My Home Industries Private Limited

Transcription

1 My Home Industries Private Limited 2nd National Workshop cum Technology Exhibition for `Promoting Energy Efficient and Cleaner Production for Sustainable Industrial Growth 8 th to 9 th March, 2018

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3 Company Profile My Home Industries Pvt Ltd (MHIPL) is established in the year 1998 with an installed capacity of 0.2 mtpa and rose to 10.0 mtpa. MHIPL entered into a Joint Venture with CRH Plc, Ireland in 2008 an internationally reputed 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 certified company. EnMS ISO 50001:2011 is under process & targeted by March BSI is the certifying body. MHIPL-MCW received CII Green Co GOLD Rating in June 2017 MHIPL is the member of CSI (Cement Sustainability Initiative ) and also have the road map for sustainability.

4 BEST PRACTICES TOWARDS ENERGY EFFICIENCY IN MCW Continuous monitoring and adopting the latest technology to improve the Electrical and Thermal efficiency of plant. 1. Replacement of CIS-CFG/RFT Grate cooler with FL Smith CB cooler with ABC inlet(unit-2) 2. Replacement of top stage cyclone with high efficient HR+ cyclone(unit-2) 3. Installation of 1800KW,6.6KV, 36Pulse VFD for PH fan(unit-2) 4. Pyro step Grate cooler replaced with Cemprotec cooler at static and 1 st grate(unit-3) 5. PD Blower replaced with Godrej Turbo blower for Primary Air fan(unit-3) 6. Installation of Waste heat recovery based power plant for all three kiln s Periodic energy audit and recording the achievements against the target and bench marking. 1. Internal Audit 2. External Audit by CII Trainings on energy conservation to employees Installation of Energy savers for Plant lighting 1. 60KVA Energy saver installed for plant lighting Installed dedicated Energy monitoring system (EMS) for monitoring and analysis of Section wise energy consumption. Energy conservation activities monitoring by Energy cell.

5 BEST PRACTICES TOWARDS ENERGY EFFICIENCY IN MCW Installation VFD s for all Major Process Fans and Bag filter fans. Replacing conventional lightings with LED in phased manner. Inlet guide vane dampers removed in various sections wherever VFD s are available. Converted motors from delta to star connection wherever possible Initiative of Quality circle concept to involve workmen and staff for problem solving projects. Conducted KEP 2nd WORK SHOP ON BEST PRACTICES in ENERGY EFFICIENCY under Cement Sector on 07&08th June 16

6 BEST PRACTICES TOWARDS ENERGY EFFICIENCY IN MCW The two days training and capacity building and 3days SGA Programme was organized at My Home Industries Limited, Mellacheruvu Plant on 13th 17th June, 2017 under KEP-SPARC membership to improvise its strategy to meet the continuous improvement in thermal and electrical energy. 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.

7 The following 9 small groups were constituted based on the scope of their existing roles and work area: SPARC -SGA TEAMS Sr.No TEAM NAME TARGET 1 FARADAY 50 KW/HR 2 SPARKS 50 KW/HR 3 MAHA ENERGY SAVERS 30 KW /HR + 2K.CAL/KG 4 ENGRGY EXPERTS 30 KW/HR 5 POWER PILOTS 30 KW/HR 6 POWER SAVING 30 KW/HR 7 ENERGY SAVING ACTION 30 KW/HR 8 SEE 60 KW/HR +5K.Cal/Kg. 9 MAHA VGU 65Kw/Hr Target from 9 Groups : 375 kw and 7 kcal/kg clinker energy saving. Achieved as on date : 145 kw

8 2Days Capacity build up Training and 3days SGA Programme organized at our plant under KEP-SPARC membership project

9 SGA Energy Conservation Projects

10 Project-1 Effective utilization of Air Compressors at Packing plant Observation: Present Packing plant operation purpose we are operating GA-75 KW compressors-3 no s Out of 3 compressors one is operation for truck loading. Two compressors operation for truck & wagon loading and third one is kept as stand by. GA-75 compressor operating for bulk loading even when truck loading not in operation, which leads to high power consumption.

11 Project-1 Effective utilization of Air Compressors at Packing plant Action taken: GX-7 Printing machine compressor air line connecting to bulk loading operation. Benefits Achieved: GA-75 Compressor operation to bulk loading avoided. Power saving:67.5 kw/hr

12 Project-2 Reduction of Specific power consumption in RABH fan Observation: The power consumption of the bag house fan is varying significantly during different operating conditions like direct mode and compound operation. Operating condition DP RABH fan power Compound Mode Direct Mode

13 Project-2 Reduction of Specific power consumption in RABH fan Action taken : Operate with different RABH DP settings of 90 mmwc, 100 mmwc, 110 mmwc by increase the reverse-air fan flow rate, which will 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 lowest total power consumption. Bag house DP settings changed from to mmwc. Benefits Achieved: Power saving -30 kw/hr Annual saving Lakhs/Annum

14 Project-3 Optimization of Auxiliary power consumption in WHR Power Plant Observation: Auxiliary power consumption-7.0 % Specific raw water consumption -7.2 lt/kwh Action taken: Cooling tower fans blade angle reduced from 11 to 8 degree to reduce the evaporation losses. Cooling water flow optimized with reference to T and vacuum. Benefits Achieved: Auxiliary power consumption reduced from 7.0 % to 6.7 % Specific raw water consumption reduced from 7.2 to 6.5 lt/kwh

15 Project-4 Optimization of Unit-1,2&3 RABH RAL s Observation: After commissioning of WHR project, as per observation dust collection in RABH-1,RABH-2,RABH-3 is reduced drastically. Action taken: Increased the off time interval from 30 min to 45 min. As a precautionary measure continue running of RAL given whenever any hopper high level sensor acts. Benefits Achieved: Total saving per day 97 kwh/day Power saving:rs.1.60 Lakhs/annum

16 Energy Performance Specific heat Consumption kcal /Kg Clinker Specific Power Consumption kwh/ton of Cement

17 PAT CYCLE GTG SEC (K.Cal/Kg Equivalent of Cement) Achieved Escerts (Base Line) Target PAT Cycle Achevied PAT CYCLE 2 Target GTG SEC (KCal/Kg Eq Cement)

18 The following Major Projects implemented during PAT Cycle-2 Sr. No Description Saving 1 Unit-3 Pyro step Grate Cooler static & 1st grate replaced with Cemprotec design 15 kcal/kg Clinker 2 Installation of 12.5 MW Waste heat recovery based power plant for all three kiln s 10 MW/hr 3 Unit-3 PD blower replaced with Godrej turbo blower for Primary Air(Unit-3) 50 kw/hr 4 VFD installed for CPP-2 PA fan s 400 kw/hr

19 WHR system Installation at MHIPL MHIPL-MCW installed and commissioned 12.5MW Waste Heat Recovery System in Jan 2017 with a capital expenditure of about Rs 120 crores and started utilizing waste heat from preheater and cooler of all the lines for power generation. Waste Heat Recovery System was installed by M/s LNVT/SINOMA Energy Conservation Ltd and achieving PLF of 85% an average. Suspension Preheater Boiler Air-Quenching Boiler (AQC) Turbine -Generator

20 WHRPP 12.5MW

21 Utilization of AFR Consumption for Pyro Processing Fool proof AFR firing system for firing hazardous waste in kilns with the technological support from FLSmidth,Denmark.

22 Conducted KEP 2 nd WORK SHOP ON BEST PRACTICES in ENERGY EFFICIENCY under Cement Sector on 07&08 th June 16

23 18 th National Award for Excellent Energy Efficient Unit from CII, Hyderabad in Sep 2017

24 Green Co rating 2016 Gold Rating

25 PATH FORWARD TO BEST PRACTICES Green Co rating Platinum Energy Saving projects implementation by SGA teams under KEP-SPARC PAT-2 Cycle target Achievement 5 S Implementation

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