters-on shop floor for better understanding andto create the awareness in every individual.
❖ Recognition letters shall be issued to the vendors afterassessment on environmental performance by the end ofMarch every Year as a part of encouragement.
❖ Emphasizing on rail/bulk transportation for inward andoutward transportations to continual improvement ofenvironment performance.
Best Practices Implemented on Energy front inGreen Supply Chain
➢ Rain harvesting pit -1 No. constructedby Padmaja Poly Packs Pvt Ltd.
Rain harvesting pit details:
Size: 3000mmx2000x2000mm
➢ M/s Webber India, Coimbatore,one of major supplier for supply ofcastings principally agreed to applyfor ISO 14001 previously andreceived the certification recently.
❖ M/s Neo Techniques, Secunderabad is authorized dealer for AtlasCopco compressors, Kluber lubricants, Asco pneumatic and Shantigears etc.,
➢ After completion of the training, M/s Neo Techniques, Secunderabadreplaced their existing conventional lighting system with LED lightsconsidering environmental benefits and energy savings.
Best Practices implemented on energy front inGreen Supply Chain
Saving : 143 Units /Month
Before After
530
387
Energy Consumption (KWh)
Director (Technical) /Sr. President (Operations)
Unit Head
DGM
(QC)
GM (E&I)
Sr.DGM(OP)
V.P
(CPP)
Sr. DGM
(Mech)
GM
(Mines)
Energy Management Team
Section Heads
Energy ManagerSr.GM (O&M)
Online Energy Monitoring❖ Energy Management System is
developed to monitor and controlthe consumption of various formsof energy through an effectiveenergy management system
❖ Discussion on Variances againstthe target during DailyCoordination Meeting
❖Monthly review by EnergyConservation cell
❖Monthly review by TopManagement for actions
❖ Energy Audits Once in 3 years byrecognized External Agency
Energy performance Review Methodology
Energy Projects Implementation Methodology
❖ Identifying the potential Energy saving equipment's /Areas by Plant Engineers.
❖ Data collection , shop floor involvement, brain storming , energy audit
❖ Categorized into No investment, Low investment and High investment.
❖ Categorized into Short term, Medium term and Long term.
❖ No / Low investment project Implementation - Immediately.
❖ High investment projects proposals – Put up for CAPEX approval.
❖ Approved Proposals are being Implemented with time frame.
❖ Review of project implementation ,Completion status and HOTO.
❖ Reporting the benefits / savings through monitoring and reviewing theperformance.
Strategies Adopted for Employee Involvement
❖ Trainings for Employee/Contract work man- 16 Training hours
❖ Participation in Seminars LAUNCHING QUALITY CIRCLE
❖ Quality circle – 21 Circles
❖ Kaizen
❖ Knowledge share through live demos
❖ Energy conservation Day Celebrations
❖ CSI Member company
❖ BEE- KEP SGA
QUALITY CIRCLE TRAINING
❖ The two days training and capacity building
workshop was organized at My Home
Industries Limited, Mellacheruvu Plant on
13th – 17th June, 2017 under KEP-SPARC
(Service package for advancing resource
conservation) membership.
❖ SGA Group are formed to identify and
implement appropriate solutions within their
area of operation to achieve energy efficiency,
higher productivity, zero defects, zero
breakdown and zero waste.
Strategies Adopted for Employee Involvement
MCW has undertaken the Capacity build-up project and Small Group Activity (SGA) under KEP – SPARC membership by forming 9 groups
.
SPARC -SGA TEAMS
Sr.No TEAM NAME TARGET
1 FARADAY 50 KW/HR
2 SPARKS 50 KW/HR
3MAHA ENERGY
SAVERS30 KW /HR + 2K.CAL/KG
4ENGRGY EXPERTS
30 KW/HR
5 POWER PILOTS 30 KW/HR
6 POWER SAVING 30 KW/HR
7ENERGY SAVING
ACTION30 KW/HR
8 SEE60 KW/HR +5K.Cal/Kg.
9 MAHA VGU 65Kw/Hr
Target from 9 Groups :375 kW and 7 kcal/kg clinker
Achieved Saving : 145 kW
Conducted KEP 2nd ‘’WORK SHOP ON BEST PRACTICES in ENERGY EFFICIENCY’ under Cement Sector on 07&08th June ’16
Internal Training Energy Cell
Awareness program on energy conservation to employees
External trainingTraining for workmen's
Implementation of ISO 50001/Green Co
CERTIFICATION OF ISO 50001
Total investment made in last three years -148.43 Crores
WON “ GOLD AWARD” IN CII GREENCO SUMMIT– PUNE IN 2017
Green Co rating 2016 – Gold Rating
17th National Award for Energy Efficiency from CII in Hyderabad in August 2016
18th National Award for Excellent Energy Efficient Unit from CII in Hyderabad in Sep 2017
Best QC Supporting Management Award received on 12th September from Home Minister, Telangana. Awarded by CCQC
Quality Circle Awards - 04 Gold Rating from Hyderabad Chapter – 13th Sep’ 17
Par Excellence 3 no’s and Excellence award 1 no received at NCQC ,
Mysore on 05.12.2017 two case stidies on safety innovations in Mines
PATH FORWARD TO BEST PRACTICES
Green Co rating – Platinum
Energy Saving projects implementation by SGA teams under KEP-SPARC
PAT-2 Cycle target Achievement
Increase of AFR to achieve 5% TSR
Development of Biodiversity Park
Aim to participate in QC International convention
