My Home Industries Private Limited - · PDF fileMy Home Industries Private Limited -MCW ... Installation of Drum motors by replacing Geared motors for feasible Belt conveyors in Packing

My Home Industries Private Limited -MCW 2nd Workshop on Best practices in Energy Efficiency in

Cement Sector7-8th July 2016

Presented by: D.Venubabu (Energy Manager)

Under the flagship of

Dr.J.Rameswara Rao, Chairman

MHIPL Rose to the reputation

Built on Quality,Environment,Safety

and Social Activities

INTRODUCTION:My Home Industries Pvt Ltd (MHIPL) is established in the year

1998 with an installed capacity 0.2 mtpa and rose to 8.5 mtpa as on date.

MHIPL entered into a JV with CRH Plc, Ireland in 2008,an internationally reputed group having the business in cement and building materials in 35 countries.

Other interests of the group are Construction & Real Estate, Power, Transport, Power Consultancy and Education.

MHIPL is an ISO 9001:2008, ISO 14001:2004, OHSAS 18001 certified company.

India’s MOST PROMISING BRAND 2015 in Infrastructure category given by World Consulting & Research Corporation

May Day Awards 2016 by State Government of Telangana-Best Management Award 2015

BEST PRACTICES TOWARDS ENERGY EFFICIENCY IN MCW

Continuous monitoring and adopting the latest technology to improve the Electrical and Thermalefficiency of plant .

Carrying out energy audit periodically, comparison of achieved results against set targets andbenchmarking.

Usage of alternative fuels to reduce consumption of natural resources and also reduce landfilling of hazardous waste.

Usage of waste heat for the generation of power(WHR). Installation of Energy savers for Plant lighting Installation VFD’s for all Major Process Fans and Bag filter fans. Installed the 1850kW 36 Pulse VFD for preheater fan to minimize the Harmonics and losses. Installation of Drum motors by replacing Geared motors for feasible Belt conveyors in Packing

plant to reduce the maintenance and energy saving. Installed dedicated Energy monitoring system for monitoring and analysis of Section wise energy

consumption. Dedicated teams to study and arrest false air in process operations and compressed air. Replacing conventional lightings with LED in phased manner. Improvement of Fly ash % in PPC. Installed the high efficiency Turbo blower for primary air application in kiln. Inlet guide vane dampers removed in various sections wherever VFD’s are available.

Thermal energy saving projects implemented

Sr.No DescriptionSaving

@K.Cal/Kg Clinker

1 Unit-1 conventional Cooler replaced with FLS SF 2*4F 15

2 Unit-2 CFG Grate Cooler replaced with FLS CB cooler with ABC inlet 10

3Unit-3 Pyro step Grate Cooler static & 1st grate replaced with Cemprotec design

15

4HR+ cyclone installed for unit-2 preheater top cyclone to improve efficiency 5

Electrical energy saving Projects implemented (Last 3 Years)

S.No Type of Projects Description of equipmentEnergy saving

kW/hr

1 VFD Installation

CM-4 vent fan

606

CM-5 vent fanUnit-3 RABH RA fan

CPP-1 cooling tower fan-2&3CPP-2 cooling tower fan-2&3Unit-2 RABH RA FANCoal mill-3 Booster fanUnit-1 RABH RA fanUnit-3 kiln feed bag filter fanUnit-3 jet air blower (Godrej Turbo blower)

2Under loaded motors

Replaced

Cm-4 –SKS separator bag filter fan-45kW replaced with 22kW motor

38

Cm-5 –mill feed belt 11kw motor replaced with 5.5kWU-1&2clinker extraction log belt 93 kW replaced with 75 kWCm-5 –SKS separator bag filter fan-45kW replaced with 22kW motorPacker 6,7 BC 3 motor replaced from 5.5 to 2.2 kWPacker 6 discharge belt conveyor 11 kW motor replaced with 5.5 kW

S.No Type of Projects Description of projectEnergy saving

kW/hr

3Miscellaneous

projects

Recirculation duct provided for VRM-2

288

60 KVA Energy saver for Unit-2 RABH LightingAvoiding the Excess Aeration in various air slides in packing plant sectionModification of cooler fans suction silencer to reduce pressure dropOptimized the operation of packing plant bag filter by switching off one fan in packer-6Replaced HPSV/MV lamps with LED’s in plant & colony

Converted motors from delta to star connection in Cement mill -1 &2 and

U-3 kiln feed silo top bag filter fans.

Fan inlet guide vane dampers removed in various sections wherever VFD’s are available

Unit-1 coal firing blower speed reduced as per the operational requirement

Reduction pressure drop across the kiln-1 inlet raiser duct

Electrical energy saving Projects implemented (Last 3 Years)

Utilization of AFR Consumption for Pyro Processing

2012-13 2013-14 2014-15 2015-16

0.93

1.49 1.6

2.48Alternative Fuels (TSR)%

2012-13 2013-14 2014-15 2015-16

3510

56336427

9036

Coal saving (MT)

2009-10 2014-15 2015-16

728.93

719.79718.2

Specific heat consumptionKcal/Kg.Clinker

2009-10 2014-15 2015-16

55.79

50.8049.5

Electrical SEC (uptoClinkerization)

kWh/Ton of clinker

2009-10 2014-15 2015-16

33.68

31.28 31.34

Electrical SEC (Cement grinding)

kWh/Ton of cement

2009-10 2014-15 2015-16

30.85

32.8533.54

% of Fly Ash addition in PPC

Plant Performance:

Energy Conservation Projects

Case Study- 1

Root cause: Mill inlet gas temperature is high to an extent of 290 Deg C & consuming

water 10 m3 /hr. No recirculation air for VRM to control the inlet gas temperature

Observation: Water consumption 10 m3/hr power consumption of VRM 11.8 kW/Ton of material.

Project: Reduction of power and water consumption in VRM-2

Idea proposed : Installation of recirculation duct at VRM to reduce inlet gas temperature

Action taken: Installed recirculation duct from VRM fan outlet to Mill inlet

Project: Reduction of power and water consumption in VRM-2

Recirculation Duct

Benefits

Before After

10

5

Water consupmtion (m3/hr)

Before After

11.8

11.5

Sp.power Consumption (kWh/Ton of Material)

Savings:Investment made - 30.0 LakhsSavings achieved - 23.0 LakhsPay Back - 1.3 Years

Project: Reduction of power and water consumption in VRM-2

Root cause: Inadequate fan inlet box area (OEM Design) High pressure drop across the fan inlet box (120 mmwg)

Observation: Preheater fan specific power consumption 8.8 kWh/Ton of material Preheater fan running at rated RPM(990 RPM)

Project: Reduction of Sp power consumption in Unit-3 PH fan

Idea proposed : Fan inlet box area to be modified for reducing the pressure drop

Case Study-2

Action taken: PH fan inlet box modified with In-house design

Project: Reduction of Sp. power consumption in Unit-3 PH fan

Before After

Pressure drop 120 mmwg Pressure drop

60 mmwg

Benefits

Before After

8.8

8.5

Sp.power Consumption (kWh/Ton of clinker)

Before After

120

60

Pressure drop (mmwg )

Savings:Investment made - 5.0 LakhsSavings achieved - 17.0 LakhsPay Back - 3 Months

Project: Reduction of Sp. power consumption in Unit-3 PH fan

Root cause: OEM Design in adequate to load open wagon High power consumption due to Dust less loading system ( DLS) More no of nuisance bag filters Low capacity integral dust collector of each spout. In efficiency DLS arrangement to handle the dust.

Observation: Huge Fugitive dust during clinker wagon loading Power consumption was 90 Kw / hr

Project: Reduction of Clinker Dust Dispersion at Wagon Loading

Idea Proposed: Installing in-house designed & fabricated dust hood to cover the open wagon. Arrangement of vent lines for each spout from existing auxiliary bag filter

in place of DLS arrangement having integral dust collectors .

Case Study- 3

BEFORE AFTER

Action taken : 1. Installed the In-house designed & fabricated hood

Project: Reduction of Clinker Dust Dispersion at Wagon Loading

Telescopic chute

Hood for Wagon With sealing curtens

BEFORE AFTER

Action taken: 2.DLS arrangement & integral dust collectors removed and installeddirect chutes. Provided separate vent lines for each spout from auxiliary bag filterlocated at hopper top.

Project: Reduction of Clinker Dust Dispersion at Wagon Loading

New Vent Lines

Integral dust collector

Direct Chute

BEFORE AFTER

Project: Reduction of Clinker Dust Dispersion at Wagon Loading

Dust dispersion

Benefits: Achieved clean environment Power consumption reduced by 35 kW/hr Loading time was minimized by eliminating the chute operation. System was simplified by installing direct chutes and hence less

maintenance Eliminate maintenance spares consumption of cassette bag filters

and spouts,buckets,outerbellows.

Savings:Investment made - 13.34 LakhsSavings achieved - 8.5 Lakhs/AnnumPay Back - 1.57 Years

Project: Reduction of Clinker Dust Dispersion at Wagon Loading

Root cause: Jet air positive displacement Blower is running with constant speed and

hence Some quantity of air vented out to atmosphere air to meet requiredvolume and pressure.

High maintenance due to high operating pressure.

Observation: Power consumption was 100 kW/hr. High maintenance

Project: Reduction of Sp power consumption in Unit-3 Primary air blower

Action proposed : VFD proposed to eliminate the venting of air to atmosphere. Godrej Turbo blower is recommended for this application due to less

maintenance and inbuilt variable speed system.

Case Study-4

Action taken: Existing primary air jet air blower replaced with latest technology turbo blower.

BEFORE AFTER

Project: Reduction of Sp. power consumption in Unit-3 Primary air blower

Benefits

Savings:Investment made - 50.0 LakhsSavings achieved - 15.8 LakhsPay Back - 3.1 Years

Before After

1080

0

Air Vent out(m3/hr)

Before After

100

60

Power Consumption kW

Project: Reduction of Sp power consumption in Unit-3 Primary air blower

High efficiency even at partial load Flow control by VFD Remote monitoring & operational control from CCR lower maintenance cost low noise & vibration Life of more than 15 years HMI color display of parameters like discharge pressure, inlet flow,

air temperature, speed of motor, input power etc.

Benefits:

Project: Reduction of Sp power consumption in Unit-3 Primary air blower

Sr.No Proposed Energy Saving projects

1 Increase of AFR-TSR to 5%

2 Reduction of Specific heat consumption to 700 kcal/kg clinker

3 Reduction of Auxiliary power consumption in CPP

4 Installation of 12.5 MW WHR

5 Installation of LED lights in plant

Way Forward

THANK YOU ALL…