My Home Industries Private Limited

2nd National Workshop cum Technology Exhibition for `Promoting Energy Efficient and Cleaner Production for

Sustainable Industrial Growth’ 8th to 9th March, 2018

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 2018. 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.

Company Profile

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 1st 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.

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

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.

BEST PRACTICES TOWARDS ENERGY EFFICIENCY IN MCW

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

The following 9 small groups were constituted based on the scope of their existing roles and work area:

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

SGA Energy Conservation Projects

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.

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

Project-1 Effective utilization of Air Compressors at Packing plant

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 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, 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 120-100 to 110-90 mmwc.

Benefits Achieved: Power saving -30 kW/hr Annual saving -10.80 Lakhs/Annum

Project-2 Reduction of Specific power consumption in RABH fan

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

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

Specific heat Consumption kCal /Kg Clinker

2015-16 2016-17 2017-18

718.24

708

711.79

Specific Power Consumption kWh/Ton of Cement

2015-16 2016-17 2017-18

79.35

76.87

77.6

Energy Performance

PAT CYCLE - 1

1036

989 987

2007-10(Base Line)

TargetPAT Cycle-1

2014-15Achevied

GTG SEC (K.Cal/Kg Equivalent of Cement)

Achieved Escerts- 502

PAT CYCLE – 2 Target - 954 GTG SEC (KCal/Kg Eq Cement)

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

The following Major Projects implemented during PAT Cycle-2

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.

Turbine -Generator Suspension Preheater Boiler Air-Quenching Boiler (AQC)

WHRPP – 12.5MW

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

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

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

Green Co rating 2016 – Gold Rating

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