MML® - Waste Heat Recovery for Reducing Carbon Footprint


Malaysian Mosaics Sdn Bhd


 
To achieve resilience at times of increasing global price competitiveness, sustainability is fundamental to the company. By continuously driving green initiatives in its manufacturing processes, MML® optimises price competitiveness without compromising product and service quality.

INTRODUCTION

With a green legacy of over five decades, since its humble beginning MML® had already embraced an eco-compatible brand philosophy. Sustainability is part of the brand’s DNA, which has been consistently synergised across its 360° infrastructure throughout the MML® tile creation process. The brand’s latest green initiative saw the implementation of the MML® Waste Heat Recovery System, which has once again elevated its energy conservation efforts, contributing towards reducing carbon footprint.

Electricity and natural gas are used in the tile manufacturing process, with 85% of its energy source being natural gas. Being fired in a kiln at about 1,300°C, ceramic tiles are then cooled to room temperature. During the cooling process, waste heat at 171°C is vented into the atmosphere. After a careful process optimisation study, MML® has implemented a system to recover this waste heat to conserve natural gas consumption.

The MML® Waste Heat Recovery System recovers waste heat from the kiln and channels the recovered waste heat to operate its upstream processes. Hence, instead of the waste heat emitting into the atmosphere, it is reused to reduce natural gas consumption and carbon footprint.

FRAMEWORK AND STRATEGY

Through the MML® Waste Heat Recovery System, during the cooling process, waste heat from the kiln is recovered and channelled to its upstream manufacturing processes – spray drying and press drying. The recovered waste heat is used to preheat combustion air from a room temperature of about 32°C to 152°C and 169°C respectively.

To achieve resilience at times of increasing global price competitiveness, sustainability is fundamental to the company. By continuously driving green initiatives in its manufacturing processes, MML® optimises price competitiveness without compromising product and service quality.

The scope of this project covers waste heat recovery. Through process optimisation, the MML® Waste Heat Recovery System recovers waste heat from the cooling process to reuse in other upstream manufacturing processes. If unrecovered, waste heat is “wasted” and emits into the atmosphere. This system provides a real-time monitoring feature, which enables remote access to monitor the system off-site.

ACHIEVEMENT AND IMPACT

Through the implementation of the MML® Waste Heat Recovery System, the company has reduced natural gas consumption by around 10% for its spray drying and press drying processes. This effectively contributes to the reduction of around 2,200 tonnes carbon footprint annually.

In line with MML® brand’s zero waste policy, this green initiative positively impacts the environment by reducing gas consumption to conserve natural gas reserves. It also contributes towards the local government’s commitment in the Paris Agreement to reduce 45% of carbon footprint by 2030. This achievement has once again marked a new CSR milestone in the arena of 4R (Reduce, Reuse, Recycle, Recover) for MML®.

FUTURE DIRECTION

MML® strives to continuously build sustainability through energy conservation activities. Moving towards their goals in sustainable energy conservation, MML® is also exploring other new initiatives such as Dynamic Voltage Control System and optimisation of milling in ball mills.

Other factors in consideration are:
  • The National Green Policy – formulated by the Ministry of Energy, Green Technology & Water, Malaysia
  • Global Sustainable Green Development
  • Benchmarking within the industry
  • The Paris Agreement on climate change

MML® brand’s commitment to comply with legal requirements and in CSR are the brand’s key factors in driving eco tiling solutions towards a sustainable future, with products that love and respect the environment.
In 1964, industry experts from Japan, Italy and France were brought in to pioneer world class technology and stringent quality management in the start up of MML® – Malaysia’s first mosaic plant. Today MML® is a world-recognised award winning brand in luxury ceramic tiles, gracing the floors and walls of residential and commercial projects around the world.