h&r johnson (india) - cii - sohrabji godrej green business

www prisohnson in

H&R Johnson (India) (A Division Of Prism Johnson Limited)

Unit: Pen, Maharashtra

Presented by: Mr. Arghya Mukherjee, Sr.GM‐OpsMr. Manoj Aswale, Sr.Mgr‐Maint

www.hrjohnsonindia.com

CII National Award for Excellence in Energy Management 2020

INDIA’S LEADING INTEGRATED BUILDING MATERIALS COMPANY


H&R Johnson (India) , Pen Plant Pen unit is the state of art diversified tiles

manufacturing unit, established in the year1997.

Only ceramic tiles plant in the world havingintegrated process for production of alltypes of products under one roof.

Specializes in high mix,low volumeproduction

Having DSIR recognized in house researchand development wing

Quest for product innovation : Innovator ofAnti Static, Germ Free, Scratch Free, StainFree, Joint Free, Anti Skid tiles


Unit Details

www prismjohnson in

Energy Consumption Overview


Energy Consumption Overview

Parameters UOM FY18 FY19 FY20 % ChangeFY20 Vs FY19

Production In Mt 94,053 90,750 86,140 (5.08)

Annual electrical energy consumption Million KWh 18.37 19.41 16.36 (15.70)

Annual cost of electricity consumption Million INR 156.39 168.31 151.11 (10.22)

Annual thermal energy consumption Million Kcal 1,18,474 1,10,912 92,919 (16.22)

Annual cost of thermal energy consumption Million INR 146.54 184.25 126.75 (31.21)

Specific electrical energy consumption KWh/Ton 195.37 213.90 189.97 (11.19)

Specific Thermal Energy consumption Kcal/Ton 12,59,652 12,22,173 10,78,706 (11.74)


Electrical Energy Consumption

Body Prep23%

Pressing 25%

Decorating 4%

Firing 16%

Finishing 16%

Utilities 16%

Department Wise Electrical Energy Share

Total Electrical Energy Consumption FY 20

Department Annual Consumption (Kwh)

Body Prep 36,98,578

Pressing 41,35,007

Decorating 6,10,115

Firing 26,23,195

Finishing 25,38,937

Utilities 25,55,795

Misc 2,02,154

Total 163,63,782


Thermal Energy Consumption

Total Thermal Energy Consumption FY 20

Department Annual Consumption Mkcal

Body Prep 36,082

Pressing 13,103

Decorating 1,895

Firing 41,310

Finishing ‐

Utilities 530

Misc ‐

Total 92,919

Body Prep39%

Pressing 14%Decorating

2%

Firing 44%

Utilities 1%

Department Wise Thermal Energy Share


Energy Consumption TOE

Electrical 13%

Thermal 87%

Energy Compostion

Body Prep37%

Pressing 16%

Decorating 2%

Firing 41%

Finishing 2%

Utilities 2%

Department Wise Total Energy Share

TOE Consumption FY 20

Department Annual Consumption TOE

Body Prep 3,923

Pressing 1,664

Decorating 242

Firing 4,352

Finishing 218

Utilities 273

Misc 17

Total 10,690


SEC Electrical Energy

FY18 FY19 FY20Sp.Electrical Energy

Kwh / Ton 195.37 213.90 189.97

195.37

213.90

189.97

175.00

180.00

185.00

190.00

195.00

200.00

205.00

210.00

215.00

220.00

Kwh/ton

SEC Electrical Energy High SEC in FY19 was due to coldrecommissioning of one oldfurnace required to accommodatechanged product mix. Additionallyfrequent process interruptions inthis FY on account of new productdevelopment activities

There was 8% and 5%reduction in plantproduction whencompared to previous twoFY. However there are 11%YOY reduction in SEC inFY20

SEC FY19

Production SEC FY20


SEC Thermal Energy

SEC FY19

Production SEC FY20

FY18 FY19 FY20Sp.Thermal Energy

Mkcal / Ton 12,59,652 12,22,173 10,78,706

12,59,652

12,22,173

10,78,706

9,50,000

10,00,000

10,50,000

11,00,000

11,50,000

12,00,000

12,50,000

13,00,000

Mkcal/Ton

Sp. Thermal Energy Reducing trend of thermal SEC is on account of

Continual improvement in thermal efficiency of Kilns. Better productivity / Cycle time.

Improved process parameters like ceramic slip density and reduced water evaporation in dryers

Improvement in heat losses in spray dryer ducts


SEC Comparison

SEC FY19

Production SEC FY20

Our AchievementFY 20

• Thermal: 1079 Kcal/Kg • Electrical: 0.189 Kwh/Kg

Industry Achievement*

• Thermal: 850 Kcal/Kg • Electrical: 0.175 Kwh/Kg

Our TargetFY 22

• Thermal : 900 Kcal/Kg• Electrical :0.180 Kwh/Kg

* Our SEC is based on our product mix. Industry achievement is based on single product. Similar product mix data is not available nationally / internationally.


ENCON Projects FY 21

SEC FY19

Production SEC FY20

ENCON Measures Planned Estimated Energy Savings Mn Rs/Yr

Approximate Investment MnRs/Yr

Tentative Project Commencement

Heat recovery from Kiln Smoke air fan for pre kiln dryers : Kiln 1 + Kiln 3 6.6 10 Q1 FY 22

Utilization of Kiln cooling section exhaust for after press dryers 3.3 2.0 Q1 FY 22

Heat recovery RLW in Kiln 3 1.0 0.01 Q2 FY21

Replacement of AODD pumps for ceramic slip handling 1.5 1.0 Q4 FY 21

Compressed air demand side management activities 1.2 1.0 Q1 FY 22

Completion of VFD installation in ball mills –4 nos 1.2 1.2 Q3 FY 21

Section wise VFD installation in Polishing Line 0.9 1.2 Q4 FY 21

Polishing Line ETP modifications 1.0 1.5 Q3 FY 21

Chain Stove chain replacement 1.4 2.0 Q2 FY 21


Implemented ENCON Projects

SEC FY19

Production SEC FY20

Year No of Proposals

Investment(INR Million)

Annual Savings(INR Million )

2017‐2018 5 0.5 4.47

2018‐2019 8 80 19.16

2019‐2020 10 70 19.24


ENCON Projects FY18

SEC FY19

Production SEC FY20

Sr.No Project Details



Payback Period (Moths)

1 VFD Inverter Ball Mill 1 0.35 0.40 11



4 Combined hot air duct from 2 Kilns to dryer 0.61 1.08 7

5 Digital Energy Monitoring Systems 2.81 1.00 36


ENCON Projects FY19

SEC FY19

Production SEC FY20









5 New Air Compressors 2 nos 4.55 11.55 4.73

6 Installation of LED lights 3.80 3.12 14.61

7 Installation of dome shaped natural light s 1.10 0.31 42.29

8 Installation of Energy Efficient Press 68.08 2.78


ENCON Projects FY 20

SEC FY19

Production SEC FY20





1 Kiln heat recovery 0.05 0.33 1.79

2 Electrically operated chiller replacement with natural cooling 1.90 6.84 3.33

3 Capacitor at ball bill 2 6&8 0.06 0.15 1.21

4 Kiln vertical entry for 600 mm x 1200 mm size tiles 0.15 1.48 3.25

5 VFD for dust collector motors 0.20 0.74 1.46

6 Capacitor for new compressors 0.06 0.49 7.89

7 Capacitor for new polishing line 0.05 0.08

8 Motion sensors for lights 0.01 0.42

9 Stirrer On / Off timer for slip tanks 0.02 0.57

10 Energy Efficient new polishing line 66.51 8.55


ENCON Project FY 18

SEC FY19

Production SEC FY20

Before After

Project Title VFD for Ball Mills

Project Details Installation of VFD for ball mills operations . Replacing conventional starter and fluid coupling

Consumption Before 95 kwh / ball mills

Consumption After 77 kwh / ball mills

Annual Savings – INRL INRL 10 for 3 ball mills

Project Investment ‐ INRL INRL 10 for 3 ball mills

Simple payback period – Yrs. 1 year

Before After


ENCON Project FY 19

SEC FY19

Production SEC FY20

Before After

Project Title Compressed Air System Modification

Project Details Replacing 6 old compressorswith 2 energy efficient compressors and air network modifications

Consumption Before 10000 Kwhd

Consumption After 6000 Kwhd

Annual Savings – INRL INRL 120

Project Investment ‐ INRL INRL 45

Simple payback period – Yrs. 0.35 Years

Pipeline NetworkBefore After


ENCON Project FY 19

SEC FY19

Production SEC FY20

Project Title LED plant lighting system

Project Details Replacing entire plant lights by LED lights





Simple payback period – Yrs. 1.15 Years


ENCON Project FY 20

SEC FY19

Production SEC FY20

Project Title Adiabatic Cooling

Project Details Replacement of electrically operated chillers with cooling towers





Simple payback period – Yrs. 0.28 years

Before After


ENCON Innovation FY20 Challenges High kiln surface temp

Project Brief : Our kilns are over 20 years old and incontinuous operation so surface energy loss from thesekilns cause of concern. Available internal coating in themarket can not be used as its deposition on tiles surfacemay damage tiles aesthetics and cause huge quality loss.Through our in‐house R&D we invented a high SRIproduct which is having high reflectance and highemissivity value (>100) and with this material Kilninternals roof, sides ,bottom and rollers are painted.

Type of innovation Product innovation

Replication potential Can be used in all furnaces

Project Impact 4.91% reduction in fuelconsumption

No deposition on tilessurface and loss of quality

Kiln Outside Surface

Before After


ENCON Innovation FY20 cont.. Challenges Low CA Temp + Dryer Fuel

Project Brief : All our kilns are fitted with combustion airpreheating system. Recovered heat from kiln used for partialheating of combustion air upto 140 deg C. Residual heattransported to dryers used for pre heating of products beforethey enter kiln. After process evaluation we identified furtherscope of extracting heat from Kiln in a different and unique waywhere the excess heat can be further tapped by throttling theoutput of a blower along with adjusting the pressure pointsinside the kiln and channelling the additional heat to combustionair preheating up to 180 dec C and pre kiln tiles drying stoppingsupplementary fuel consumption.

Type of innovation Process innovation

Replication potential Can be used in all furnaces

Project Impact 3% reduction in kiln fuelconsumption

50% fuel reduction in drier



ENCON Innovation FY20 cont.. Challenges Low Productivity + High SEC

Project Brief : Earlier single rectangular tiles (e.g. 600 mm x1200mm) used to enter kiln on 1200 mm side, while the kilnuseful width is 2000 mm, resulting in gross capacityunderutilization and loss of energy. Entry of the kiln wasmodified to make entry position of tiles vertical i.e. 600mm side ,accordingly kiln firing curve modified and kiln exit tilescollections mechanism modified. Now 3 tiles enters kilns on 600mm side and 1900 mm of useful kiln width is being utilized.Apart from energy saving it improves productivity and savedhuge modification cost in foreign exchange.

Type of innovation Engineering innovation

Replication potential Can be used in all furnaces.Presently done in kiln 1

Project Impact 39% reduction in specificfuel consumption

60% improvement inproductivity



Renewable Project FY 20

SEC FY19

Production SEC FY20

Project Title Roof top Solar Power Generation

Project Details 1.2 MW rooftop based Solar power plant installed in the year 2019. Plant was partly commissioned in Dec.19 and remaining plant commissioning is awaited for restart of plant post lockdown

Solar generation before project commissioning

0 Kwhd

Estimated average solar power generation capacity

5000 Kwhd

Estimated Annual Savings –Million Rs

9.2

Project Investment – INRL Opex mode + Facility development

Simple payback period – Yrs. 6 months

Before After


Utilization of RE sources

SEC FY19

Production SEC FY20

Technology – Electrical

Type of Energy Onsite / Offsite

InstalledCapacity (MW)

Generation(million Kwh)

% of Overall ElectricalEnergy

Solar Roof top

Onsite 1.2 MW

Technology – Thermal

Type of Energy Onsite / Offsite

InstalledCapacity (Mkcal)

Usage (Mkcal)

% of Overall ThermalEnergy

Biomass Onsite 1.2 MW


Waste Management

SEC FY19

Production SEC FY20


Energy Monitoring

SEC FY19

Production SEC FY20


Daily Energy Reports

SEC FY19

Production SEC FY20


Teamwork

SEC FY19

Production SEC FY20

Initiatives SnapshotDescription

Others

▪ International Drivers Day Celebration ▪ International Women's Day Celebration▪ SPC /SQC training ▪ Lean manufacturing and leadership development

Environment Management System

▪ Celebration of World Environment Day on 6th June.▪ Regular plantation activities inside plant premises ▪

Safety

▪ Safety gate meeting on 1st of every month▪ Celebration of National Safety Week ▪ Safety and housekeeping audits ▪ Bimonthly safety committee meeting for safety analysis

Energy Management Awareness

ISO 50001 Energy Management training program Energy Conservation Day Celebration On the Job training Departmental in house training

4

3

1

2


Certifications

SEC FY19

Production SEC FY20

Green Pro Certificate GRIHA Certificate

ISO Certificate IGBC Member

All products manufactured in the facility are Green Pro

certified

All products manufactured in the facility are GRIHA

certified

Manufacturing facility is ISO 9001: 2015, ISO 14001:2015 and ISO 4001:2018 Certified.

ISO 50001 implementation is in

progress

We are proud member of IGBC community

since ……


Long term EE vision

SEC FY19

Production SEC FY20


Awards & Accolades

BEE First Prize 2015 & Certificate Of Merits

Award in the year 2005


SEC FY19

Production SEC FY20

Thank you

We Can Make a World of Difference

Start a conversation at RedRampProject.org

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h&r johnson (india) - cii - sohrabji godrej green business

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