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Confederation of Indian IndustryEnergy Management Cell

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C O N T E N T S

Page No.

Executive Summary

1. Introduction 1

2. Energy Saving Opportunities in Various Sectors

Cement 5

Caustic Chlorine 58

Aluminium 89

Glass 121

Ceramics 161

Copper 199

Paper 229

Fertilizer 310

Foundry 400

Textiles 448

Engineering 484

Sugar 530

Power Plant 596

3. List of Suppliers Address 628

4. List of Energy Auditors 650

5. List of Energy Service Companies 654

6. Financial Mechanism 655

7. Government incentives 667

8. Reference 689

9. Conclusion 693

Confederation of Indian Industry - Energy Management Cell

521

EXECUTIVE SUMMARYThe Republic of India (India), the world’s sixth largest energy consumer, plans major energyinfrastructure investments to keep up with increasing demand—particularly for electric power.India also is the world’s third largest producer of coal, and relies on coal for more than halfof its total energy needs.

Indian Renewable Energy Development Agency Limited is a Public Limited GovernmentCompany established in 1987, under the administrative control of Ministry of Non-ConventionalEnergy Sources (MNES) to promote, develop and extend financial assistance for renewableenergy and energy efficiency/conservation projects with the motto: “ENERGY FOR EVER”

About Investors’ ManualIndian Renewable Energy Development Agency (IREDA) has received a line of credit from theInternational Bank for Reconstruction and Development (IBRD) / Global Environmental Facility(GEF) towards the cost of “India: Second Renewable Energy Project”.

As a part of this line of credit, technical assistance plan (TAP) is envisaged for institutionaldevelopment and technical support to IREDA. Preparation of this investors’ manual forenergy efficiency sector – industrial sub sector, as a guide to intending entrepreneurs, is oneof these TAP activities.

Objective of this Manual:The objective is to prepare an Investors’ Manual covering the topics like energy savingpotential for various industries, technologies available to improve energy efficiency, equipmentsuppliers, government policies / incentives available for the sector, terms of IREDA and otherfinancial institutions extending support to such projects etc.

The end objective of the activity is market development for energy efficiency / conservationproducts & services. The whole effort is to prepare a simplified and user-friendly manualbased on inputs from various stakeholders in energy efficiency sector.

Confederation of Indian Industry (CII) – Energy Management Cell (EMC) was awarded thetask of preparing this manual by IREDA.

CII – EMC adopted the following methodology in preparing this manual:

1. Analyze the existing data available with CII and develop a detailed action plan for execution

2. Identify industries under energy intensive and non-intensive categories

3. Review the detailed energy audits carried out by CII in various sectors and estimateenergy saving potential possible in identified energy intensive and non-intensive sectors

4. Analyze literature available with CII

5. Discuss with industry experts / Consultants

6. Identify list of energy saving measures to be undertaken in each industry

7. Evaluate technical details for each of the proposed energy saving measures in variousindustries

Investors Manual for Energy Efficiency

522Introduction

8. Prepare / identify the list of equipment suppliers (National & International), EPS Contractors,Energy Service Companies, etc., who can take up these energy saving measures

9. Review the collected data with experts in each of the energy intensive and non-intensiveindustries

10. Prepare / identify the list of consultants / energy auditors etc., who can be approachedfor conducting energy audit, preparation of DPR, etc.

11. Interacting with IREDA and other financial institutions

12. Preparation of a brief note of finance mechanism available for taking up energy efficiencyprojects from IREDA and other financial institutions

13. Preparation of a brief description of government policy / incentives / concessions availablefor identified energy saving projects / equipment identified in various energy intensive andnon-intensive sectors


The various sectors identified under this project, and the share of energy in the manufacturingcost, is as under:

Sector Power & Fuel cost as % of Production cost

1 Cement 43.72 Caustic Chlor 40.73 Aluminium 33.44 Glass 30.95 Ceramic 25.36 Copper 24.07 Paper 23.78 Fertiliser 18.49 Foundry 13.710 Steel 13.311 Sponge Iron 12.812 Synthetic Textiles 11.313 Textile 10.314 Engineering 6.015 Tyre 7.716 Drugs & Pharma 4.617 Dairy 4.218 Sugar 2.0*19 Petro Chemical 2.020 Refinery 2.0

* cost equivalent of bagassee consumed


524Introduction

These projects are all proven projects, which have been implemented successfully in Indianindustry.

The objective of highlighting these projects is to facilitate the potential investors, in having aquick reference of the various energy saving measures and also enable them make decisionson investment.

Summary of this reportThis report focuses on energy conservation methodologies in 16 major sectors of Indianindustry.

The energy intensive sectors not included in this report are:• Steel & sponge iron• Petrochemcial• Refinery

The reason for exclusion of these sectors is:

• These sectors are technology specific

• The players in this sector are very few in number

• The players in these sectors are cash-rich and may not approach financial institutions forfunding energy saving projets. Alternately, they may approach for technology upgradatioonprojects, but these companies are well aware of these projects they need to take up infuture.

S.No Sector Annual saving Investment opportunityPotential Rs. Million, Rs. Million,

(US $, Million) (US $, Million)

1 Cement 3500 (70) 7000 (140)2 Caustic Chlor 8600 (172) 30000 (600)3 Aluminium 500 (10) 1000 (20)4 Glass 550 (11) 800 (16)5 Ceramic 350 (7) 725 (14.5)6 Paper 3000 (60) 5000 (100)7 Fertiliser 2000 (40) 6000 (120)8 Foundry 1800 (36) 3500 (70)9 Sythetic Fibre 1300 (26) 2500 (50)10 Textile11 Tyre 860 (17) 1750 (35)12 Drugs & Pharma 1100 (22) 1800 (36)13 Sugar 4200 (84) 6000 (120)14 Engineering 5000 (100) 10.000 (200)15 Copper 750 (15) 1500 (30)16 Power Plants 3000 (60) 5000 (100)

Total 37,510 (730) 82,575 (1651.5)


525

The various sectors highlighted in this report offer an annual saving potential of Rs 37510.million. This, in turn, creates an investment opportunity of Rs82575 million, to achieve theprojected energy savings.

This report will serve the objective of its preparation, in promoting / development of market forenergy efficient equipment & suppliers in Indian industry.


1

Introduction

India’s Energy scenario

BackgroundIndia’s economic growth is currently recovering from a mild slowdown in 2002, which wasmainly attributable to weak demand for manufactured exports and the effects of a drought onagricultural output. Real growth in the country’s gross domestic product (GDP) was 4.8% for2002, and is projected to rise to 5.7% in 2003. The economic effects of recent politicaltensions in the region have been quite modest.

OilOil accounts for about 30% of India’s total energy consumption. The majority of India’s roughly5.4 billion barrels in oil reserves are located in the Bombay High, Upper Assam, Cambay,Krisha-Godavari, and Cauvery basins.

Future oil consumption in India is expected to grow rapidly, to 3.2 million bbl/d by 2010, from2.0 million bbl/d in 2002.

Natural GasIndian consumption of natural gas has risen faster than any other fuel in recent years. Fromonly 0.6 trillion cubic feet (Tcf) per year in 1995, natural gas use was nearly 0.8 Tcf in 2000and is projected to reach 1.2 Tcf in 2005 and 1.6 Tcf in 2010.

CoalCoal is the dominant commercial fuel in India, satisfying more than half of India’s energydemand. Power generation accounts for about 70% of India’s coal consumption, followed byheavy industry. Coal consumption is projected in the International Energy Annual 2002 toincrease to 450 million short tons (Mmst) in 2010, up from 369 million short tons in 2000.

India is the world’s third largest coal producer (after China and the United States), so mostof the country’s coal demand is satisfied by domestic supplies.

ELECTRICITYAs per recent estimate, total installed Indian power generating capacity is about 112,000 MW.The government had targeted capacity increases of 100,000 megawatts (MW) over the nextten years.

Per-Capita ConsumptionPer capita energy consumption in India is only 350 kWh (277 Kg of oil equivalent (KOE)),which is just 3.5 per cent of that in the USA, 6.8 per cent of Japan, 37 percent of Asia and18.7 per cent of the world average.


2Introduction

But, energy intensity, which is energy consumption per unit of GDP, is one of the highest incomparison to other developed and developing countries. For example, it is 3.7 times that ofJapan, 1.55 times of the USA, 1.47 times of Asia and 1.5 times of the World average.

The industrial sector is the highest consumer of electricity (34 percent) followed by agricultural(30 per cent) and domestic (18 per cent) sector.

The importance of energy as a driver for economic growth in India Is greater than in mostcountries. The world development report ranks India sixth in its list of countries requiringenergy for GDP growth.

a. Huge gap between supply & demand b. Massive T & D losses

c. Average cost of supply exceeds d. Increasing losses of SEBs average tariff

0

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20000

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40000

50000

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Energy Consumed in kJ per $ of GDP

Capacity Addition in last 5 yr Plan (MW)

30000

16000

Target Actual

T & D Losses35%

10%

India Benchmark

Price (Rs./kWh)3.4

1.41

0.22

1.922.42

Industry Domestic Agriculture Avg Price Cost

Avg. SEB Rate of Return

-12%

-18%

1992-93 1998-99


3

Energy conservation is one of the prime areas of focus to overcome the supply – demand gap.Whilst the generation increase has been steady, the consumption pattern has also beensteady.

Electricity consumption in India

The electricity consumption profile in India has, by and large, been the same in the last fiveyears. There has been a small drop in the irrigation / agriculture based consumers, whichhas been equated by a small increase in the consumption profile of domestic consumers. Thecommercial & miscellaneous users and the industrial consumers have not varied a lot.

This has been the profile in spite of the increase in GDP & per capita power consumption.

The per capita power consumption in 1996 – 97 has been 334.26 kWh compared to 350 kWhin 2001-02.

The per capita national income has increased from 10149 in 1996-97 to 17736 in 2001-02.

01020304050

Perc

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DOMESTIC IRRIGATION OTHERS

Electricity Consumption - Profile

1996-972001-02


4Introduction

Energy Saving Opportunities inVarious Sectors


5

Cement

Per Capita Consumption 100 kg

Growth percentage 8%

Energy Intensity 45% of manufacturing cost

Energy Costs Rs 70,000 million (US $1400 million)

Energy saving potential Rs.3500 m (US $ 70 million)

Investment potential on energysaving projects Rs.7000 m (US $140 million)


6Energy Conservation in Cement Industry

1.0 IntroductionCement is one of the core industries, which plays a vital role in the growth of the nation. Indiaranks third among cement producing countries in the world behind China and USA and hascome a long way, since the installation of the first cement plant at Porbandar in 1914. Thepresent per capita consumption is around 100 kg, which is much lower than the per capitaconsumption of 255 kg in the developed countries.

The per capita consumption is expected to increase to about 120 kg in the next 2 years.

India has the requisite quantity of cement grade limestone deposits, backed by adequatereserves of Coal. The technical expertise and managerial skills of the personnel have growntremendously resulting in efficient operation of the plant. The latest cement plants that arebeing installed in the country are comparable with the best in the world. India therefore hasa major role to play in the future global cement market.

A large quantity of cement and clinker are being exported particularly from the state of Gujaratare being exported to other Asian & African countries.

2.0 Present Capacity & Capacity UtilisationThere are 124 major cement plants with an installed capacity of 135 million tonnes as on 31March 2002. The Indian cement plants are a blend of a few high energy consumption old wetprocess plants with a capacity of 300 TPD and modern dry pre-calciner plants with capacitiesupto about 7500 TPD.

The annual production of cement by the major cement plants in the year 2001- 02 was around102.4 million tonnes with a capacity utilisation of nearly 80%. (Source CMA data)

3.0 Growth PotentialThe cement demand has been growing at about 8% in the country. However, there has beensubstantial increase in capacity of the plants in the recent past through plant upgradation andslack capacity is available in the industry.

The strategy of the Indian cement industry is to meet the additional demand in the industrythrough production of blended cement and utilising the slack capacity available in existingplants.

Additionally, there are 300 mini cement plants with an installed capacity of 11.10 million tonsproducing about 6.0 million tons (2001-02 data)

The major types of cement produced in India include – Ordinary Portland Cement (OPC) –33, 43 & 53 grader and blended cements such as Portland Pozzolana Cement (PPC) andPortland Slag Cement (PSC).

The OPC varieties account for about 70% of the production, while the blended cements PPC& PSC account for 18% and 10% of the production respectively. There has been a recenttrend to produce more quantities of blended cement varieties.


7

4.0 Cement Manufacturing – technologiesLimestone is the raw material used in the manufacture of cement. In India, three types ofprocesses are being used for cement manufacture and are given below:

• Wet process < 5% of the production

• Dry Suspension (SP) process < 8% of the production

• Dry Precalciner (PC) process > 85% of the production

The detailed description of the different processes is given below.

4.1 Wet ProcessThe oldest plants in the country are wet process plants. These plants are characterised bylow technology, low capacity, high man-power and higher energy consumption. The maximumcapacity of the wet plants operating in India is only 300 TPD.

With the current trend towards higher capacity, lower energy consumption and better qualitythe wet plants are being gradually converted or phased out. The main feature of the wetprocess is that the limestone is ground in wet condition and fed to the kiln as slurry. Majorityof the wet process plants have been stopped or converted and less than 5% of the cementis produced through this process

4.2 Dry SP ProcessThe Dry SP (Suspension Pre-heater) plants are comparatively modern plants and of moderatecapacity (upto 1500 TPD). In comparison to the wet plants, the dry SP plants are energyefficient.

The characteristic feature of the dry SP plants is that the limestone is ground in dry conditionand then fed to the kiln system through the pre-heaters.

4.3 Dry Precalciner ProcessThe Dry precalciner process is the latest process and characterised by high capacity (morethan 3000 TPD) and energy efficiency. More than 90% of the cement is produced throughthis process and the detailed process description is as under:

Cement is manufactured from Limestone and involves the following main steps:

• Mining

• Crushing

• Raw meal grinding

• Pyro-processing

• Cement grinding



Raw Mill Blending & Storage

Coal storage

Coal Crusher

Coal Mill

Pyro processing

Clinker storage

Cement mill

Packing & Despatch

Purchased coal

Slag or Fly-ash

Gypsum

Fine

Additives

Raw Meal

Fine

Mines Crushing Pre-blending

Block Diagram – Cement Industry – Dry Process Precalciner Process

MiningThe major raw material for cement manufacture is limestone. The limestone is mined in opencast mines in the quarry and then transported to the crusher through dumpers / ropeways.

Conventionally, the limestone was being mined by the usual methods of drilling and blasting.The latest trend is to install miners which have the advantage of lower operating cost inaddition to being environment friendly.

CrushingThe mined limestone is conveyed to the crusher through dumpers or ropeways. The materialis then crushed in the crusher to a size of about 25 – 75 mm. The crushing is done in twostages in the older plants while in the modern plants normally single stage crushing is done.The typical crushers used are jaw crusher and hammer crusher.

Raw meal grindingThe crushed limestone is ground into a fine powder in the dry condition. Generally, the ballmill is used for grinding in a dry SP plant, while a Vertical Roller Mill (VRM) is used in a dryPC plant. The VRM is comparatively more energy efficient consuming only 65% of the energyconsumption of the ball mill. The ball mill along with a pre-grinding system such as roll pressis also used in some of the plants with very hard and abrasive limestone.

Pyro-processingThis is the most important step in the manufacture of cement. This takes place in the kilnsystem. The kiln is a major consumer of electrical energy and the only consumer of thermalenergy in a cement plant.


9

The ground raw meal after getting preheated in the pre-heater system enters the calciner.The calciner is a vessel provided between the preheater and calciner. The calcination oflimestone and the conversion into clinker takes place in the precalciner and kiln respectively.

Cement grindingThe clinker produced in the kiln stored in the silo / stock-pile is ground along with Gypsum(about 5%) to produce Ordinary Portland Cement (OPC). The generally used grindingequipment is the ball mill in various cement plants in India. In some of the recently installedplants the VRM has been installed with satisfactory results. The other types of cement suchas PPC (Portland Pozzolana Cement) and PSC (Portland Slag Cement) are also produced bygrinding clinker with fly-ash and blast furnace slag respectively.

5.0 Energy Intensity of Cement IndustryThe production of cement is highly energy intensive with more than 45% of the manufacturingcost being contributed by energy (electrical & thermal). The Indian cement industry is nextonly to the Iron & Steel industry in terms of the overall value of the energy consumption inthe country.

The total value of energy consumed in the Indian cement industry amounts to nearly aboutRs 70,000 millions (USD 1400 millions).

Energy consumed in cement industry - Rs 70,000 million (USD 1400 million)

6.0 Specific Energy Consumption – Average and TargetsThe average specific energy consumption of various Indian cement plants in 2001 - 02 isabout 98 units / ton of cement (OPC – 43 grade). There are about 10 numbers of cementplants who have done extremely well and are operating with a specific energy consumptionless than 85 units / ton.

The thermal energy consumption average is about 760 kcal/kg of clinker. Based on the studyof the latest cement plants, the target energy consumption for a new cement plant could beas below:

Specific Electrical Energy consumption : 75 units/ton of OPC – 43

Specific Thermal Energy Consumption : 715 kCal/kg of clinker

7.0 Energy Saving potential and Investment potentialThe various studies of Indian cement industry indicates an energy saving potential of about5%, which amounts to Rs 3500 millions (USD 70 millions). The investment potential for theseprojects is about 7000 millions (USD 140 millions).



8.0 List of Energy Saving ProjectsThe list of energy saving projects, which can be implemented in different sections of a cementplant are listed below:

Mines and CrusherShort-term• Increase operating capacity of primary & secondary crusher• Reduce idle run of crushers and belts• Reduce idle operation of dust collection equipment

Long-term

• Install bulk analyser for crushed limestone

Raw mill grinding & storageShort-term

• Avoid idle running of raw mill conveyor system (Auxillaries)

• Avoid idle operation of raw mill lubrication system

• Optimise starting & stopping sequence of raw mill (to minimise idle running of fans)

• Minimise false air entry in raw mill system

Medium-term

• Install variable louvre system for roller mill

• Install high efficiency dynamic separator for roller mills

Long-term

• Use vertical roller mill instead of ball mill

• Control raw meal feed size by installation of tertiary crusher

• Install belt and bucket elevator in place of pneumatic conveying

• Installation of efficient mill intervals – diaphragm and liners

• Install online X-Ray analyser for raw meal

• Install slip power recovery system / VFD for raw mill fan / ESP fan

• Install external mechanical recirculation system for roller mills and optimise air flow

• Kiln, Pre-heater & cooler

Short-term

• Install CO and O2 analyser at kiln inlet and preheating outlet

• Maintain proper kiln seal (inlet and outlet) to avoid false air infiltration

• Reduce leakages in the preheater system


11

• Minimise primary air to kiln

• Utilise the cooler waste heat for flyash / slag / coal

• Install soft starters for clinker breaker

Medium-term

• Install VFD for cooler fans and cooler ID fans

• Opptimise the cooler exhaust chimney height to reduce the exhaust fan power consumption

• Install water spray in cooler to minimise fan power consumption

Long-term

• Install system for firing waste tyre, bark, rice husk, groundnut shell and urban waste inprecalciner

• Conversion from pneumatic conveying of kilnfeed to mechanical mode

• Conversion from single channel to multichannel burners

• Replace planetary cooler with grate cooler

• Replace conventional coolers (planetary / grate) with high efficiency coolers

Coal yard & coal mill

• Elimination of spontaneous combustion, by proper stacking

• Avoid idle running of coal conveyor & crusher

• Optimise starting & stopping sequence of coal mill to reduce idle operation of fans

• Maintain higher residue for precalciner firing

• Increase residue of coal mix, if possible

Cement Grinding, Storage & Packing

Short-term

• Water spraying on the clinker at cooler outlet (Temp above 90oC, consumes more grindingenergy)

• Reduce cement mil vents and recirculate to reduce cement loss

• Avoid idle running clinker conveyor – dust collector fan

• Avoid idle running of cement silo exhaust fans

• Optimise starting & stopping sequence of cement mill to avoid idle running

• Increase production of blended cement (PPC and PSC)

• Use of grinding aids

• Optimise water spray compressor capacity



Long-term

• Optimise cement grinding fineness – Install particle size analyser and optimise the particlesize distribution

• Install belt conveyor / screw conveyor / bucket elevator system instead of pneumaticconveying

• Installation of roller press / impact crusher / VRM as a pregrinder before the ball mill

Compressors & Compressed Air SystemShort-term

• Eliminate compressor air leakages by a vigorous maintenance programme

• Maintain compressed air filters in good condition

• Install compressed air traps for receivers

• Optimise compressor discharge pressure

Medium-term

• Install screw compressors with VFD in place of old compressors

• Replace multiple small units with single larger units

• Install intermediate control system for compressed air systems

Electrical SystemShort-term

• Avoid unnecessary lighting during day time

• Use energy efficient lighting

• Distribute load on transformer network in an optimum manner

• Improve power factor

– Individual compensation

– Group compensation

– Centralised compensation

• Replace over sized motors

• Replace with energy efficient motors

• Use VFD for low / partial loads

• Convert delta to star connection for motors loaded below 50% of full load (for occasionalpeak load provide automatic-star-delta-convertor)

• Install energy saver in fluorescent lighting circuit

• Fixing of light fixtures at optimum height


13

• Operate lighting system at lower voltage (say 360 V in 3 phase)

• Use servo stabliser in lighting circuits

• Replace conventional fluorescent tubes (40 W) with slim tubes (36 W)

• Optimise system operating voltage level

Medium-term

• Install demand controller for maximum utilisation of demand

• Use of electronic ballast in place of conventional chokes

DG SetsShort-term

• Increase loading on DG sets

• Install VFD for cooling tower pumps and fans

• Convert electrical heating furnace to thermal heating

Long-term

• Install WHR system in DG set for preheating furnace oil

• Install vapour absorption refrigeration systems utilising DG jacket with heat or exhaust heat

Newer technologies (Long-term)

• Install high efficiency cooler – CFG / CIS / SF across bar / Pygostep / IKN pendulam –cooler

• Install low pressure drop cyclones for preheater

• Install latest high-level control systems for kiln, raw mill and cement mills

• Install WHR systems to recover heat from preheater and cooler exhaust

9.0 Long-term case studies11 actual case studies, which have been implemented successfully in the Indian cementplants, have been included.

Each of the individual case studies presented in this chapter includes:

• A brief description of the equipment / section, where the project is implemented

• Description of the energy saving project

• Implementation, methodology, time frame and problems faced during implementation (ifany)

• Benefits of energy saving projects

• Financial analysis of projects and

• Replication potential



• Diagram of the system or photograph of the project is also included, wherever applicable.

The data collected from the plant is presented in its entirety. However, the name of the plantis not revealed to protect the identity of the plant. Similar projects can be implemented byother units also to achieve the benefits.

A word of caution here. Each plant is unique in its own way and what is applicable in oneplant may not be entirely applicable in another identical unit. Hence, these case studies couldbe used as a basis and fine-tuned according to the individual plant requirement before takingup for implementation.


15

Case Study - 1

Installation of High Efficiency Dynamic Separator for Raw Mill

BackgroundThe Raw Mill is one of the important equipment in the Cement industry used for grinding

Limestone into fine raw meal powder. The older plants had Ball Millsfor this operation. Consequently the energy efficient Vertical RollerMills (VRM) came into being. The VRMs have comparatively 30 – 35% lower energy consumption than the Ball Mills. In the older Cementplants the VRMs had a simple static separator installed for separationof the coarse and fine material. The separator was an integral partof the VRM.

In the conventional separators, the ground material is lifted to theseparator by high velocity hot air at the louvres. The separatorseparates the coarse and fine particles and fine particles are carriedaway by the airflow to the dust collectors. The coarse material subsidesthrough the raising freshly ground material. This creates additionalpressure drop in the VRM and also leads to increased circulationinside the Mill. The particle size distribution is also wider with bothvery fine and coarse particles present.

The latest trend has been to install cage type high efficiency separator.In these separators, the material enters radially through a cage type

separator. The coarse material after separation is collected in a cone just below the separatorand is dropped on to the grinding table through a gravity air lock. In this manner the contactbetween the freshly ground material and the coarse is avoided.

The advantages of these separators are as below.

• Closer particle size distribution

• Less pressure drop across the VRM

• Higher output at the same fineness as before or finer productat the same output rate

Previous statusIn a million tonne dry process pre-calciner plant, a Vertical RollerMill (VRM) was being used for grinding raw meal. The VRM hada conventional static separator.

Energy saving projectThe existing static separator was replaced with a new cage type dynamic high efficiencyseparator.



Implementation methodology & time frameThe new separator could not be accommodated in the Mill body. So the Mill casings weremodified to accommodate the new separator. Hence, to save on time the drawings wereprepared and the new separator assembled outside and kept ready for installation.

With all these preparations, the actual installation needed only 21 days of Mill stoppage.However in majority of the cases, the new separator can be fitted into the existing mill casingitself.

Benefits of the projectThere was an increase in the output of the Mill, finer product and reduction in the specificpower consumption of the Mill. Additionally, the Mill vibration also got reduced resulting introuble free operation.

The power saving amounted to 2.5 units / ton of Raw meal or 3.0 units / ton of Cement whichannually amounted to 18 lakh units / year.

Financial analysisThis amounted to an annual monetary saving (@ Rs 3.0 /unit) of Rs 270 million (Rs.5.4million) (US$ 0.11 million). The investment made was around Rs 300 million (Rs.6.0 million) (US$ 0.12 million) period for this project was 13 months.

Replication potentialThere are about 150 vertical roller mills in Indian cement industry. The application of the highefficiency separator is possible in about 50 installations. The investment potential is thereforeRs 300 millions (USD 6 million)

Cost benefit analysis• Annual Savings – Rs 270 million

• Investment – Rs 300 million

• Simple payback - 13 months


17



Case Study - 2

Replacement of the Air-lift with Bucket Elevator for Raw-mealTransport to the Silo

BackgroundThe raw-meal after grinding in the Raw mill is conveyed to the silo for storing and blending.

The transport of raw-meal is conventionally done through pneumaticconveying systems such as air-lift. The pneumatic conveying systemconsumes more power, nearly 3 to 4 times that of the mechanicalconveying system.

Bucket Elevator for raw meal conveying Also, the pneumatic conveyingsystem puts in air to the silo, which has to be removed. Conventionally,the pneumatic conveying system was being preferred as themechanical system (particularly the Bucket elevator) was not veryreliable and the plant required operation continuously.

In the recent years with the improvement in the metallurgy of thebucket elevators links and chains, bucket elevators that can operatecontinuously in a reliable manner have been developed. These alsohave been installed in many plants with substantial benefits.

Previous statusIn a million tonne dry process pre-calciner plant, operating with aVertical Roller Mill (VRM), the raw meal was being conveyed with the

help of an air-lift.

Energy saving projectThe air-lift was replaced with a bucket elevator. The air-lift was retained to meet the stand-by requirements.

Implementation methodology & time frameThe installation of the Bucket elevator took about 6 months. There was no stoppage of theplant, and the installation of the Bucket elevator was done parallely. The system was hookedon during a planned stoppage of the raw mill.

Benefits of the projectThe implementation of this project resulted in reduction of power from 140 units for the air-lift to 40 units for the Bucket elevator. The air to be ventilated from the silo also got reducedwith the installation of the mechanical conveying system. The silo top fan was downsized totap this saving potential. The saving annually amounted to 6.8 lakh units / year.


19

The total benefits amounted to a monetary annual savings of Rs. 2.24 millions. The investmentmade was around Rs. 5.4 millions. The simple payback period for this project was 29 months.

Benefits of mechanical conveying• Low energy consumption (25 - 30% of Pneumatic conveying)

• Reduction in power consumption of silo top dedusting system

Replication potentialIn each cement conveying to a higher elevation is required in 3 sections – raw mill (raw mealconveying to silo), kiln (kiln feed conveying to the preheater top) and cement mill (cementconveying to cement silo).

This project has been taken up by design in all the new plants for all the three and majorityof the older plants. The potential for replacement however exists in about 40 installations.The investment potential for this project is about Rs 200 millions (USD 4 millions)

Cost benefit analysis• Annual Savings – Rs 2.24 millions

• Investment – Rs 5.4 millions



21

Case Study - 3

Replacement of Existing Cyclones with Low Pressure Drop(LP) Cyclones

BackgroundThe Pre-heaters comprising of 4/5/6 stages of cyclones is an important part of the Kiln section

in a Cement Plant. In the pre-heaters the waste gas coming out ofthe Kiln system is used for pre-heating the kiln feed material. Withincreased focus towards more heat recovery from the waste gas, thenumber of pre heater stages have been increased from 4 to 5 / 6.The increase in the number of stages however led to increase in thepressure drop across the system and hence higher fan power. Thisled to the development of cyclones, which have a lower pressuredrop. The low pressure drop (LP) cyclones have the advantage of

• Low pressure drop. Hence, lower Pre-heater fan powerconsumption.

• Higher output rate with the same Pre-heater fan

• Reduction in thermal energy consumption

Previous statusIn a million tonne dry process pre-calciner plant, there were 4 stagesof conventional cyclones with a twin cyclone at the top. The pressure

drop across the top twin cyclone was about 100 – 125 mmWg.

Energy saving projectThe existing top stage twin cyclone was replaced with alow pressure drop cyclone.

Implementation methodology & time frame

The top cyclone was at a height of nearly 106 metres.The implementation of this project involved removal ofthe existing cyclone and fixing of the new LP cyclone.The normal procedure involves the following steps:

• Removal of the bricks inside the existing top cyclone

• Removal of the old cyclone

• Installation of the new cyclone

• Refractory lining of the new cyclones

This procedure however needs a stoppage of the plant of more than 90 days. The plant couldnot afford such a long stoppage and the consequent loss of production.



Hence, the procedure was improvised to reduce the plant stoppage time. The improvisedprocedure adopted by the plant is as below:

• The entire cyclone was assembled at the ground floor

• The inside brick lining was also done at the ground floor only

• The plant was then stopped and the existing cyclones removed

• The entire twin cyclone along with brick lining was lifted to the top and fixed. A specialcrane was used for lifting the cyclones of about 150 MT to a height of about 106 metres.

In this manner, the project could be implemented with a stoppage of only 20 days.

Benefits of the projectThere was an increase in the output of the Kiln, reduction in pressure drop of the pre-heater,reduction in Kiln section power consumption and reduction in Kiln specific thermal energyconsumption. The comparison of the conditions and the energy consumption before and afterinstallation of the LP cyclones are as below:

Parameter Before Implementation After Implementation

Clinker Production 2650 TPD 2850 TPD

DP across Top Cyclone 100 – 125 mmWg 70 – 90 mmWg

Kiln section Power 30 kWh /ton 28.5 kWh / ton

Heat Consumption 830 kCal / kg 810 kCal / kg

The implementation of this project resulted in a power saving of 1.5 units / ton of Clinker,which annually amounted to 14 lakh units / year. Additionally there was also the thermalenergy reduction of about 20 kCal / kg. The increased output of 200 TPD of clinker also aidedin reducing the fixed cost component.

Financial analysisThe total benefits amounted to a monetary annual savings of Rs 2.4 millions. The investmentmade was around Rs 2.2 millions. The simple payback period for this project was 11 months.

Benefits of low pressure drop cyclone• Lower pressure drop across P.H.

• Reduction in P.H. fan power consumption

• Increase in clinker production

• Reduction in thermal energy consumption.

Cost benefit analysis• Annual Savings - Rs.2.4 millions

• Investment - Rs.2.2 millions




Replication potentialThe replacement with LP cyclones has been implemented only in about 25% of the plants and

that too only in majority of the cases for the top cyclones.The potential for replacement with LP cyclones existsin atleast about 100 cyclones (50 plants x 2 cyclonesper plant). The investment potential is about Rs 1000millions (USD 20 millions)

LP cyclones for preheater


23


25

Case Study - 4

Install a high level control system for kiln operation

BackgroundThe Kiln is an important equipment in a Cement plant. The steady and continuous operationof the Kiln is essential for producing good quality Clinker,higher level of output and lower energy consumption. Theolder Kilns are operated more based on manual control ofvarious process parameters.

In the next level of operation systems, rule based PIDcontrols were introduced such as – changing the coalquantity based on temperature, varying fan speed withdrought etc., were introduced.

The recently installed high level control systems are basedon an “adaptive-predictive” methodology. Based on theseveral operational parameters, the results are predictedand action taken accordingly.

The actual results are also measured periodically and given as inputs to the system. Thishelps in refining the prediction mechanism and improving the overall efficiency of the controlsystems.

In the latest plants high level control systems have been installed and the control is moreautomated. The system operates the plant much the same way, as the best operator woulddo, on a continuous basis.

Previous statusIn a 2200 TPD dry process pre-calciner plant operating at a capacity of about 2350 TPD, theKiln was being controlled with conventional PLC method.

Energy saving projectA new high level control system was introduced to operate the Kiln.

Implementation methodology & time frameThe Kiln was initially started in the manual method and after reaching the steady operationthe Kiln was put in the high level control system.

Benefits of the projectThere was a marginal increase in the output of the Kiln, reduction in pre-heater exhausttemperatures, Cooler Exhaust temperature and steady operation of the Kiln.



The benefits achieved are as below.

• Reduction in Pre-heater exhaust temperature by 5°C.

• Reduction in Cooler exhaust temperature by 5°C.

• Variation in exhaust temperatures reduced from ± 10°C to ± 5 °C.

• Variation in clinker litre weight reduced.

• Reduction in thermal energy consumption by 10 kCal / kg of clinker

• Additionally there was also an improvement in the outlet of the kiln by about 3%

Financial analysisThe implementation of this project resulted in an annual saving of Rs 3.0 millions (only thethermal energy saving). The investment made was around Rs 4.0 millions. The simple paybackperiod was 16 months.

Replication potentialThe system has been successfully installed in about 20 numbers of plants (particularly thelatest plants). The potential exists in atleast 30 number of kilns in India. The investmentpotential is about Rs 120 millions (USD 2.4 millions)





27



Case Study - 5

Usage of Cheaper Fuels for Calciner Firing

BackgroundThe Kiln and the Calciner are major consumers of fuel in a Cement plant. The fuel costamounts to nearly 20 % of the manufacturing cost.The increasing cost of fuel and the competitionamong the units have made the Cement units totake up many thermal energy saving projects. Theplants are also looking for avenues for reducingthe cost by replacing the costly fuels with cheaperfuels. The possible fuels that have been tried bythe Cement units include Lignite, Rice husk andGround-nut shell.

Previous statusIn a million tonne dry process pre-calciner plant, Coal was being used as fuel for firing in boththe Kiln and Calciner. The Coal was having a Calorific value of about 5900 kCal / kg with acost of about Rs. 2000 / MT.

Energy saving projectA provision was made to utilise Rice husk in the Calciner. With the new system it was possibleto replace part of the coal fired in the Calciner with Rice husk.

Implementation methodology & time frameA hopper was installed by the side of the pre-heater building for storing the Rice husk. Therice husk was fed to this hopper with the help of front end loaders. The Rice husk wasconveyed to the Calciner with the help of a Rotary blower of 32 m3 / hour capacity. The wholesystem was fabricated with the waste material available in the plant. The system was hookedup with the main system during a brief stoppage of the plant. The system could be operatedfor about 8 months of non- rainy dry season.

Benefits of the projectThe implementation of the project resulted in the reduction of the cost of fuel used in theCalciner. The cost comparison of Coal and Rice husk are as below;

Parameter Coal Rice husk

Cost Rs.2000 / MT Rs. 750 / MT

Calorific value 5900 kCal / kg 2900 kCal / kg

Energy cost Rs. 340 / MMkcal Rs. 260 / MMkcal


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The rice husk was used for replacing about 10% of the total coal used for firing in thecalciners. This resulted in reduction of the total thermal energy cost, with the other conditionssuch as output, temperature, pressure etc. remaining the same. There was also a marginalreduction of the power consumption in the coal mill, as the rice husk was used directly withoutgrinding. The rice husk becomes wet and handling becomes difficult during the rainy season.Hence, the usage of rice husk was restricted to the non-rainy and dry season (about 8 monthsin a year).

Financial analysisThe annual benefits (in the form of reduction in thermal energy cost) was about Rs. 3.5millions. The equipment required for conveying and firing in the pre-heater was fabricated in-house with available material and hence the investment was negligible.

Benefits of using cheaper fuel• Reduction in thermal energy cost

• Marginal reduction in coal mill power consumption

Replication PotentialSeveral systems are operating in plants abroad with waste materials such as used tyres,municipal waste etc., This is an excellent project with good replication potential.

The discussions with various consultants and experts indicates that there is tremendouspotential for installing such systems. There is a need to initiate a demonstration project – acomprehensive one with mechanisms for collection of waste, processing & firing in the kiln.With the successful installation of a system in one / two installations can lead to a highreplication effect.

The benefits of implementing this project is two-fold - Reduction of fuel cost in the cementplant and waste disposal.

Cost benefit analysis• Annual Savings - Rs. 3.5 millions

• Investment – Negligible


31

Case Study - 6

Variable Speed Fluid Coupling for Cooler ID Fan andReplacement with Lower Capacity Motor

BackgroundThe fans in a Cement Plant are major consumers of power. One of the important fans in aCement plant is the Cooler vent fan. The hot clinker produced in the Kiln is cooled in theCooler with the help of air. The air after exchanging heat with the hot clinker is partly usedin the Kiln as secondary air & tertiary air and the remaining air is vented through the Coolerexhaust fan.

The exhaust air quantity keeps varying according to the operation of the Kiln, clinker production,coal quality, clinker quality etc,. The Cooler ID fan therefore has to be designed with excesscapacity to meet the extreme requirements. Also, the Cooler ID fan has to be continuouslycontrolled so that the Kiln hood draught is maintained at – 1mmWg to – 4 mmWg.

Typically, the control of the Cooler ID fan is through the damper. The damper is put on closedloop with the Kiln hood draught. The control of a centrifugal fan by damper is an energy in-efficient method as part of the energy supplied to the fan is lost across the damper. The latestenergy efficient method is to vary the speed of the fan to meet the varying requirements.Many plants have adopted this control and achieved substantial benefits. In a Cement plant,the Cooler ID fan offered a good scope for saving energy. The details are as below.

Previous statusIn a million tonne dry process pre-calciner plant, the Kiln had a conventional grate Cooler andthe Cooler ID fan was being controlled by damper. The fan was driven by a HT motor(6.6 kV) of 315 kW and the consumption was around 123 kW. The observations on the systemare as below:

• The operation of a centrifugal fan by throttling the damper is energy inefficient, as part ofthe energy supplied to the fan is lost across the damper. The energy efficient method isto vary the speed to meet the process requirements.



Cost benefit analysis• Annual Savings - Rs. 1.15 millions• Investment - Rs. 0.5 millions• Simple payback - 5 months

• Also, the loading of the motor is only 39 %, leading to in-efficient operation of the motor.

In this system, there was a good potential to incorporate a variable speed mechanism and alsoderating the motor to reduce the energy consumption.

Energy saving projectA Variable Fluid Coupling (VFC) was installed for the Cooler ID fan. The hood draught wasmaintained by varying the speed through the VFC. The existing 315 kW, 750 rpm & 6.6 kVmotor was replaced with a 230 kW, 750 rpm & 6.6 kV motor.

Implementation methodology & time frameAfter installation of the VFC, the speed of the fan was reduced manually in a gradual mannerfrom 750 rpm. The control of the hood draught was still done through the damper. The otherconditions remained the same as before. Consequent to the satisfactory operation of the VFCin manual fashion, it was put in closed loop with the hood draught.

The project took about 2 week for installation. This was taken up along with the annual Kilnshut down and hence the additional stoppage of the Kiln was avoided. The implementationwas done in a phased manner and the closed loop operation of the VFC was put into effectin about a months time. As the VFC usage is well established and reliable, no problems werefaced during implementation of the project.

Benefits of the projectThere was a drastic reduction in the power consumed by the Cooler ID fan. The comparison ofthe conditions and the power consumption before and after installation of the VFC are as below:Power consumption with damper control - 123 kWhPower consumption with VFC - 76 kWh

The installation of VFC resulted in power saving of 47 kW. The total annual power saving wasabout 3.84 lakh units.

Financial analysisThis amounted to an annual monetary savings (@ Rs 3.30 / unit) of Rs. 1.15 million. Theinvestment made was around Rs 0.5 millions. The simple payback period for this project was5 months.

Benefits of variable fluid coupling & lower capacity motor• Damper loss avoided• Higher PF and motor efficiency• Lower power consumption


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Case Study - 7

Variable Frequency Drives for Cooler Fans

BackgroundThe fans are major consumers of power in cement plant. The Coolerfans are some of the important fans in the Cement plant. The hotclinker produced in the Kiln is cooled in the Cooler with the help ofcool atmospheric air.

The cool atmospheric air supplied to the Cooler through multiplenumber of Cooler fans. The Cooler air quantity is dictated by theclinker production, condition of the Kiln & Cooler and other processparameters.

The clinker bed through which the cooler air is to be pushed, alsovaries from time to time. This alters the system resistance and hencethe fan flow. In the older Coolers, the fans are controlled by throttlingof inlet dampers / controlling the inlet guide vanes.

In both these controls, a part of the energy supplied to the fan is lostacross the damper / guide vane. The capacity control is also slowand not very accurate. The latest method of control is to vary thespeed of the fans to control the capacity.

Many plants have adopted this control and achieved substantial benefits both in the form oflower energy consumption & better control. The details of the implementation of this projectin a Cement plant is detailed below.

Previous statusIn a million tonne dry process pre-calciner plant, the Kiln had a conventional grate Cooler and7 numbers of Cooler fans were being operated for supplying the Cooling air. The first four fanswere regularly throttled to meet the varying requirements. The observations made on thesystem are as below:

• The operation of a centrifugal fan by throttling the damper is energy inefficient, as part ofthe energy supplied to the fan is lost across the damper.

• Also, the loading of the motor is varying between 50 % to 60 %, leading to in-efficientoperation of the motor.

The energy efficiency of this system can be improved by installing a VFD and varying thespeed to meet the process requirements.

Energy saving projectThe first four fans were installed with Variable Frequency Drives (VFDs).


35

Implementation methodology & time frameAfter installation of the VFDs, the varying requirement of the process was met by varying thespeed, thus avoiding the damper pressure drop. The fans were operated with damper fullyopen. The VFDs were put in closed loop with the volume flow to ensure constant flow of airto the Cooler.

The project took about 2 week for installation. This was taken up along with the annual Kilnshut down and hence the additional stoppage of the Kiln was avoided. As the VFD usage iswell established and reliable, no problems were faced during implementation of the project.

Benefits of the projectThere was a drastic reduction in the power consumed by the Cooler fans. The power savingin the fans is on account of

• Saving in the energy lost across the dampers

• Increase in the operating efficiency of the motor. The efficiency of the motor depends onthe V/f ratio. In the case of the VFD, the voltage is varied to maintain the V/f ratio at thedesigned value. Hence, the efficiency of the motor is maintained at a higher level even atlower loading of the motor.

The comparison of the conditions and the power consumption before and after installation ofthe VFDs are as below:

Drive Rating (kW) Power Power Savingconsumption consumption throughbefore VFD after VFD VFD

Fan – IA 75 Kw 45 kW 32 Kw 13kW

Fan – IB 75 kW 44 kW 30 kW 14 kW

Fan – IC 110 kW 68 kW 54 kW 14 kW

Fan – IC 110 kW 59 kW 44 kW 15 kW

Total Saving - 57 kW

The installation of VFD resulted in power saving of 57 kW. The total annual power saving wasabout 4.57 lakh units.

Financial analysisThis amounted to an annual monetary saving (@ Rs 3.30 / unit) of Rs 1.50 million. Theinvestment made was around Rs 2.50 million. The simple payback period for this project was20 months.



Benefits of variable frequency drive• Damper loss avoided

• Constant V/f ratio - hence higher motor efficiency

• Excellent control of capacity

Replication potentialA cement plant has got about 30 – 35 numbers of fans driven by LT (415 Volts) motors. Theapplication for VFD for cooler fans is a proven project. Majority of the plants have alreadyimplemented the high potential VFD projects in the cement plant.

The potential for installing VFD exists in atleast another 5 fans in say about 100 plants. Theinvestment potential is therefore (500 VFDs each with an average investment of Rs 200,000)- Rs 100 millions (USD 2 millions)

Cost benefit analysis• Annual Savings - Rs. 1.50 million

• Investment - Rs. 2.50 millioin


NoteThough the company has utilised in-house resources, the investment equivalent for the projectis Rs.1.0 million. This has been taken for financial calculations.


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Case Study - 8

Replacement of Existing Cooler I Grate with High EfficiencyCooler System

BackgroundThe Cooler is an important equipment in the Kiln section of Cement plant. The clinker coolerperforms the important function of cooling the hot clinker produced in the Kiln thereby

recuperating the heat back to the Kiln in the form ofhot secondary air. The operation of the Cooler istherefore important for producing good quality clinkerand operating the plant in an efficient manner.

The older Cement plants had conventional gratecoolers for cooling the Clinker. These Coolers havea maximum recuperation efficiency of 65 – 70 %.The present trend has been to replace part of theseCoolers with a high efficiency system with higherrecuperation. Two such systems are popularly beingadopted in many Cement plants in our country. The

adoption of these systems have resulted in a saving of 35 – 50 kCal / kg of clinker in manyplants.

Previous statusIn a 2500 TPD dry process pre-calciner plant operating at a capacity of about 2800 TPD, theplant had a conventional Grate Cooler. The plant wanted to increase the capacity of the plantto about 3000 TPD and also improve the energy efficiency.

Energy saving projectThe plant replaced the I grate with high efficiency cooler system. This was done to increasethe capacity of the Cooler and also improve the thermal efficiency of the system.

Additionally the following capacity upgradation measures were also implemented simultaneously.

• Increasing the height of the Calciner

• Installation of high efficiency classifier for both Raw mill and Coal Mill

• Conversion of the existing two fan system to three fan system

• Installation of high efficiency nozzles for GCT

Implementation methodology & time frameThe installation of the high efficiency Cooler was taken up simultaneously with the otherupgradation plans. The first grate comprising of nine rows of conventional plates was replacedwith high efficiency grate plates. The Kiln was stopped for about a month for the installationof the high efficiency Cooler. The stabilisation time was around 5 days.


39

Benefits of the projectOn account of the capacity upgradation projects the capacity of the Kiln increased from 2800TPD to 3000 TPD. The installation of the high efficiency Cooler resulted in reduction in theCooler air quantity and cooler exhaust air quantity. There was also an improvement in thesteady operation of the Kiln, better quality and lower temperature Clinker. The over-all benefitsachieved are as below.

Parameter Before Implementation After Implementation

Clinker Production 2800 TPD 3000 TPD

Cooler air 2.6 Nm3 / kg 2.1 Nm3/ kg

PH outlet air 1.475 Nm3/ kg 1.444 Nm3/ kg

Clinker Temperature 180. C 120. C

PH outlet Temperature 370. C 336. C

PH loss 217 kcal / kg 191 kcal / kg

Cooler & Clinker loss 131 kcal / kg 120 kcal / kg

Radiation loss 69 kcal / kg 65 kcal / kg

Heat Consumption 780 kcal / kg 745 kcal / kg

Apart from the above quantified benefits the installation of the high efficiency Cooler alsoresulted in

• Stabilised Cooler operation

• Avoiding of snow-man formation

Financial analysisThe implementation of this project resulted in an annual saving of Rs. 12 millions (only thethermal energy saving). The investment made was around Rs. 29 millions. The simple paybackperiod was 24 months.

Benefits of high efficiency cooler• Less cooler air

• Lower cooler exhaust and clinker temperature

• Compact - hence less radiation losses

• Thermal energy saving - 30 to 40 kCal/kg of clinker

Replication potentialThe above project is a potential replacement of the existing cooler with high efficiencycomponents. The potential for replacement exists is about 30 plants in India. The totalinvestment potential is Rs 900 millions (USD 14 millions).

Cost benefit analysis• Annual Savings - Rs. 12 millions

• Investment - Rs. 29 millions



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Three types of high efficiency coolers are currently available and operating in Indian cementindustry. They are namely – CFG / CIS from Fuller / FLS, Pendulam cooler from IKN andPyrostep cooler from Krupp Industries. All the three have tremendous benefits for energysaving.

Long-term optionsA long term option exists particularly for the olderplants (kilns of age say more than 25 years) to entirelythrow out the existing cooler and replace it with aentirely new high efficiency cooler.

The benefits are 3 fold – Higher energy efficiency(80-90 kCal/kg of clinker ie., three times that of thisproject), better product quality and ease of operation.

The energy saving alone would be about Rs 40millions. The investment required for totalreplacement would vary from Rs 300 millions to Rs500 millions. Therefore the energy saving alonecannot justify the replacement. The capacityaugmentation benefits also if included can make theproject more attractive.

IKN – Pendulum Cooler

SF Cross bar cooler



Case Study - 9

Installation of Low Primary Air Burner in Place of ExistingConventional Burners

BackgroundThe primary air is used for conveying and distributing the fuel into the Kiln. Conventionallysingle channel tubular burners were being used for this purpose. The quantity of primary airhad a major bearing on the thermal efficiency of the system as ambient cold air was beingused as primary air. Hence, efforts have been taken up by various suppliers of equipment toreduce the quantity of primary air by improvising the burners. Thus, the dual channel burnersand multi-channel burners came into being. The installation of these low primary air burnersresulted in reducing the primary air quantity from about 20 – 22 % to 11 – 12 % in the caseof dual channel burners and 5 – 7 % in the case of the multi-channel burners.

Previous statusIn one of the cement plants, the Dual channel burner was being used for Kiln firing. Theprimary air quantity was around 12 %.

Energy saving projectThis was replaced with a Multi channel burner. The total quantity of the Multi channel burnerwas only 5% (including the coal conveying air).

Implementation methodology & time frameThe project was implemented over a period of 9 months. The new Multi channel burner alongwith the new coal conveying system was procured and erected. The hooking up with the Kilnwas done during the annual maintenance stoppage. There was no problem during theimplementation of the project.


43

BenefitsThe implementation of this project resulted in the following benefits:

• Reduction in Specific thermal energy consumption from 750 Kcal / Kg to 743 Kcal / Kg,thus saving about 7 Kcal / Kg .

• The flame had become sharper and shorter.

• There was also a marginal reduction in the quantity of Cooler vent air.

Financial analysisThe total annual benefits amounted to Rs 3.2 millions. The investment made was aroundRs 8.5 millions. The simple payback period for this project was 32 months.

Benefits of high efficiency burner• Reduction in thermal energy consumption - 7 kcal/kg of clinker

• Marginal reduction in cooler vent air

• Sharper and shorter flame

Replication PotentialThe potential for installing low air burner exists is about 40 installations. The potential investmentfor this is about Rs 350 millions (USD 7 millions)


• Investment - Rs. 8.5 millions



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Case Study - 10

Usage of High Efficiency Crusher as a Pre-grinder Before theCement Mill

BackgroundThe final process in a Cement plant is the operation of grinding of cement from clinker in aCement Mill. The Cement mills are generally Ball Mills. The Ball Mills can be either open-circuit or closed circuit mills. The evaluation of the Ball Mills indicate that the Ball Mill is notenergy efficient in the coarse size reduction. The present trend is to install a Roll press orImpact Crusher as a pre-grinder before the Mill for the initial size reduction. The installationof the pre-grinder has the following advantages.

• Increase in capacity

• Reduction in specific energy consumption

Hence, all the Cement plants which have open circuit mills can install a pre-grinder systemand achieve substantial energy saving.

Previous statusIn one of the Cement plants of 2800 TPD capacity, the Cement Mill was an open circuit mill.The Mill was a two-chambered Combidan mill of 125 TPH capacity. The Specific powerconsumption was 29.0 units / ton of OPC - 43. The mill chambers were 5.77 m & 6.75 m longwith a diameter of 4.4 m.

The plant went for capacity upgradation in the Kiln and Raw mill sections and also startedproducing blended Cement varieties such as PPC and PSC. This necessitated a requirementfor higher Cement mill capacity.

Energy saving projectThe plant installed a Horizontal Impact Crusher (HIC) of 300 TPH capacity (includingrecirculation). The HIC was to act as a pre-grinder and perform the initial size reduction beforethe Mill. The HIC had a three deck-vibrating screen to separate and return the coarse materialback to the HIC. The coarse was sent to the HIC back by gravity while the fines wereconveyed to the hopper through a belt conveyor. The fines from the hopper can be later fedto the Mill through a belt conveyor. Thus the HIC and the Mill were made independent so thatthe operation of one does not affect the other. The modified system is schematically shownin the figure.

Implementation methodology & time frameThe HIC was installed separately and then hooked up to the system. The hooking up of theHIC took about 5 days. The installation of the HIC increased the capacity of the Cement millfrom 125 TPH to 140 TPH. Consequently some more modifications were taken up to furtherincrease the capacity of the Mill.

The modifications that were done are as below;

• The three deck screen originally installed were of 12 X 37 mm, 8 X 20 mm and 3 X 8 mmsizes. Consequently, after operating the plant the last screen size was modified to 5 X 12mm.

• The diaphragm was shifted by 0.7 M towards the inlet

• The mill ventilation was improved by cutting open some of the dummy side diaphragmplates.

• The grinding media sizes were gradually changed and were converted ultimately as below.

Identification Earlier Modified

I Chamber 90 – 60 mm 60 – 30 mm

II Chamber 15 mm Balls & 15 X 12 mm Balls &12 X 12 mm Cylpebs 12 X 12 mm Cylpebs

The stabilisation of the system with all the modifications as mentioned above took nearly anyear.


• Increase in capacity from 125 TPH to 175 TPH

• Reduction in power consumption from 29.0 units to 25.7 units per ton of OPC - 43

Financial analysisThe total annual benefits amounted to Rs. 15 millions (only power saving). The investmentmade was around Rs 40 millions (in 1996). The simple payback period for this project was32 months.

Note:Three types of pre-grinding systems are presently available for Indian cement industry toincrease the energy efficiency. The systems implemented in India include – Impact crushers,Roll press and VRM.

All three systems are equally effective in increasing the output and reducing the specificenergy consumption. However the energy saving alone does not justify the investment inmany cases. Hence, the plant should consider the implementation of this project in thecapacity upgradation.

The replication potential exists in 30 cement plants and the investment potential for thisproject is Rs 1200 millions (USD 24 millions)



• Simple payback – 32 months


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Case Study - 11

Conversion of Open Circuit Cement Mills to Closed Circuit byInstalling High Efficiency Separator

BackgroundThe final process in a cement plant is the operation of grinding of cement from clinker in aCement Mill. The cement mills are generally Ball Mills. The Ball Mills can be either open-circuitor closed circuit mills. In the case of open-circuit Ball Mills, the coarse material passes oncethrough the system and hence the grinding is not uniform.

The particle-size distribution is also broader with the presence of particles of different sizeranges. In view of this the recently installed Cement Mills are all closed circuit mills.

In the closed circuit mills the material at the outlet of the mill is fed to the separator. In theseparator the coarse and fines are separated and the coarse is fed back to the mill for furthergrinding.

The installation of the closed circuit mills have the following advantages.

• Increase in capacity

• Avoiding of over & under grinding

• Reduction in specific energy consumption

Hence, all the old cement plants can convert their open circuit mills to closed circuit mills andachieve substantial energy saving.

Previous statusIn one of the older cement plants, the raw mill and the kiln sections were modernised byinstalling Vertical Roller Mill and a new dry process pre-calciner Kiln. The Cement Mill sectionwas retained as it is, with the old long tube mills with high-energy consumption. There weretwo Cement Mills namely C/M – 2 & C/M – 3 which were being operated continuously. Thecapacity and other details of the mills are shown below.

The total production of the two Cement Mills was 70.8 TPH at a specific power consumptionof 35.9 units per ton. The specific energy consumption is comparatively higher with a goodpotential for energy saving. Additionally, there was also a requirement for capacity increasein the Cement Mill.

Energy saving projectThe two Cement Mills were close circuited by installing a common O-sepa type separator. Asinstalling individual separator was more expensive, a common separator was installed. Theseparator was slightly of higher capacity to take care of additional capacity requirement infuture with Roll Press.

Details Cement Mill – 2 Cement Mill – 3

Size 2.6 M F X 12 M long 3.2 M F X 11.4 M long

Compartments 3 3

Mill Drive 1300 HP 2000 HP

Output 25.2 TPH 45.6 TPH

Fineness 280 m2 / Kg 280 m2 / Kg

Specific Power consumption 38 units / ton 34.8 units / ton

Implementation methodology & time frameThe separator and the Bag filter were located above the mills by constructing two floors overthe mills, as space was not available. As the operation of the Cement Mills was critical fromthe production point of view, the implementation was taken up in a phased manner. Thebuilding construction, erection of Bag house, Air separator etc. were all done with minimalstoppage. The over all stoppage was only 35 days for one mill.

The other modifications that were done are as below;

• The Mills were converted to two chamber mills.

• The ordinary liners were converted to Stepped liners in the I chamber and Drag-peb linersin the II chamber.

• The II chamber grinding media were converted to cylpebs.

• The air balancing was done by both the suppliers and the Plant team


• Increase in capacity from 70.8 TPH to 81.0 TPH (both mills together) ie. 22% increase overthe existing capacity.

• Reduction in specific power consumption from 35.9 units / ton to 32.0 units / ton.

• Better, Cement cooling due to larger amount of air flow through the air separator.

• Avoidance of over grinding (particulate under 3 microns size came down from 4.8% to2.7%).

• Increase in Cement strength by 10 % over open circuit Mill for same quality of clinker.

Financial analysisThe total annual benefits (energy saving and increased production) amounted toRs 120 millions. The investment made was around Rs 350 millions. The simple paybackperiod for this project was 36 months.

Replication potentialPresently many high efficiency separators from all the motor manufacturers are available andoperating in India. All are equally good and help in reducing the energy consumption andincreasing the overall output of the mill.

The introduction of the high efficiency separator and close circuiting of the mill is possible inabout 30 mills with an investment potential of Rs 1500 millions.




Case Study - 12

Install A Co-Generation System For Recovering Heat FromKiln Pre heater And Cooler Exhaust

BackgroundThe cement kiln is a major consumer of heat with heat consumption ranges from 685 kCal/kg in the modern plant to about 800 kCal/kg in the older plants. Out of this heat, nearly about25% of the heat energy is vented from the preheater and cooler. The heat is vented at lowertemperatures of 300 – 350°C from the preheater and 250- 300°C from the cooler exhaust. Asmall part of this heat is utilised for coal drying and limestone drying depends on the requirementof the plant.

Thermal Energy Balance - Typical

The heat can be utilised for generating power and partly meets the power demands of theplant. The cooler exhaust is generally clean and dust free, while the preheater air is dustladen with a particle concentration of about 250 gms/m3.

Previous StatusIn a one million tonnes per year cement plant with a 4 stage preheater system, the exhaustheat loss from the system (preheater and cooler) was about 40%

170 kCal/kg 330oC

Kiln – Theoretical – requirement – 420 kCal/kg

300°C

Radiation loss 70 Kcal/kg

Preheater

Cooler

750 Kcal/kg Coal firing

140 kCal/kg (Recoverable)



Energy saving projectsInstall a steam based waste heat recovery system for recovering heat from preheater andcooler exhaust and generating power.

Implementation methodology and problems faced The project is currently under implementation.The stoppage expected for this project is about 2 months. The overall time target forimplementation of this project is about 9 months

Benefits of the projectThe benefits of the projects are:

The power plant based on waste heat is expected to generate 7.6 MW with a net exportablepower of 7 MW

This will generate about 1,68,000 units/ day which otherwise would have been bought fromthe state grid.

Financial AnalysisThe annual benefit expected on account of the power generated from the WHR plant isRs. 200 millons. The total investment made is about Rs.900 millions, which has paybackperiod 54 months

Replication potentialThe implementation of WHR in Indian cement industry has not been taken up in a big way.Out of total 130 cement plants only 3 units have tried the system and that too not verysuccessfully. There is a need to initiate and install a few demonstration sites, which canconvince the industry to go forward.

Two immediately proven systems – steam based waste heat recovery system (supplied bymany WHR system suppliers) and organic liquid based WHR systems (supplied by Ormat,Israel) are already operating in several plants abroad satisfactorily and have a goodimplementation potential in India.

The only obstacles in the way of implementing this project is – dust removal from preheaterair and high investments (payback period always more than 5 years) On a conservativeestimate the WHR potential in Indian cement industry is about 150 MW.





55



Supplier AddressHigh-efficiency separatorMr V C RaoManaging DirectorLNV Technology Private LimitedI-E, Alsa Regency (1 floor)165, Eldams RoadChennai - 600 018Tel: 2431 4259/69/79Fax: 2431 [email protected]

AUMUND ENGINEERING PVT. LTD.LAKSHMI NEELA RITE CHOICE CHAMBERS5, BAZULLAH ROAD, T. NAGAR,CHENNAI - 600017Tel. No. : 91-44-28222048/49 Fax : 91-44-28222046

Material Handling EquipmentMr K.J.PuetzChairman & Managing DirectorMr. Rajiv ManchandaSr. Vice President - CorporateEnexco Teknologies India LimitedB-17, Geetanjali EnclaveNew Delhi -110017Phone: +91-11-2669 2847- 50 (4 lines) / 26691524 / 2669 2425(2 lines)Fax: +91-11-2669 1543Email: [email protected]

Bharat Heavy Plate &Vessels Limited(Ministry of Industry, Department of HeavyIndustry)B.H.P.V PostVisakhapatnam –12Andhra PradeshPhone : 0891-517381 - 91 (10 lines)Fax : 0891 – 517626

Mr. R G KumarDirectorBHP ENGINEERS LTD.F-42A,1st Main Road,Annanagar EastChennai-600102Tel: +91(044) 26208176Fax: +91(044) 26203328Email: [email protected] /[email protected]/[email protected]

All cement plant machineryMr. A K DemblaPresident - MarketingHumboldt Wedag India Ltd.C-29, Ground Floor, Nehru Enclave

Opp Paras CinemaNew Delhi 110019Tel: 011 26426031/5037/26416578Fax: 011 26443175Email: [email protected]

Mr Rakesh SharmaVP - Mktg & Business DevFuller India LimitedCapital Towers180, Kodambakkam High RoadChennai 600034Tel: +91 (44) 28253182 (D) / 8276030 / 8276343 /8279569Fax: +91 (44) 28279393Email: [email protected]

Mr R. K SharmaHead MarketingLarsen & Toubro LimitedCement & Allied MachineryG4 Building, 2nd FloorPowai Works, Saki-Vihar RoadMumbai 400 072, IndiaTel:+91-22-28581401/11 Extn:2423 / Direct line:+91-22-2858 1752Fax: +91-22-28581633 / 28581126e-mail: [email protected]

Automation SystemsMr. Arjun GuptaTechfab Systems507 Eros Apartments, 56 Nehru PlaceNew Dehli - 110 019Tel.:+91.129.527 29 95email: [email protected]

Prof Mathai JosephExecutive DirectorTata Consultancy Service1, Mangaldas Road,Pune - 411 001Phone: +91 20 612 2809Fax: 91 20 612 3713Email: [email protected]

Mr Jayant KulkarniManager – MktgSystemsTata Honeywell Limited55-A/8 & 9, Hadapsar Industrial EstatePune 411 013Tel: +91 (020) 2675531 / 672612Fax: +91 (020) 2679404 / 672205Email: [email protected]

Mr Debashish GhoshManager Commercial MarketingAllen-Bradley India LtdC-11, Industrial Area


57

Site 4SahibabadGhaziabad 201010Tel; +91 (120) 2895247 – 52Email: [email protected]

Mr K S Krishna KumarProduct ExecutiveRamco Systems LimitedSBU Head - Enterprise Process SolutionsNo 64, Sardar Patel RoadTaramaniChennai 600113Tel; +91 (44) 2354510Fax: +91 (44) 2352884Email: [email protected]

Fly-ash conveying systemMICAW BEEKAY LTDBeekay House, L-8,Green Park ExtensionNew Delhi -110016

ConsultantsMr. VasudevaUnit DirectorNational Council for Cement and BuildingMaterialsA-135, Defence ColonyNew Delhi-110 024Tel:0129- 5241963,5310909,5312423Fax: 91-129-5242100Email: [email protected]

Mr A K PathakPresident & Chief ExecutiveResearch and Consultancy DirectorateACC-RCDACC CampusLBS MARGThane 400 604Tel: 022 25823631

Mr Kapil WadhawaDeputy ManagerHoltec Engineers Pvt LtdHoltec Center,A Block, Sushant LokGurgoan-122001Phone: (91) 124-638-5095Fax: (91) 124-638-5114E-mail: [email protected]

Vertical Roller MillsMr. K B SharmaVice President - MarketingLOESCHE INDIA Ltd.E-2, First Floor, Defence Colony

New Delhi-110 024Telf:91 11 2464 76 70Fax:91 11 2464 76 [email protected]

Waste Heat Recovery Systems

Mr Edward J. LoringSales & Marketing ManagerExergy IncorporatedPost Office Box 209Hanson, MA 02341Tel: (781) 294-8838Fax: (781) [email protected]

Mr Yehuda Lucien BronitzckyChairmanOrmat Industries LimitedPO Box 68, 81100 YavneIsraelTel: 972 8 943 3777Fax: 972 8 943 [email protected]

Dr J M ChawlaManaging DirectorCaldyn Thermowir Pvt. Ltd.A-102 Satya ApartmentsMasab TankHyderabad 500028

Mr Tadashi NishimuraExecutive Vice President - MarketingKawasaki Heavy Industries Ltd.8, Niijima, Harima-cho, Kako-gun,Hyogo 675-0155, JapanPhone : 81-794-35-2131Fax : 81-794-35-2132

Mr A K SundararajanDy General ManagerBharat Heavy Electricals LimitedTiruchirapalli-620014Phone - 91(431) 2520713, 2520642Fax - 91(431) 2520306

Mr S V PendseSr Manager – Sales & MarketingThermax LtdEnergy systems DivisionD-1, MIDC Industrial AreaChinchwad,Pune 411 019Tel : (020) 4126349Fax : (020) 7474640Email : [email protected]


58Energy Conservation in Caustic Chlorine Industry

Caustic Chlorine

Per Capita Consumption 1.5 kg

Growth percentage 5.5%


Energy Costs Rs 17900 million (US $360 million)

Energy saving potential Rs.650 m (US $ 13 million)

Investment potential on energysaving projects Rs.1300 m (US $26 million)


59

IntroductionElectrolysis of salt results three products - caustic soda, chlorine and hydrogen in the proportionof 1:0.88:0.025. The first two form the major products whereas hydrogen comes in the negligibleproportion.

Caustic soda is produced by electrolysis of salt(NaCl). Power and salt form the key inputs. Morethan 75% of the production and sales is in thelye form because caustic soda is generated inliquid form. This liquid form called ‘lye’ is thenevaporated to obtain solids or flakes. Most of theend users use aqueous solution of caustic soda.Thus, it makes economic sense to keep it in lyeform. Transportation of lye is cumbersomewhereas solid form is easy to transport. It isprimarily for this reason that lye is converted into solid form.

In India, caustic soda is more in demand than chlorine. However, in global markets it is thedemand for chlorine, which drives the demand-supply of caustic soda.

Paper & pulp, manmade fibers, and soaps form the major user industries of caustic soda inthe domestic market. Paper & pulp industry is the largest single user sector of caustic sodain India.

For caustic soda manufacturers balancing the prices of caustic soda and chlorine becomescritical to get maximum returns on an ECU.However as caustic soda and chlorine are usedin different kinds of industries, the demand forthem is rarely balanced. This creates problemsfor manufacturers in marketing these twoproducts.

The units are mainly located on the west coastof India, due to two reasons, namely abundantavailability of salt, one of the key inputs requiredfor the production of caustic soda and proximityto user industries. Power and salt form the keyinputs in the manufacturing of caustic soda. Power is a major cost item as it accounts foralmost 65% of the total cost of production.

The capacities in the domestic sector have outstripped demand growth.

Thus, only those producers who have access to cheap power and use latest technology willbe able to survive in the long-term.

The growth profile of caustic chlor industry in India is about 4%.



Demand & Consumption (Indian Scenario)Demand growth for caustic soda depends on growth in the user sectors. Demand is furtheraffected by the substitution of caustic soda with other alkalis.

Paper & pulp, man-made fibers, soaps and alumina are the major user sectors of caustic sodaand they account for more than 80% of the domestic demand.

Paper and pulp sector has been growing at the rate of around 6% pa, in volume terms. Soapindustry is expected to grow at the rate of around 9-10% pa. The demand for caustic sodais growing from this industry. Caustic soda is used in the conversion of bauxite into alumina.The demand from this sector is however sluggish. Demand from man made fiber industry, hasslowed down as the sector itself, is growing at a sluggish pace of less than 6% pa. Thusoverall the demand is expected to grow at a moderate rate of around 6-7% pa.

Apart from these industries, caustic soda and chlorine find use in other industries such as,chemical, water treatment, etc.,

Demand spread over various user sectors insulates caustic soda from the downtrend in anyone sector. Conversely, spurt in demand in any one of the user sectors does not translate intoequivalent growth in demand for caustic.

Demand also suffers from substitution effect to some extent. Based on the considerationssuch as price, availability and the final application, it is substituted by other alkalis such assoda ash. Though the extent of substitution is small, its effect gets magnified during recessionwhen demand from user sector falls.

Most of the capacity additions in India were planned in early 90’s when the domestic causticsoda sector was doing well.

Demand & Consumption(Global Scenario)Globally the chlor-alkali industryis driven by the demand-supplyof chlorine unlike in India andtherefore globally, caustic soda isconsidered as a byproduct.Demand for chlorine is higher thanthat of caustic and many a timesa part of caustic produced in theprocess is wasted.

Domestic Consumption Pattern of Caustic Soda in Various Sectors

9%

30%

12%14%

25%

2%

8%

0%

5%

10%

15%

20%

25%

30%

35%

Chem

ical

Pape

r & P

ulp

Alum

ina

Soap

Indu

stry

Man

mad

e Fi

bres

Wat

er T

reat

men

t

Othe

rs

Perc

enta

ge


61

Global consumption pattern of caustic soda also differs from that of Indian consumption.Globally chemicals account for 40% of the total consumption followed by paper & pulp, etc.

The major manufacturers of caustic soda/ chlorine are located in USA, China and SaudiArabia. USA is the largest consumer and is also a net importer whereas the China and SaudiArabia are the net exporters. Exports from China affect the domestic industry in a major way.

World production of caustic is estimated to be around 40 million ton per year. India accountsfor about 4% of the world production.

Cost of power in caustic soda producing regions (FY97)Country Power tariff (Rs)

USA 1.8

China 1.0

Saudi Arabia 0.8

India 2.8 (4.2 in FY98)

The ProcessCaustic Soda (NaOH), is manufactured commercially by the electrolytic process based on theFaraday’s law of electrochemistry.

The basic equation depicting the process for manufacture of caustic soda commercially is :

NaCl + H2O —————> NaOH + ½ Cl2 + ½ H2

The above reaction is initiated by passage DC current through an aqueous solution of sodiumchloride (Brine). Chlorine gas is liberated at the anode and hydrogen as by product isliberated at the cathode of the electrochemical cell.

The electrolyte leaving the electrolyte cells is saturated with chlorine. Most of the chlorine isremoved by adding acid (HOCl + HCl -> Cl2 + H2O), then the remaining chlorine is convertedto chloride by adding caustic soda and sulphite (NaOH + HCl -> NaCl + H2O), (2NaOH +NA2SO3 + Cl2 -> Na2SO4 + 2NaCl + H2O). Some of the chlorine from the dechlorinationprocess and from other streams on the plant, is reacted with caustic soda to produce sodiumhypochlorite (2NaOH + Cl2 -> NaOCl + NaCl + H2O). Sodium hypochlorite is sold to makebleach products.

Chlorine gas formed at the anode of the electrical cell is cooled and dried of any moisture.It is then compressed and cooled to -36 degrees celcius so that it forms a liquid.The liquidform of chlorine is less bulky and easier to transport.

Some of the chlorine gas formed in the electrical cell is burned in hydrogen, which is formedat the cathode of the electrical cell. This reaction produces hydrogen chloride gas (Cl2 + H2-> 2HCl). This gas is dissolved in water to form a 32 per cent hydrochloric acid solution.



Domestic Consumption Pattern of Caustic Soda in Various Sectors

9%

30%

12%14%

25%

2%

8%

0%

5%

10%

15%

20%

25%

30%

35%

Chem

ical

Pape

r & P

ulp

Alum

ina

Soap

Indu

stry

Man

mad

e Fi

bres

Wat

er T

reat

men

t

Othe

rs

Perc

enta

ge

Domestic over capacity and cheaper imports resulted in a glut of caustic soda in domesticmarket in the last few years. This can be seen from the fall in capacity utilisation over theyears.

The average capacity of the domestic caustic soda plants is 150 tpd as against the global sizeof 450 tpd. This indicates very low economies of scale.

The latest production figures for the last three years is depicted in the form of a graph below:

1343.8

1481.3 1480

1200

1300

1400

1500

000'Metric Tonne

Year

Year wise Production for Caustic Soda

Series1 1343.8 1481.3 1480

1999-2000 2000-2001 2001-2002


63

Conventional processesDiaphragm Cell

Diaphragm cell contains a diaphragm, usually made of asbestos fibers. This separates theanode from the cathode and allows ions to pass through electrical migration simultaneouslyreducing the diffusion of products. The diaphragm permits a flow of brine from anode tocathode and prevents side reaction. Sodium ions along with sodium chloride are dischargedinto the cathode chamber. Thus sodium chloride is separated in evaporators when causticsoda is obtained in the form of aqueous solution. The recycled salt is combined with fresh saltfor further use.

This process is now obsolete and is not being used in any commercial manufacturing processin India.

Mercury CellThis process is one of the older processes being used in India and accounts for nearly 30%of the caustic production in the country.‘

In this, anode (made up of graphite or titanium) remains fixed and a moving pool of mercuryacts as cathode. Free sodium from the sodium chloride solution (salt water) forms a sodiummercury amalgam. The amalgam is decomposed using in a separate vessel with soft waterproducing 50% caustic solution and hydrogen gas. The depleted salt water is cleansed ofchlorine, re-saturated with salt, purified and recycled.

This is an older process and has the advantage of relatively lower capital costs. However, ithas two significant disadvantages:

• Power consumption is high at around 3,200 kwh per ton of caustic soda (100%) comparedto low power consumption in diaphragm cell and membrane cell.

• Mercury cell plants are pollution hazards since mercury is a major pollutant and alsoevaporates in small quantities at the operating temperature.

Because of the high specific energy consumption and pollution hazards, the process is nowbeing phased out. The process is depicted schematically below:



Mercury Cell

Raw Salt Diluted Brine

Raw Brine

Caustic Precipitants Solution

Dechlorination Residue

Purified Brine Hydrochloric Hydrochloric Acid Acid

Anolyte Amalgam Mercury Water Caustic Solution (47.5%) Hydrogen

Dispatch/ Flaking Unit Hydrogen Dispatch Bottling/ Boiler

Flaking Unit

Brine Saturation

Precipitation

Filtration

Heat Exchangers

Cooling

Drying

Compression

Liquefaction

Bottling

Electrolysis

Amalgam Decompositio

Cooling

Storage

Mercury Removal

Mercury Removal

Cooling


65

Membrane CellThis is the most modern process and accounts for about 70% of caustic chlor production inIndia.

This cell uses a semi-permeable membrane to separate the anode and cathode compartments.Membrane cells separate the compartments with porous chemically active plastic sheets thatallow sodium ions to pass, but reject hydroxyl ions.

Sodium ions diffuse to the cathode area where they react with de-mineralized water to produce30-35 % caustic soda and hydrogen gas (The caustic soda is subsequently concentrated to50 % levels). The salt water is dechlorinated, purified, and recycled in the process. Theschematic diagram of a typical membrane cell is shown below:

This process has been gaining importance in the country because of number of advantagesover the mercury cell process which are as follows;

It has lower power consumption of 2,400-2,500 kwh per ton of caustic soda as compared toaround 3,200 kwh per ton in the mercury cell process. When a mercury unit is converted tomembrane cell, it is able to increase its capacity by nearly 20% because the available powercan now produce more quantities of caustic soda.

It has lower maintenance cost than the mercury cellprocess and simpler plant operations.

Caustic soda produced has high purity and thus findsmore market like in pharmaceuticals, semiconductor,biotech etc.

The disadvantages of this process are:

• Itis more capital intensive

• It requires dependence on imports for technology.

• The selectively permeable membrane is manufactured under patent by only a selectcompanies in the world. The three major names in this business are Dupont, ICI Chemicalsand Asahi Chemical Co under different brand names.

Na+ H2O

Cathode Anode

Weak NaOH Soln

Feed Brine Dilute caustic soln (28%)

Lean brine, Cl2 H2, NaOH (32%)



350-370o C To Vacuum Caustic Molten (47.5 %) Salt (400-450o C) 66 % 98 %

Vacuum

Caustic Flakes

Pre concentration

Final concentration

Flaking

D rum

Salt

Heater

• The technology for the cells for the reaction is also available with a select few companieslike Di Nora of Italy, ICI of UK and Asahi of Japan.

• It requires high quality of salt solution.

• The major impurities in the raw salt (NaCl) are sodium sulphate, Calcium chloride andmagnesium chloride which needs to be removed to the traces level (parts per billion) asthey directly affect the membrane operation and life.

• Membranes need to be replaced once in every three years.

• Power consumption of the membrane cells increase by 40-50 KWh/Ton of caustic per yearbecause of the contamination of the membranes.

• After 3-4 years time it becomes economically viable to replace the membranes with newones.

For ease of transportation and requirement at the user end, a small percentage of causticsoda is converted to flakes. The flaking proces is detailed below:

Power is the most important input in the production of caustic soda. It accounts for about 65%of the total cost of production.

The cost of power from co-generation is half the purchased power. The producers with theco-generation plant therefore benefit from low variable cost. However the initial capital costfor setting up these power plants is very high.

Caustic soda can be manufactured in any of the following types of cells - mercury cell,membrane cell and diaphragm cell. Power consumption by membrane cell is the least of allthe three cells.


67

Energy requirement (For 1 ton of caustic) by Electrolytic processes

Energy kwh/ton Mercury Diaphragm Membrane

Electricity 2800-3200 2500-2600 2300-2500

Steam (equivalent) 0 700-900 90-180

Total 2800-3200 3200-3500 2390-2680

Relative energy cost % 92 100 75

Cost of setting up a green field plant based on membrane cell comes to around Rs 1.0 billionfor 100 TPD plant whereas that of converting the mercury cell to membrane cell comes toaround Rs 0.8 billion for 100 TPD plant.

Total energy consumption in caustic chlor is Rs 17900 million (USD 360 million).

Energy Consumption PatternIndustries in India thereby assuring a regular and cheap source of power. The data regardingthe captive power plants for caustic chlorine industry is attached as Annexure-1.

From the total power consumed in the process, almost 90% is utilised in the electrolytic cellsin form of DC. Rectifiers are used to convert AC current to DC current.

Diode based rectifiers are slightly less efficient (96-96.5 %) than the more advanced thyristorbased rectifiers which have an efficiency advantage of 0.5-1%.

Specific energy consumption for various steps of the process is as follows for the membraneprocess. In a caustic chlorine process, all the energy consumption is measured on 100%caustic output basis.

1) Cell house:Two kinds of cell configurations are preferred in the manufacturing process. Depending on theconfiguration the SEC of the cell house changes. The Typical average figures of these twoconfigurations are:a) Monopolar arrangement : 2300 KWh/Ton caustic (App.)b) Bipolar arrangement : 2250 KWh/Ton Caustic. (App)

The lowest initial consumption recorded for cell house globally is 2150 KWh/Ton caustic. Asentioned the power consumption increases every year because of the membrane contamination.

The feed parameters to the cell also play an important part in the specific energy consumptionof the cell. The feed brine concentration and temperature should be properly monitored. Adecrease of 1 Deg C of temperature of feed brine or caustic can increase the energyconsumption of a cell by 5-6 KWh/Ton. Also an increase of dilute caustic concentration by 1%can increase the specific energy consumption by around 13-14Units.

All these parameters are required to be monitored online continuously and close loop controlsare employed for maintaining the parameters. Good and advanced Instrumentation and controlsform the backbone of any caustic chlorine industry.



View of membrane cell house

2) Chlorine Liquefaction:The chlorine produced on the anode side of the cell iswet and slightly impure. This chlorine is treated in thechlorine house where it is cooled, dried and filteredand finally liquefied.

This whole process is quite energy intensive as a lotof cooling water and chilled water load is there. As athumb rule the chlorine compression and coolingrequires 204-205 KWh/MT Cl2 and another 50-55 KWh/MT Cl2 is required for refrigeration. This takes the totalin a chlorine house to 250-255 KWh/ton of Chlorineliquefied.

Any reduction in the specific energy consumption of the chiller or chlorine compressor willhave a marked effect on the SEC of chlorine house.

3) Evaporator House :The caustic solution obtained from the cells is of 32% concentration and needs to beconcentrated further for use as 47.5 % lye (aqueous soln.) or as dry flakes. Typically, a 3-effect evaporator is used for concentrating to about 47.5% and steam at 11 - 12 kg/cm2 isused for this purpose.

4) Flaking Unit :Caustic soda is also sold as flakes which is 99%pure. This is obtained by further concentration of47.5 % caustic from the evaporator house in theflaking unit.

In flaking unit there is a pre concentrator whichconcentrates 47.5 % caustic lye to 61%. Theheat for this is provided by the vapours of thefinal concentrator (at around 360-370 Deg C) ina shell and tube type heat exchangers. This isfurther concentrated to 98% in the finalconcentrator unit. The energy consumption in theflaking section is both fuel and electrical.

The specific energy consumption is 100 KWh/Ton flakes as electrical energy and 100Litre/Ton of furnace oil.

Use of hydrogen in place of furnace oil makes economic sense if hydrogen is excess (assumingit is also used in the main boiler) and is not sold separately in a more profitable manner.1 NM3 of hydrogen gas is equivalent to 0.29 Ltr of furnace oil in terms of heat value.

Brine Distribution arrangement in cellhouse


69

In some cases prilling of caustic is also done to supply caustic as prills just like Urea.

Caustic Prilling UnitCaustic prilling units have been employed by some major players, one of them being GujaratAlkalies and Chemicals limited.



CASE STUDY 1

Avoid Valve Throttling at the Identified Pumps of Brine Sectionby Providing VFD With Close Feedback Control

BackgroundThe caustic soda plant consumes substantial power for pumping brines due to feed variation,fine capacity control of the pumps. Pumps therefore are essential for operation of plant atlower energy consumption. A case study involving the VFD control of the pumps in a causticsoda plant is described below.

Present StatusSystem is designed for 250 TPD caustic production

The plant team observed that almost all brine pumps have control valve in re-circulation onmain line. Control valve on these re-circulation not open more than 30 – 40%. Heavythrottling on the re-circulation valves indicates high capacity and rating for the pumps.

Valve control is an energy inefficient way of capacity control

The best energy efficient method of capacity control for a pump (or for that matter anycentrifugal equipment) having varying capacity requirements is to vary its RPM, which can bebest achieved with a variable frequency drive (VFD).

Energy Saving ProjectThe plant team installed Variable Frequency Drives (VFD) for all identified pumps with dischargepressure of the main header as feedback control from the main header .

The VFD can be provided with a closed loop pressure sensor control. This pressure sensorwill continuously sense the pump discharge header pressure and give a signal to the VFD,to either increase or decrease the RPM of the pump, thereby matching the varying capacityrequirements.

BenefitsInstallation of VFDs has resulted in an annual energy saving potential is Rs.1.34 million. Thiscalled for an investment of Rs.1.23 million, which had a simple payback period of11 months.

Potential for ReplicationTypically in caustic soda unit, there are about 30 pumps(brine and water) in operation and tthere is a potentialfor application of VFD in atleast about 25 pumps. Onlyabout a quarter of this potential has been tapped. Thepotential for replication is therefore very high for thisproject.





71



CASE STUDY 2

Replace Steam Ejector with Water Ring Vacuum Pump forBrine Dechlorination

BackgroundBrine dechlorination of the return brine is an essential process requirement of any causticchlorine plant. This dechlorination is done by using vacuum of the order of 400-450 mm HGon the hot return brine thereby sucking the excess free chlorine.

Present StatusSteam ejectors are normally installed to meet the vacuum requirements of the return brinedechlorination section. The vacuum required in the section is to the tune of 400-450 mmHg.200-250 Kg of steam per hour at 8-10 Kg/cm2 pressure is utilised in this ejector system.

The plant team of a 250 TPD caustic chlor unit in India observed good potential to reduce thecost of operation, by installing water ring vacuum pump in place of steam ejector. Theoperation of cost of an ejector is more than the water ring vacuum pump.

The team knew that this is a proven project and has been implemented in many other plants.A vacuum of 600-650 mm Hg is easily achievable with a water ring vacuum pump. This willmeet the requirement of vacuum conditions to be maintained in the brine de-chlorniationsection.

Energy Saving ProjectThe plant team installed a water ring vacuum pump in place of steam ejector for the brinedechlorinating condenser. The capacity of the vacuum pump was the same as that of theexisting ejector.

This step has resulted in reduction of atleast 50% of steam requirement.

BenefitsThe annual energy saving achieved by replacing steam ejector with water ring vacuum pumpis Rs. 0.3 million (at a steam cost of Rs 350/Ton) This called for an investment of Rs. 0.2million, which had a simple payback period of 8 months.





73



CASE STUDY 3

Provide VFD For One Chlorine Compressor And Avoid BypassControl During Load Variation

BackgroundAcid ring centrifugal chlorine compressors are normally employed for chlorine compressionbefore liquifaction in any caustic plant (using any process). In a typical 250 TPD plant, fivechlorine compressors were available in the plant (4 X 70 TPD and 1 X 40 TPD). The suctionpressure of the chlorine header is to be maintained at –45 mm WC.

Present StatusIt was observed by the plant team that the suction pressure of chlorine header is very crucialfor the plant operation (maintaining differential pressure across membranes between hydrogenand chlorine compartments). This is maintained by regulating the bypass control valve of oneof the chlorine compressors.

In a 250 TPD plant in India, there were four compressors running (3 x 70 TPD and 1 x 40TPD). Three compressors were operated with full valves opening and header suction pressurewas controlled by controlling the bypass valve of one compressor.

Bypass control is one of the most energy efficient methods of capacity or head control asthere is no reduction in the energy consumption with process load. This poses a good savingpotential in the compressor.

112 kW

Chlorine Compressor

V F D

Acid Separator

- 45 mm WC

35 % Open

CWR CWS

Moist Chlorine from Cell house

Sulphuric Acid Return


75

Energy Saving projectThe plant team observed that after initial startup of the compressor the bypass valve need notbe used and a VFD may be installed in one of the compressors.

Any variation in load can be taken care of by giving a closed feedback control to the VFD fromthe suction header pressure and keeping the set point as –45 mm WC. This ensures optimumsupply of chlorine, as per requirement

BenefitsThe annual energy saving achieved by installing a VFD to one of the chlorine compressorsin a 250 TPD plant is Rs. 0.57 million. This called for an investment of Rs 0.75 million. Thisinvestment will be paid back in 16 months.

Replication PotentialThis project has been implemented only in one or two units. The potential for replication isextremely high.





77

CASE STUDY 4

Install Thermocompressor And Utilise Flash Steam in theI- Effect Heat Exchanger

Present StatusCaustic at 130oC is entering the flash vessel and comes out at a temperature of 80 – 90 oC.In the process of flashing, the caustic concentration increases by upto 3% in the flash tankand the temperature falls from 130oC to 80 – 90 oC. The temperature of caustic has to bemaintained in the vertical heat exchanger of about 130oC. To maintain the temperature of130oC, the typical ∆T of maximum 30oC is required, which needs a steam of condensingtemperature of 160oC, This is eqivalent to a steam pressure of 8 ksc.

The flash vessel is at a temperature of 80oC, which is equivalent to a steam saturationpressure of 0.5 ksc(a). Since the vapors from flash vessel contain some caustic vapors also,the pressure has to be maintained lower say about 0.3 ksc, to get the equivalent temperature.

RecommendationThere is an excellent potential to recover heat by installing a thermocompresor and using livesteam at a pressure of 12 ksc as a motive steam. The flash generated in the vessel can berecovered and reused in the plant. Care has to be taken of material of construction of Heatexchanger and ejector. Installation of a thermocompressor( ejector) has been succesfullyimplemented in many plants and resulted in good savings.

BenefitsA 250 TPD caustic chlor unit in India has implementedthis proposal and has achieved an annual savings ofRs. 3.20 million. This required an investment ofRs. 4.50 million and got paid back in 17 months.





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CASE STUDY 5

Replace Existing Reciprocating Refrigeration Compressors by

BackgroundRefrigeration load is the major power consumer in caustic chlorine plant. It is required forChlorine Liquification. The process is quite energy intensive as a lot of cooling water andchilled water load is there. Any reduction in the energy consumption in the compressor willresult in very high saving.

Present StatusIn a caustic chlor unit in India, reciprocatingcompressors (450 TR) were operating in therefrigeration system and meeting the demand ofthe entire plant.

The compressors were in continuous oeprationas there was very low load variation in thesystem. The load variation occurs only whendemanded by production schedules or duringpeak load hours. The specific energy consumptionfor producing chilled water at 10 Deg C was1.0 - 1.2 KW/ TR

Energy Saving ProjectThe plant team compare the performances of Reciprocating and Centrifugal / Screwcompressors, based on plant visits to other installations and discussions with industry experts.It was observed that the Centrifugal / Screw compressors operate with specific powerconsumption of 0.60 - 0.65 KW/ TR.

The plant team replaced the existing reciprocating compressor with screw/centrifugalcompressors. For the same operating conditions, the power consumption of the compressorsreduced by around 40%.



On a load of 450 TR the existing power consumption in the reciprocating compressors is480 KW. The new centrifugal/screw compressors have a power consumption of 290 KW.

BenefitsThe annual savings achieved by this replacement of compressors is Rs 5.60 million withinvestment of Rs. 7.0 million (including civil work and controls), which had a simple paybackperiod of 15 Months.





81



Case study 6

Install commercial Co-generation system for Caustic ChlorineIndustry

BackgroundThe power from state electricity boards of India apart from being costly at an average rateof Rs 4.0/Unit also lacks quality and reliability. Generating power through captive power plantcan be a solution in terms of quality and cost. A co-generation plant can be used for efficientutilisation of energy in various processes.

Power quality plays an important role in a caustic chlorine plant. Refrigeration and steamrequirement also contribute to a significant figure to total energy cost. Considering the abovefactors Co-generation is best solution for a caustic chlorine plant in terms of low specificenergy consumption and quality of power. The following case study involves setting up of aco-generation plant in a typical caustic chlorine plant of 200 TPD involving membrane celltechnology.

Present StatusThe power requirement for a caustic chlorine plant of 200 TPD is around 2600 kWh/TonCaustic which comes to around 23 MW so a captive plant based on furnace oil/naptha of 25MW capacity will be sufficient to support the plant power needs.

Apart from generating power of 24-25 MW, steam can be generated from flue gases. The fluegas temperature from the DG is around 380–400 Deg C. Steam can be generated at 10 kg/cm2 using waste heat recovery boiler at the rate of 0.5 TPH per MW of generation. For 25MW DG sets about 12.5 TPH steam can be generated by installing waste heat recoveryboilers. The steam requirement is around 11 TPH for a 200 TPD plant in various processesthe breakup of which is as follows (the consumption pattern may vary slightly depending ontechnology used and product mix):

1. Evaporator house : 0.7 Ton/ Ton of caustic soda(Caustic concentration unit)

2. Brine House : 0.4 Ton/ Ton of caustic soda

3. Flaking Plant : 0.2 Ton/ Ton of caustic soda

About 1.5 TPH steam left out of total generation after fulfilling the requirement in variousprocesses. This steam can be use for refrigeration of capacity 300 TR at the rate of 220 TRper TPH of steam. The refrigeration can be use to cool air, which can be supply to DG roomfor cooling. Supply cold air at about 24-25 Deg C to DG room. This will increase the efficiencyof DG set by 1-1.5 %.


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Schematic flow diagram for a typical co-generation plant for 200 TPD plant

Refrigeration contributes a significant role in a caustic chlorine industry. Refrigeration is requiredfor chlorine liquefaction. For a 200 TPD plant the refrigeration load is about 600 TR, considering80 % of chlorine is liquefied (rest goes in the production of hydrochloric acid). The returnjacket cooling water from the DG set jacket is at 75-80 Deg C and offers an excellentopprotunity to produce refrigeration through a Vapor Absorption System based on hot water@ 40 TR/MW of generation. This will result in drastic reduction of refrigeration cost asrefrigeration power consumption is around 55 Kwh/Ton of chlorine liquefied. This alone willresult in a savings of App. Rs 1.30 Crores/Year.

As VAM is considered as green refrigeration the add on benefit is the clean and green imageof the plant and product.

The following are the benefits of co-generation in a caustic power plant.

• The cost of power generation is Rs 2.5 to Rs 2.7 per unit for furnace oil based DG plant,as compare to an average of Rs 4.00 per unit from SEBs.

• Refrigeration is free of cost resulting from waste heat.

• Steam required for various processes can be generated from flue gas and thus free.

• VAM is pollution free and reflects a clean and green image of the company products.

• Overall by installing the waste heat recovery systems from flue gases and jacket coolingwater, the efficiency of the DG set is also enhanced by 10-12 % thus bringing down thecost of power.

Flue gas 180-200oC

Flue gas 380-400oC

Steam for evaporator (12 KSC) Jacket Jacket 5.8 TPH water water 50oC-55oC 75oC-80oC

Steam for brine house 3.3 TPH (5-6 Ksc)

Steam for flaking unit 1.7 TPH (12 Ksc)

Steam for VAM for DG room aircooling (8-9 Ksc)

1.5 TPH

Waste heat recovery boilers

Chilled water 8-10 Deg C

DG Set 25 MW

VAM

Chlorine liquefaction



• Cooling the DG room by cool air at 24-25 Deg C will increase the efficiency of DG by 1-1.5 % as for every 6 Deg C reduction in room temperature there is a increase in efficiencyby 1 %. This itself results in a savings of Rs 8-10 Crores per annum.

Cost Benefit AnalysisBy installing captive cogeneration plant for a plant of 200 TPD based on membrane celltechnology the total annual savings from all the sources come out to be around Rs 3.70million. This requires an investment for DG sets, VAM machines and other control equipmentsto the tune of Rs 12.70 million. This offers a simple payback of 42 months.





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CASE STUDY

Convert existing mercury cell based plant to membrane cellbased plant.Background

The latest technology for manufacturing caustic chlorine is membrane cell. The powerconsumption in a caustic chlorine plant is a major issue since it shares 70% of the total costof production. Any reduction in power consumption may lead to high profitability. The casestudy involving using selectively permeable synthetic polymeric membrane instead ofconventional high energy intensive mercury cells fro electrolytic manufacturing of caustic sodaand chlorine.

Present Status

Caustic soda is still produced by conventional mercury cell technology in some cases. It is anold technology and has only advantage of low capital cost. The specific energy consumptionof mercury cell house is around 3100 kwh per ton of caustic soda (including utilities) compareto 2600 kwh per ton of caustic soda for a membrane cell based plant. Also carry over ofmercury from mercury cell house leads to pollution hazards, as mercury is a major pollutant.Thismakes the product un acceptable to the high end users like phrma, biotech and electronicindustry. In mercury cell technology caustic comes out at 47-48 % concentration and inmembrane cell caustic comes out at 32 % concentration, so a caustic concentrator is requiredto concentrate the caustic to required percentage. The specific energy consumption ofmembrane cell house and the membrane life is highly affected by the impurities in brine. Themajor impurities in raw salt are sodium sulphate, calcium chloride and magnesium chloride.The impurity level should be in ppb instead of ppm.

To convert from the existing mercury cell to membrane cell, the cell house has to be completelychanged and replaced with the new electrolysers. Rectifiers also need replacement as thecells are in parallel instead of series in mercury cell.

The other major revamp is needed in the brine purification section. Since ultrapure brinequality is needed for membranes, a brine filtration and polishing system is required. Thevendors list is enclosed in the annexure.

A caustic concentration unit also needs to be added to concentrate caustic from 32% to47.5% (rayon grade caustic). This increases the steam consumption by 0.65-0.7 Tons/Toncaustic.

The high purity product is sold at a premium over mercury cell product in high end industriesthus increasing the revenue by 10-12 crores annually from caustic alone.

Energy Saving Project

A 250 TPD plant in India converted its earlier mercury cell based unit to new membrane cellbased technology.


87




Cost Benefit Analysis

The total cost of the project including civil work is around Rs 1200 million. This will result inan annual savings of Rs 200 million (including increased revenue from high quality product).This gives a simple payback of 72 Months.


89

Aluminium


Energy Intensity 35 – 40% of manufacturing Cost

Energy Costs Rs.5000 million ( US $ 100 million)

Energy saving potential Rs.500 million (US $ 10 million)

Investment potential on energy

saving projects Rs.1000 M ( US $ 20 Million)


90Energy Conservation in Aluminium Industry

1.0 IntroductionThe aluminium industry emerged in India in early 1940s. The installed capacity has grownfrom 2,500 tonnes in 1943 to 7,14,000 tonnes in 1997-98.

Aluminium production in the country has also progressively gone up from 4,045 tonnes in1950-51 to 5,53,644 tonnes in 1997-98 both in private and public sector.

The electrical sector in India is the most important consumer of aluminium products with over50% of the off - take of total production. Apart from this sector, aluminium has wide and varieduses in transport, building and construction, consumer durables, utensils, packaging, coinageand other miscellaneous uses. The per capita consumption in India is about 0.5 kg.

The total production of aluminium in India is accounted for by five major producers, namelyNALCO, HINDALCO, INDAL, BALCO and MALCO. These producers are integrated producersfrom bauxite mining to metal production. The high capital cost of setting up an aluminiumsmelter (at around US $ 3300/ton) and the need of a Captive Power Plant, have restrictedproduction only to these producers.

Company Installed capacity (tons) Production(tons)

NALCO 230,000 200,162HINDALCO 242,000 200,607INDAL 117,000 38,600BALCO 100,000 88,198MALCO 25,000 26,077TOTAL 714,000 553,644

With the growing importance of the electric sector in India, the demand for the products ofthis industry is bound to rise at a rapid rate in future.

In Aluminium industry, both aluminium refining and smelting process are energy intensive.Considerable attention has to be paid to energy conservation in both refining and smeltingprocess. Data collected and analysis indicate that the energy saving potential in Aluminiumindustry is about 8-10 % of the total energy bill.

2.0 Energy intensity in Indian Aluminium IndustryThe industry is highly energy intensive. It accounted for 2.8% of total energy Indian industryenergy consumption. In terms of energy consumption the aluminium industry ranks first withfigures of 300 GJ /ton of metal compared with the figures of 20 and 15 GJ/ton for copper andzinc respectively.

Electrical energy is the major energy consumption in Alumina refining and Smelter. In Aluminiumrefinery next to electrical energy coal and fuel oil are the major energy consumers.

The share of energy cost is about 35-40% of the manufacturing cost. The total energy costinvolved in Indian Aluminium industry is about Rs 500 Crores/annum.


91

3.0 ENERGY CONSUMPTION PATTERNAluminium is a highly energy intensive process with the most efficient operation requiring about300 GJ/ tonne of the metal. The major areas of energy consumption in the Aluminium refiningprocess (Bayer process) are the digestion and calcination stages.

3.1 Typical energy consumption in Alumina plant

3.2 Energy consumption is Smelting process

Total Energy input is 16.24 GJ/T. Distribution of energy consumption in a medium level Aluminaplant among the various process stages is shown in fig.

Alumina

Bauxite

Preparation 0.37 GJ/T

2.3%

Precipitation 1.06 GJ/T

6.5%

Digestion 4.79 GJ/T

29.5%

Settling Washing 0.65 GJ/T

4.0%

Evaporation 4.3 GJ/T 26.5%

Calcination 5.07 GJ/T

31.2%

Electrolysis Process

Process heat

29.2 GJ/T

16.2 KG/Ton Through

5.8 GJ/T Electricity

Molten metal 0.9 GJ/T

14.9 GT/T through effluent gases

Radiation, Convection & Other losses

Al2O3



On average, around the world, it takes some 15.7 kWh of electricity to produce one kilogramof aluminium from alumina.

4.0 ENERGY SAVING POTENTIAL IN INDIAN ALUMINIUM INDUSTRYThere are five major manufacturers with total installed capacity of 7 lakh tons per annum ofAluminium in India. The total energy consumption in the Aluminium industry is about Rs 500Crores.

Annual Saving Potential InvestmentEnergy Bill requiredRs Crores Rs Crores % of Energy bill Rs Crores

500 50 8-10% 100

5.0 ALUMINIUM MANUFACTURING PROCESSThe most important ore for aluminium is bauxite, which contains gibbsite (Al2O3. 3H2O),boehmite (Al2O3), Diaspore (Al2O3.H2O) and oxides of silicon, iron and titanium in varyingamounts.

Aluminium is manufactured from bauxite using refining and smelting process. In Aluminiumrefining process, Alumina is produced from Bauxite. Bayer process is used for producingAlumina from Bauxite. From Alumina, Aluminium is manufactured using Hall Heroult smeltingprocess.

5.1 Alumina refining - Bayer processThe aluminium industry relies on the Bayer process to produce alumina from bauxite. Itremains the most economic means of obtaining alumina, which in turn is vital for the productionof aluminium metal. Typically about two tonnes of alumina are required to produce on tonneof aluminium.

The bayer process can be considered in three stages:

Extraction

The hydrated alumina is selectively removed from the other (insoluble) oxides by transferringit into a solution of sodium hydroxide (caustic soda):

Al2O3.xH2O + 2NaOH —> 2NaAlO2 + (x+1) H2O

The process is far more efficient when the ore is reduced to a very fine particle size prior toreaction. This is achieved by crushing and milling the pre-washed ore. This is then sent to aheated pressure digester.

Conditions within the digester (concentration, temperature and pressure) vary according to theproperties of the bauxite ore being used. Although higher temperatures are theoreticallyfavoured these produce several disadvantages including corrosion problems and the possibilityof other oxides (other than alumina) dissolving into the caustic liquor.

Modern plants typically operate at between 200 and 240 °C and can involve pressures ofaround 30atm.


93

The resulting liquor contains a solution of sodium aluminate and undissolved bauxite residuescontaining iron, silicon, and titanium. These residues sink gradually to the bottom of the tankand are removed. They are known colloquially as “red mud”. The amount of redmud generated,per tonne of alumina produced, varies greatly depending on the type of bauxite used, from0.3 tonnes for high grade bauxite to 2.5 tonnes for very low grade.

Decomposition

Crystalline alumina trihydrate is extracted from the digestion liquor by hydrolysis:

2NaAlO2 + 4H2O —> Al2O3.3H2O + 2NaOH

This is basically the reverse of the extraction process, except that the product’s nature canbe carefully controlled by plant conditions (including seeding or selective nucleation, precipitationtemperature and cooling rate).

The clear sodium aluminate solution is pumped into a huge tank called a precipitator. Fineparticles of alumina are added to seed the precipitation of pure alumina crystals as the liquorcools. The alumina trihydrate crystals are then classified into size fractions and fed into arotary or fluidised bed calcination kiln.

Calcination

Alumina trihydrate crystals are calcined to remove their water of crystallisation and preparethe alumina.

The flow diagram of the Bayer process is shown in fig.



Material balance for the production of one tonne of Alumina is given below.

ALUMINA

1000 kg

5.2 Aluminium smelting – Hall-Heroult processThe basis for all modern primary aluminium smelting plants is the Hall-Héroult Process, Aluminais dissolved in an electrolytic bath of molten cryolite (sodium aluminium fluoride) within a largecarbon or graphite lined steel container known as a “pot”.

The production of aluminium involves the electrolysis of alumina dissolved in molten crystolite(Na3Al F6) at 960oC – 970oC using carbon anodes. The carbon anode is of either Soderberg(Self baking type) or prebaked type.

An electric current is passed through the electrolyte at low voltage, but very high current,typically 150,000 amperes. The electric current flows between a carbon anode (positive),made of petroleum coke and pitch, and a cathode (negative), formed by the thick carbon orgraphite lining of the pot.

Molten aluminium is deposited at the bottom of the pot and is siphoned off periodically, takento a holding furnace, often but not always blended to an alloy specification, cleaned and thengenerally cast.

A typical aluminium smelter consists of around 300 pots. These will produce some 125,000tonnes of aluminium annually. However, some of the latest generation of smelters are in the350-400,000 tonne range.

ALUMINA REFININGS 90.9%

EFFICIENT

CaO 39 kg Na2Co3 74 kg Water 921 l

RED MUD

1963 kg GAS &

Bauxite 49%

A1203 2247 kg

Alumina 1000 kg


95

On average, around the world, it takes some 15.7 kWh of electricity to produce one kilogramof aluminium from alumina.

The Potline

Pots are organised into “potlines” within an aluminium smelter

A pot consists of two main parts:

1. A block of carbon, which has been formed by baking a mixture of coke and pitch. Thisblock serves as an anode (or positive electrode).

2. Under the anode is a large rectangular steel box lined with carbon made by baking amixture of metallurgical coke and pitch. This lining is the Cathode (or negative electrode).

Between the anode and the cathode is a space filled by electrolyte. This mixture must beheated to about 980°C, at which point it melts and the refined alumina is added, this thendissolves in the molten electrolyte.

This hot molten mixture is electrolyzed at a low voltage of 4-5 volts, but a high current of50,000-280,000 amperes. This process reduces the aluminium ions to produce molten aluminiummetal at the cathode, oxygen is produced at the graphite anode and reacts with the carbonto produce carbon dioxide.

2Al2O3 + 3C —> 4Al + 3CO2

However some of the metal, instead of being deposited at the bottom of the cell, is dissolvedin the electrolyte and reoxidised by the CO2 evolved at the anode:

2Al+ 3CO2 —> Al2O3 + 3CO

This reaction can reduce the efficiency of the cell and increases the cell’s carbon consumption

The electrolyte used is cryolite (Na3AlF6) which is the best solvent for alumina. To improve theperformance of the cells various other compounds are added including aluminium fluoride andcalcium fluoride (used to lower the electrolyte’s freezing point).

The electrolyte ensures that a physical separation is maintained between the liquid aluminium(at the cathode) and the carbon dioxide/carbon monoxide (at the anode).

Anode

The carbon anodes used in the Hall-Heroult process are consumed during electrolysis.

Two designs exist for these anodes; “Söderberg” and “Pre-Bake”.

Pre-Bake anodes are made separately, using coke particlesbonded with pitch and baked in an oven. Pre-bake anodesare consumed and must then be changed. Soder berganodes on the other hand are baked by the heat from theelectrolytic cell, they do not need changing but are“continuously consumed”.

Pre-Bake carbon anodes



Soderberg Cell

Soderberg technology uses a continuous anode which is delivered to the cell (pot) in the formof a paste, and which bakes in the cell itself.

Prebake Cell

Pre-bake technology uses multiple anodes in each cell which are pre-baked in a separatefacility and attached to “rods” that suspend the anodes in the cell. New anodes are exchangedfor spent anodes - “anode butts” - being recycled into new anodes.

The newest primary aluminium production facilities use a variant on pre-bake technologycalled Centre Worked Pre-bake Technology (CWPB). This technology provides uses multiple“point feeders” and other computerised controls for precise alumina feeding.

A key feature of CWPB plants is the enclosed nature of the process. Fugitive emissions fromthese cells are very low, less than 2% of the generated emissions. The balance of theemissions is collected inside the cell itself and carried away to very efficient scrubbing systems,which remove particulates and gases.


97

Computer technology controls the process down to the finest detail, which means thatoccurrence of the anode effect - the condition, which causes small quantities of Perfluorocarbons(PFCs) to be produced - can be minimised. All new plants and most plant expansions arebased on pre-bake technology.

Material balance for producing 1 tonne of Aluminium from Alumina is shown in fig.

6.0 List of Energy saving proposals in Alumina Refining plant

6.1 Aluminium RefineryMedium term projects

1. Install variable frequency drive for spent liquor pump feeding to evaporator

2. Install variable frequency drive (VFD) for red mud pond feed pump

3. Install variable frequency drive for filtered aluminate liquor pump

4. Install seal pots for condensate recovery at digesters, evaporators, HP and LP heaters

5. Install variable frequency drive (VFD) for spent liquor pump feeding to PHE

6. Optimise the operation of filter feed pumping system

Bath Make – up

43 kg

99% Alumina

Carbon Anode

Electrolytic Reduction

960 C

Gas 1340 kg & DustMolten

Aluminium

Blending

Slag (A1=A1203)

A1 INGOTS 1000 kg

Flux C 12 etc



7. Optimise the operation of the slurry pumps in precipitation area

8. Optimise excess O2% in kiln ii by continuous monitoring

9. Avoid air infiltration in kiln flue gas exhaust line

10. Replace Red mud filter vacuum pumps with new high efficiency vacuum pumps

11. Utilise the standby body in evaporator and increase the steam economy

Long term projects1. Install thermo-compressor and recover flash steam from pure condensate tank in evaporator

section

2. Install mechanical conveying system to convey material from ESP bottom to kiln

3. Segregate Pick-Up And Drying Zone Vacuum In Red Mud Filters

4. Sweeten the digestion process by adding Gibbsitic bauxite having higher solubility indownstream of higher temperature digestion circuit.

6.2 Aluminium SmelterMedium term projects

1. Installation of Data acquisition system

2. Installation of Thyristor control in coke conveying vibrators in carbon plant

3. Install correct size cooling water supply pump for rectifier cooling

4. Install a screw conveyor and avoid the operation of a centrifugal fan in Carbon plant

5. Installation of variable frequency drive for fire hydrant pump

6. Installation of variable fluid coupling for scrubber fans

7. Reduce external bus bar voltage drop across bypass joints and across rod to stud joints

8. Improve insulation of sidewalls of the pots to minimise the heat loss due to convectionand radiation

Long term projects

1. Convert the Soderberg technology to the pre baked cathode technology in the pots

2. Install point feeding in the Aluminium Pots

3. Coating of cathode surface of electrolytic cells with Titanium Boride (TINOR)

4. Replacement of hot tamping mix with cold tamping mix

5. Install variable fluid coupling for scrubber ID fans and avoid damper control


99

Case study –1

INSTALL VARIABLE FREQUENCY DRIVE FOR SPENT LIQUORPUMP FEEDING TO EVAPORATOR

Back groundThe centrifugal pumps have to be selected to match with the process requirement. Selectionof higher capacity or head of the pump results in operating the pump with valve throttling tomatch with the process requirement.

The valve throttling at the discharge side of the pump leads to pressure loss across thecontrol valve and hence energy loss. This could be avoided by optimising the operation of thepump with variable frequency drive and keeping the control valve fully opened.

Present statusThe spent weak liquor from the hydrate filtration and red mud filtration sections are concentratedin the evaporators. Centrifugal pump is used for pumping the hydrate filtration from the spentliquor tank to the evaporator.

The design specifications of the pump are as follows:

• Capacity = 100 m3/h• Head = 75 m WC• Motor = 75 kW

The pump is operating with severe discharge valve throttling (about 40-50% opening). Thisindicates excess capacity/ head available in pump.

The detailed analysis reveals that the actual head required for the pump is not more than 75m WC, comprising of static head of 10 m WC, pressure drop across preheaters of 50 m WCand line losses (due to friction and bends) of 10 m WC.

The maximum feed rate maintained in the new evaporator stream is 75-80 m3/h.

The schematic diagram of the system is shown in fig. From Hydrate

Filtration

Evaporator 80 m3/h

40%

1752 – ½ 100 m3/h

75 m 75 kW

(58.5 kW)

Spent liquor tank



The operation of a pump with valve throttling is an energy inefficient method of capacitycontrol, as a part of the energy supplied to the pump is lost across the valve.

The best energy efficient option to optimise the excess capacity/ head as well as achieveoperational flexibility is to install a variable frequency drive (VFD) for the pump and vary itsRPM.

The VFD can be operated in a closed loop with pressure sensor control. The pressure sensorwill continuously sense the header pressure and give a signal to the VFD, which in turn willeither increase or decrease the speed of the pump, exactly matching the varying requirements.

Energy saving projectVariable frequency drive (VFD) with feed back control for the spent liquor feed pump to newevaporator was installed.

BenefitsReduction in power consumption of about 400 units/day was achieved.

Financial analysisThis amounted to an annual monetary saving (@ Rs 3.50/unit) of Rs 0.18 million. Theinvestment made was Rs 0.45 million. The simple payback period for this project was31 Months.





101



Case study –2

INSTALL THERMO-COMPRESSOR AND RECOVER FLASHSTEAM FROM PURE CONDENSATE TANK IN EVAPORATORSECTION

BackgroundWhen high pressure condensate is exposed to lower pressure, due to enthalpy difference apart of condensate flashes into steam. Generally in process plant the high pressure flashsteam is recovered using flash vessels.

If the condensate pressure is very low and exposed to atmosphere, the flash steam is alsosent to atmosphere. This leads to heat loss. The cost of flash steam is as high as the costof main steam.

Hence there is a good potential to save energy by recovering the flash steam using thethermo compressors. The thermo compressor is operating based on the venturi principle.Motive steam at comparatively higher pressure is used to compress the low pressure flashsteam and delivered at an intermediate pressure. The steam at intermediate pressure can beutilised for the process.

Present statusThe digestor section is the heart of the alumina processing plant. There are two streams ofdigestors in the plant, with each stream having seven digester vessels. The steam consumptionin the digesters is about 58-60 TPH at a pressure of 70 kg/cm2.

The condensate from the digestor coils is collected in a flash vessel located in the digestorsection. The flash steam at a pressure of about 4 – 6 kg/cm2 is utilized in the red mud filtrationplant for causticizing slurry preparation, pond water heating and filtrate heating applications.

The condensate from the flash vessel at a pressure of 4 – 6 kg/cm2 is sent to the purecondensate tank. The pure condensate tank is at atmospheric pressure and hence flashingof condensate occurs.

The best method of avoiding flash steam is to recover it and utilize to replace/ substitute costlylive steam. One of the methods of recovering flash steam is to install thermo-compressors.

Flash steam recovery using thermo-compressor systems have been in successful operationin several chemical & petrochemical, pulp & paper and sugar industries. This becomesparticularly attractive, when the plant has commercial cogeneration.

The recovered flash steam can be used for to either substitute MP/ LP steam or is connecteddirectly to the steam header. The schematic diagram of the system is shown below.


103

70 ksc 60 TPH 415°C

140°C

4 – 6 ksc

Condensate to Steam Plant

100°C

Pure Condensate Tank

Vent Steam

Flash Steam

60 TPH 70 ksc 260°C

Digester

Flash Vessel

3 TPH

Steam Plant

Flash Steam

Evaporator or LP header

Thermo Compressor

Motive Steam 14 – 15 ksc

PCT

Energy saving projectThermo compressor was installed to recover the flash steam from the pure condensate tankand the recovered steam is sent to low pressure steam header.

The motive steam used is about 18-20 TPH at a pressure of 12 kg/cm2.

The schematic diagram of the modified system is shown below.



BenefitsThe quantity of flash steam recovered was about 3.0 TPH.

Financial analysisThis amounted to an annual monetary saving of Rs 5.48 million. The investment made wasRs 3.00 million. The simple payback period for this project was 7 Months.





105



Case study – 3

INSTALL SEAL POT SYSTEM FOR CONDENSATE RECOVERY

BackgroundConventional steam are prone for frequent failure and hence steam leakage. In large steamusers, specifically wherever the steam consumption is more than 1 ton/hr failure of steamtraps lead to heavy steam leakage and hence energy loss.

The latest trend is installing seal pots wherever the steam consumption is more than 1 ton/hr. in a seal pot condensate level is maintained in an enclosed vessel. The draining ofcondensate is done using an automatic control valve, which is operated based on seal potcondensate level. A vent is also provided in the seal pot for removing the non condensablegases.

Installing the seal pots for condensate recovery totally eliminates the steam leakage andmaximises the condensate recovery.

The advantage with a seal pot system, is that it is highly reliable and requires very little orno maintenance. However, the system will require higher level of instrumentation and control.

Present statusThe digestors and evaporators are the major consumers of live steam in alumina refineryplant. The next major steam consumers are the HP heaters and LP heaters. Steam traps areinstalled for condensate recovery in all the users.

Over a period of time, due to frequent failure of steam traps, these have got by-passed orremoved. This results in steam passing and considerable heat loss.

The trend amongst the industries, where steam consumption is more than 1 TPH, is to replacethe steam traps with seal pot systems.

The seal pot system, comprises of an empty vessel (called the seal pot), to which thecondensate line is connected. The seal pot is provided with a small vent at the top, for releaseof non-condensable gases.

A control valve is provided at the bottom of the seal pot to regulate the condensate flow. Thisvalve operates in closed loop with a level indicator controller (LIC) provided at the seal pot.The condensate is pumped to the steam plant, through the pure condensate/ alkalinecondensate tanks.


107

Seal pot

Air vent

Digester

MP steam

The schematic diagram of the steam trap system is shown in fig.

Energy saving projectSeal pots were installed for condensate recovery in the following equipment.

• Digesters

• Evaporators

• HP heaters & LP heaters

BenefitsThe steam savings achieved was about 250 kg/hr.






109

Case study – 4

OPTIMISE EXCESS O2% IN KILN BY CONTINUOUSMONITORING

Back groundFor the combustion process the quantity of air supplied is an important parameter. To ensurethe complete combustion of the fuel the quantity of air supplied should be more than thestoichiometric air quantity of the fuel.

Oxygen level in the flue gas is an indication of the quantity of excess air sent for the combustionprocess. Higher the O2 level, higher will the quantity of excess air sent and vice versa.

With increase in quantity of excess air sent for combustion, the flue gas loss increases andhence the operating efficiency of the furnace decreases.

For oil-fired system the optimum recommended O2 level in the flue gas is 3-4%.

Present statusThe calcination of alumina is carried out in the kiln. The production rate in the kiln is 530MT/day of calcined product. The average fuel consumption in the kiln is about 2000 lit/hr.

Combustion analysis was carried out in Kiln. The percentage of Oxygen level in the exhaustflue gas and its temperature were measured at the outlet of the kiln.

The measured value at the kiln exhaust is as below:• O2 % - 8.0 %• Temperature - 201 oC

The quantity of excess air supplied is very high compared to the requirement. Hence, thereis a good potential to save energy by optimising the quantity of excess air sent for thecombustion process

Energy saving projectOnline oxygen analyser was installed and the % of oxygen level inthe flue gas is continuously monitored.

The combustion air supply to the kiln is controlled and percentageoxygen of 3% is maintained in the flue gas.

BenefitsOn a conservative basis atleast 2% increase in combustion efficiency and hence reduction infuel consumption was achieved.


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Case study -5

SEGREGATE PICK-UP AND DRYING ZONE VACUUMS IN REDMUD FILTERS

BackgroundThe rotary drum filters are used for red mud filtration in the Alumina plant. The rotary drumsare subjected to vacuum where filtration is taking place. The vacuum is created using thevacuum pumps.

The rotary vacuum filter is divided into two major zones – pick-up zone and drying zone. Thepick-up zone is where the drum dips into the slurry in the trough and built-up of cake starts.This zone typically requires a vacuum of about 380-400 mm Hg.

On the other hand, the drying zone is one where, the built-up of cake on the drum is completeand drying takes place. This zone typically requires a vacuum of about 250-280 mm Hg.

Typically in this system one set of vacuum pumps are used for maintaining the same vacuumat both the zone. Maintaining higher vacuum has no direct benefit on the process.

In vacuum pumps the power consumption is proportional to the level of vacuum created.

Hence there is a good potential to save energy by segregating the two zones and installingtwo set of vacuum pumps, operating at the required vacuum level.

Present statusThere are 11 nos. of vacuum pumps (about 4 to 5 will be in operation) to cater to the vacuumrequirements of the rotary vacuum filters in the red mud filtration area. These vacuum pumpsare one of the major electrical energy consumers in the aluminium refining plant.

The design specifications of the vacuum pumps are:Capacity = 1320 m3/hVacuum = 510 mm HgSpeed = 720 RPMMotor = 125 HP

Vacuum in both pick-up and drying zones are maintained at 380-400 mm Hg. This is becauseall the vacuum pumps are connected to a common header and the pick-up & drying zonesare connected to this common header.

Maintaining a higher vacuum in the pick-up zone has no direct benefit on the process, but onthe other hand results in higher power consumption in vacuum pumps.


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The typical vacuums required are 400-450 mm Hg in pick-up zone and 250-300 mm Hg indrying zone.

Energy saving projectThe pick-up zone and drying zone vacuum headers are segregated and vacuum pumps arededicated to individual zones.

Pick up zone vacuum pumps are operated at a vacuum level of 380-400 mmHg and for thedrying zone the vacuum pumps are operated at a vacuum level of 250 mm Hg.

BenefitsSegregation of vacuum pumps for the pick up and drying zone resulted in electrical energysaving of 1800 units/day.


250 mm Hg

1320 m3/h 510 mm Hg

125 HP 11 Nos. (6↑)

400 mm Hg

400 mm Hg

400 mm Hg

300 mm Hg

RMF





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Case study –6

SWEETEN THE DIGESTION PROCESS BY ADDING GIBBSITICBAUXITE HAVING HIGHER SOLUBILITY IN DOWNSTREAMOF HIGHER TEMPERATURE DIGESTION CIRCUIT

BackgroundThe hydrated alumina is selectively removed from the other (insoluble) oxides by transferringit into a solution of sodium hydroxide (caustic soda). Bauxite is crushed and pre washed andthen sent to a heated pressure digester.

Conditions within the digester (concentration, temperature and pressure) vary according to theproperties of the bauxite ore being used. Typically the digesters operate at between 200 and240 °C and can involve pressures of around 30atm.

The latest trend is addition of Gibbsittic Bauxite in suitable flash tank in the down stream ofdigestion circuit. This increases productivity without any further addition of steam.

About 30 grams per litre more Alumina can be dissolved by addition of Gibbsitic bauxite indigested Boehmitic slurry stream. It results in substantial increase in Alumina super saturationlevel utilizing the heat energy of flashing circuit. This has been shown in the Alumina solubilitycurve.



Gibbsitic slurry addition in the downstream of slurry addition

Energy saving projectGibbsitic slurry addition was taken up in the down streamof the digestion circuit.

BenefitsImplementation of the above project resulted in annualsaving of 113.88 Lakh KWH of electrical power, 16,985MT of coal and 1577 KL of fuel oil.

Financial analysisThis amounted to an annual monetary saving ofRs 42.9 million. The investment made was Rs 0.95million. The simple payback period for this project was1 Month.

Boehmitic Bxt. Slurry

FREQUENY DRIVE FOR

FLOW CONTROL

Gibbsitic Bxt. Slurry

Sweetening S.H.Tic

600 psig steam

243 0 C 243 0 C 243 0 C 243 0 C

1 2 3 4 5 7 6

Spent Liquor



• Simple payback - 1 month


117



Case study –7

REPLACE OLD HORIZONTAL STUD SODERBERG (HSS) CELLSWITH MODERN POINT FEEDER PREBAKE CELLS

Back GroundFor Aluminium smelting horizontal stud soderberg (HSS) cells are used. The characteristicsof HSS system are as follows:

• Higher specific energy consumption

• Higher GHG & fluoride emissions

• Lower level of automation

• Higher raw material consumption

• Higher solid waste generation

The latest trend is installing multipoint feeder prebake cells. Pre-bake technology uses multipleanodes in each cell which are pre-baked in a separate facility and attached to “rods” thatsuspend the anodes in the cell. New anodes are exchanged for spent anodes - “anode butts”- being recycled into new anodes.

The newest primary aluminium production facilities use a variant on pre-bake technologycalled Centre Worked Pre-bake Technology. This technology provides uses multiple “pointfeeders” and other computerised controls for precise alumina feeding.


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Computer technology controls the process down to the finest detail, which means thatoccurrence of the anode effect - the condition, which causes small quantities of Perfluorocarbons(PFCs) to be produced - can be minimised.

The characteristics of prebake technology are as follows:• Economical for capacities of 150000 tpa and above• Highly automated and capital intensive technology• Normal line amperage over 150 KA• Lower specific energy and raw material consumption• Dry scrubbing of exhaust gases with alumina for fluoride recovery

Present statusIn one of the Aluminium smelters in India, relatively old Horizontal Stud Soderberg (HSS) cellsare used for production of aluminium from alumina.

The present specific energy consumption of Aluminium production is as below.

AC for electrolysis - 15.558 kWh/Kg of Aluminium

Energy saving projectIt is proposed to revamp the entire system by installing modern point feeder prebake (PFPB)cells. The proposed system require energy consumption of about 990 million kWh/year toproduce 29500 tons/year of aluminium.

The specific energy consumption for producing one tonne of Aluminium would be as givenbelow.

• AC for electrolysis – 14.00 kwh/kg of Al. (Electrical energy)

BenefitsThe benefits of the new proposed system are as follows:

• Retrofit prebake cells with point feeders, operate at around 10% higher energy efficiency

• About 50% GHG emissions reduced due to modern process controls

• 50% reduction in hazardous waste generated

• 30% reduction in water consumption

• Reduction in specific consumption of raw materials – Coal tar pitch, cryolite, aluminiumfluoride and Petroleum coke

Financial AnalysisThe annual energy saving potential @ Rs 1.80/unit isRs 84.10 million.

Cost benefit analysis• Annual Savings - Rs.84.10 million


120Energy Conservation in Glass Industry

Glass

Growth percentage 7.2 %

Energy Intensity 30 % of manufacturing cost

Energy Costs Rs.5000 million (US $ 100 Million)

Energy saving potential Rs 500 million (US $ 10 million)

Investment potential on energy

saving projects Rs. 80 Crores (US $ 16 Million)


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About the sector:The Indian glass industry is an energy-intensive industry and has been recognized by its rapidgrowth and modernization efforts after the economic reforms initiated by the government in1990. It represents one of the largest markets and the manufacturing capacity for glassproducts in the region after China.

Over 80 % of the industry output is sold to other industries, and the glass industry as a wholeis very dependent on the building industry, and the food and beverage industry.

The glass industry is diverse, both in the products made and the manufacturing techniquesemployed. Products range from intricate hand-made lead crystal goblets to huge volumes offloat glass produced for the construction and automotive industries.

The float glass, container glass, glass fiber and glass tableware are manufactured by about100 large scale companies which operate with modern and large scale melting furnacetechnologies. They are mostly located in Gujarat, Bombay, Calcutta, Bangalore andHyderabad.

The industry, on the other hand, is also represented in the country by more than 300 mediumand small-scale enterprises and cottage industry units. The historical glass-making town ofFirozabad in UP State is a well-known location, which meets the 70 per cent of demand forglass products in the country by using outdated pot and tank furnaces.

Manufacturing techniques vary from small electrically heated furnaces in the ceramic fibresector to cross-fired regenerative furnaces in the flat glass sector, producing up to 600 tonnesper day.

An indicative breakdown of the different sectors of glass industry is given in the table below.

Sector % of Total Production

Container Glass 60

Flat Glass 20

Continuous Filament Glass Fibre 2.0

Domestic Glass 4.0

Special Glass 14

Container glass production is the largest sector of the glass industry, representing around 60% of the total glass production. The sector covers the production of glass packaging i.e.bottles and jars although some machine made tableware may also be produced in this sector.

The beverage sector accounts for approximately 75 % of the total tonnage of glass packagingcontainers. The main competition is from alternative packaging materials such as steel,aluminium, cardboard composites and plastics.

Production pattern and Growth rate of Glass Industry in IndiaAn account of the different segment of this industry is given below:

The overall production growth in the glass industry was recorded at 7.2% during 2002 ascompared to 6.5% last year.



Barring glass tableware, other segments of the glass industry registered a moderate growthwith glass containers and wares at 9%, sheet and float glass at 5%.

Glass Containers and Hollow WareThere are 44 units producing glass containers and hollow wares with an installed capacity of15 lakh tonnes per annum.

Flat GlassThe combined capacity of sheet glass, float glass and figured and wired glass is around 135million sq. m. per annum. The present per capita consumption of float/sheet glass in India is0.5 kg, which is very low in comparison to 2.5 kg in Indonesia and 3.5 kg in China.

Vacuum Flask and RefillsThere are, at present, 8 manufacturing units with a total installed capacity of around 36 millionnumbers per annum. Production in 2000-01 was about 18 million numbers.

Laboratory/Scientific GlasswareThis segment of the glass industry comprises items like neutral glass tubing, laboratoryglassware and chemical process equipment. There are six units in this segment. The installedcapacity of neutral glass tubing is 46600 tonnes per annum. The growth rate is expected tobe around 3% per annum during the period 2001-02.

Fibre GlassProduction of fibreglass is highly capital and technology intensive. The present installedcapacity is about 55,000 MT per annum. The expected growth rate of the industry is 12%.

Glass Manufacturing process:The manufacture of any glass can be split up into four phases:

1. Preparation of raw material,

2. Melting in a furnace,

3. Forming and

4. Finishing


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The below diagram gives typical glass manufacturing process:

The products of this type of process are predominantly flat glass, container glass, and pressedand blown glass. The procedures for manufacturing glass are the same for all products exceptforming and finishing.

As the sand, limestone, and soda ash raw materials are received, they are crushed and storedin separate elevated bins. These materials are then transferred through a gravity feed systemto a weigher and mixer; here the material is mixed with cullet to ensure homogeneous melting.

The mixture is conveyed to a batch storage bin where it is held until dropped into the feederto the melting furnace.

All equipment used in handling and preparing the raw material is housed separately from thefurnace and is usually referred to as the batch plant.

As material enters the melting furnace through the feeder, it floats on the top of the moltenglass already in the furnace. As it melts, it passes to the front of the melter and eventuallyflows through a throat leading to the refiner. In the refiner, the molten glass is heat conditionedfor delivery to the forming process.

After refining, the molten glass leaves the furnace through forehearths (except in the floatprocess, with molten glass moving directly to the tin bath) and goes to be shaped by pressing,blowing, pressing and blowing, drawing, rolling, or floating to produce the desired product.

Pressing and blowing are performed mechanically, using blank molds and glass cut intosections (gobs) by a set of shears.

The float process is different, having a molten tin bath over which the glass is drawn andformed into a finely finished surface requiring no grinding or polishing. The end productundergoes finishing (decorating or coating) and annealing (removing unwanted stress areasin the glass) as required, and is then inspected and prepared for shipment to market.

Any damaged or undesirable glass is transferred back to the batch plant to be used as cullet.



Furnaces in a glass IndustryThe furnace most commonly used is a continuous regenerative furnace capable of producingbetween 50 and 300 tons of glass per day. For smaller capacities recuperative furnaces orpot type furnaces without heat recovery are also being used.

A furnace may have either side or end ports that connect brick checkers to the inside of themelter.

Side port regenerative furnace


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End port regenerative furnace

Process DescriptionContainer Glass

Glass containers are produced in a two stage moulding process by using pressing and blowingtechniques.

There are five essential stages in automatic bottle production.

1. Obtaining a piece of molten glass (gob) at the correct weight and temperature.

2. Forming the primary shape in a first mould (blank mould) by pressure from compressed airor a metal plunger.

3. Transferring the primary shape into the final mould (finish mould).

4. Completing the shaping process by blowing the container with compressed air to the shapeof the final mould.

5. Removing the finished product for post forming processes.



Simplified diagrams of the two main forming processes are shown in figure

Glass containers are conveyed through various inspection, packaging, unpacking, filling andre-packaging systems.

Flat GlassThe term flat glass strictly includes all glasses made in a flat form regardless of the form ofmanufacture. However, for the purposes of this document it is used to describe float glass androlled glass production.

Most flat glass is produced with a basic soda lime formulation, a typical float glass composition.

Float glass and rolled glass are produced almost exclusively with cross-fired regenerativefurnaces.

The Float Glass ProcessThe basic principle of the float process is to pour the molten glass onto a bath of molten tin,and to form a ribbon with the upper and lower surfaces becoming parallel under the influenceof gravity and surface tension.

The molten glass flows from the furnace along a refractory lined canal, which can be heatedto maintain the correct glass temperature. At the end of the canal the glass pours onto thetin bath through a special refractory lip (“the spout”) which ensures correct glass spreading.


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At the exit of the float bath the glass ribbon is taken out by lift-out rollers, and is passed througha temperature controlled tunnel, the lehr, to be annealed.

Glass is thus gradually cooled from 600°C to 60°C in order to reduce residual stresses,caused during the forming process, to an acceptable level.

The cooled glass ribbon is cut on-line by a traveling cutter.

On-line coatings can be applied to improve the performance of the product (e.g. low emissivityglazing).

Continuous Filament Glass FibreThe most widely used composition to produce continuous fibres is E Glass, which representsmore than 98 % of the sector output.

The glass melt for continuous filament glass fibre is generally produced in a cross-fired fossilfuel recuperative furnace.

The molten glass flows from the front end of the furnace through a series of refractory lined,gas heated canals to the forehearths.

The glass flowing through the bushing tips is drawn out and attenuated by the action of ahigh-speed winding device to form continuous filaments.

The filaments are drawn together and pass over a roller or belt, which applies an aqueousmixture, mainly of polymer emulsion or solution to each filament. The coated filaments aregathered together into bundles called strands that go through further processing steps,depending on the type of reinforcement being made.

The main products are chopped strands, rovings, chopped strand mats, yarns, tissues, andmilled fibres.

Chopped strands are produced by unwinding the cakes and feeding the filaments into amachine with a rotating bladed cylinder.



Energy Consumption patternGlass making is energy intensive and the process energy accounts for a full 30 percentof the cost of glass products. In general, the energy necessary for melting glass accountsfor over 75 % of the total energy requirements of glass manufacture. Other significantareas of energy use are forehearths, the forming process, annealing, factory heating andgeneral services.

The choices of energy source, heating technique and heat recovery method are central to thedesign of the furnace. The same choices are also some of the most important factors affectingthe environmental performance and energy efficiency of the melting operation.

In recent decades the predominant fuel for glass making has been fuel oil, although the useof natural gas is increasing. There are various grades of fuel oil from heavy to light, withvarying purity and sulphur content. Many large furnaces are equipped to run on both naturalgas and fuel oil, and it is not uncommon for predominantly gas-fired furnaces to burn oil onone or two ports.

The third common energy source for glass making is electricity, which can be used either asthe only energy source or in combination with fossil fuels.

The energy usage pattern in different types of industries is as below:

Container glass:

The typical energy use for the Container Glass Sector, which accounts for around 60 % oftotal glass output is: furnace 79 %, forehearth 6 %, compressed air 4 %, lehr 2 %, and others6 %.

Float glass:The energy usage distribution for a typical float glass process is shown in.2 below, but energyusage in particular processes may vary slightly. It can be seen that over three quarters of theenergy used in a glass plant is expended on melting glass. Forming and annealing takes afurther 5 % of the total. The remaining energy is used for services, control systems, lighting,factory heating, and post forming processes such as inspection and packaging.


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The energy usage distribution for a typical continuous filament process is shown below.

Energy usage in particular processes may vary depending on the size of the melter and thetype of downstream processes. It can be seen that generally over three quarters of the energyis used for melting. Forming, including bushing heating, and product conversion account foraround 15 %, and the remaining energy is used for services, control systems, lighting, andfactory heating.

Continuous Filament glass:

As discussed earlier fuel oil and natural gas are the predominant energy sources for melting,with a small percentage of electricity. Forehearths and annealing lehrs are heated by gas orelectricity, and electrical energy is used to drive air compressors and fans needed for theprocess. General services include water pumping, steam generation for fuel storage and traceheating, humidification/heating of batch, and heating buildings.

In order to provide a benchmark for process energy efficiency it is useful to consider thetheoretical energy requirements for melting glass.

The three important components, which forms the basis for the theoretical requirement is asbelow:

• The heat of reaction to form the glass from the raw materials;

• The heat required, enthalpy, to raise the glass temperature from 20 °C to 1500 °C; and

• The heat content of the gases (principally CO2) released from the batch during melting.

The actual energy requirements experienced in the various sectors vary widely from about 3.5to over 40 GJ/tonne. This figure depends very heavily on the furnace design, scale andmethod of operation. However, the majority of glass is produced in large furnaces and theenergy requirement for melting is generally below 8 GJ/tonne.



Some of the more general factors affecting the energy consumption of fossil fuel fired furnacesare outlined below. For any particular installation it is important to take account of the site-specific issues, which will affect the applicability of the general comments given below.

a) The capacity of the furnace significantly affects the energy consumption per tonne of glassmelted, because larger furnaces are inherently more energy efficient due to the lowersurface area to volume ratio.

b) The furnace throughput is also important, with most furnaces achieving the most energyefficient production at peak load. Variations in furnace load are largely market dependentand can be quite wide, particularly for some container glass and domestic glass products.

c) As the age of a furnace increases its thermal efficiency usually declines. Towards the endof a furnace campaign the energy consumption per tonne of glass melted may be up to20 % higher than at the beginning of the campaign.

d) The use of cullet can significantly reduce energy consumption, because the chemicalenergy required to melt the raw materials has already been provided. As a general ruleeach 10 % increase in cullet usage results in an energy saving of 2 - 3 % in the meltingprocess.

Energy saving potential (data from CMIE)The total cost of production of glass in India account to a total of Rs 1470 crores. The energycost alone forms about 30% the total manufacturing cost.

The energy saving potential in Indian glass industry is about 10-15% of the total energycost. The energy saving offers a good investment potential of about Rs 130 crores inthe glass sector.

Energy Conservation:Process energy accounts for a full 30 percent of the cost of glass products. In the faceof growing challenges from foreign manufacturers and other materials, the glass industryseeks to reduce energy use as part of its broader effort to lower glass production costs.

Present glass manufacturing facilities clearly offer a large opportunity for energy savings.Whereas melting one ton of glass should theoretically require only about 2.2 millionBtu, in practice it requires a minimum of twice that much because of a variety of lossesand inefficiencies and the high quality of glass that is often required. One of the maingoals set forth in the glass vision statement is to cut the gap between theoretical and actualenergy requirements by half.

In a glass industry, the melting process is by far the most energy intensive of the primaryglassmaking processes and is responsible for the majority of energy consumption.

The figure records 75% on the tank furnace; and more energy, nearly 85%, is consumed inthe case of the pot furnace.


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Thus, when energy conservation efforts are made, top priority must be placed on the furnace,then on the lehr.

The unit energy consumption means the energy required to make the product of unit amount(1 kg or 1 ton). It is expressed either by unit energy consumption if energy is used as the unitor by unit fuel consumption if the amount of fuel is used as the unit.

Basically, energy conservation in the glass factory is to reduce the unit energy consumption.To reduce unit energy consumption, it is necessary to reduce the amount of fuels used, whileit is important as well to increase production without increasing the amount of fuels, and toreduce the failure rate of production, thereby ensuring production increase in the final stage.

ENERGY SAVING SCHEMES IN GLASS INDUSTRYList of all possible energy conservation projects in a typical glass industry

1. Install Variable Frequency Drive (VFD) For Combustion Air Blower

2. Install Variable Fluid Coupling for cooling blowers in furnace

3. Install correct head fans for furnace cooling

4. Reduce rpm of furnace chimney blower by 10%

5. Replace the existing inefficient cooling blowers with energy efficient blowers with efficiencygreater than 75%

6. Avoid recirculation through the stand-by blower of throat cooling

7. Replace old inefficient reciprocating compressors catering to instrumentation requirementswith high efficiency compressors

8. Install lower capacity air compressor to cater high pressure compressed air requirementscatering to furnace primary air requirements and minimize unloading power consumptionby compressor

9. Segregate low pressure and high pressure compressor air systems and operate LP airsystem catering to instrumentation systems at lower pressure

10. Install Variable Frequency drives to screw compressor catering to process air requirements(furnace combustion requirement) and reduce power consumption



11. Reduce pressure settings of hp air compressors catering to furnace combustionrequirements

12. Install correct head pumps for cooling tower catering to cooling requirements ofinstrumentation compressors

13. Avoid water flow through idle compressors / condensers and install next low head pumpsfor hp compressor cooling

14. Optimise the combustion air supply to the furnace and maintain 3% O2 in the flue gas

15. Preventing cold air from entering through the inlet opening of the lehr and reducing heatloss in the furnace

16. Improve insulation of the walls of the lehr and reduce radiation losses

17. Reduce the conveying length of product from the furnace to the lehr and reducetemperature drop

18. Install automatic voltage stabilizer in street lighting feeder and optimise operating voltage

19. Replace copper ballast with high frequency electronic ballast in all fluorescent lamps

20. Optimize pressure settings of air compressors

21. Arrest leakages in compressed air system

22. Install transvector nozzles for identified cleaning points

23. Replace existing V-belt drives with flat belt drives for identified equipment

24. Convert delta to star in the identified lightly loaded motors

25. Balance system voltage to avoid unbalance in motor load

26. Replace faulty capacitors

27. Install automatic voltage stabiliser and operate lighting circuit at 210 volts

28. Install soft start cum energy saver for motors

29. Replace old motors with energy efficient motors

30. Use transluscent sheets to make use of day lighting

31. Install timers for automatic switching ON-OFF of lights

32. Install timers for yard and outside lighting

33. Grouping of lighting circuits for better control

34. Operate at maximum power factor, say 0.96 and above

35. Switching OFF of transformers based on loading

36. Optimise DG set operating frequency

37. Optimise DG set operating voltage

38. Replacement of Aluminium blades with FRP blades in cooling tower fans

39. Install temperature indicator controller (TIC) for optimising cooling tower fan operation,based on ambient conditions

40. Install dual speed motors/ VSD for cooling tower fans


133

Case Study - 1

Preheat Feed Material Furnace UsingWaste Heat from Flue Gas

BackgroundBatch and cullet is normally introduced cold into the furnace, before being heated and meltedby the heat in the glass tank. And the flue from the furnaces after the regenerator typicallyleaves at a temperature of about 500-600oC.

An important process improvement currently being contemplated by the glass industry is thepreheating of the batch feed by using exhaust gases from the furnace.

An analysis of the melt furnace and its regenerator indicates that there is enough energyavailability in the furnace exhaust gases to preheat the incoming combustion air to presentlevels and to preheat the batch to 400 oC. Depending upon the specific operating conditions,5-10% of the energy necessary to melt glass could be obtained from waste heat.

By this method, the total fuel consumption by the furnace can be reduced by atleast5%. The economics of batch/cullet preheaters are strongly dependent on the capacity of thefurnace and the preheater.

This preheating method allows a better usage of energy in the furnace area. But such apreheat operation is difficult to accomplish without modification in the batch handling methods.

Normally, a number of storage bins hold the raw material. The raw materials are weighedindividually, fed to a collecting belt, and conveyed to a mixer. A pan mixer is used to blendthe dry materials. From the mixer, the blended batch is transferred to a surge hopper andfeeder. The material is then fed to a pelletiser, where water is added to about 4% by weightas a binder for the pellets. The pelletised material is then conveyed through a high temperaturecontinuous preheater, which is heated by the waste gases of the glass melting furnace.

The presently available systems for preheating the batch feed is as below:

Direct preheatingThis type of preheating involves direct contact between the flue gas and the raw material(cullet only) in a cross-counter flow. The waste gases are supplied to the preheater from thewaste into direct contact with the raw material. The outlet temperature of the cullet is up to400 ºC.



The system can also incorporate a bypass that allows furnace operation to continue whenpreheater use is either inappropriate or impossible.

Diagram of a direct preheater:

Indirect preheatingThe indirect preheater is in principle a cross-counter flow, plate heat exchanger, in which thematerial is heated indirectly. It is designed in a modular form and consists of individual heatexchanger blocks situated above each other. These blocks are again divided into horizontalwaste gas and vertical material funnels. In the material funnels the material flows from the topto the bottom by gravity. Depending on the throughput, the material reaches a speed of1 - 3 m/h and will normally be heated up from ambient temperature to approximately 300°C.The flue gases will be let in the bottom of the preheater and flow into the upper part by meansof special detour funnels. The waste gases flow horizontally through the individual modules.Typically the flue gases will be cooled down by approximately 270°C – 300°C.

In general, the following benefits can be experienced.

• Energy savings of atleast 5 %.

• Reduction in NOx emission (due to lower fuel requirements and lower furnace temperatures).


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• In the case of direct preheating, reduction of acidic compounds, SO2, HF, and HCl, of60%, 50% and 90% respectively have been found (difference before and after cullet bed).

Case studyA container glass plant with a furnace capacity of 370 tonnes/day had a specific energyconsumption of about 4000 kJ/kg of glass. The temperature of exit flue gas from the furnace,after the regenerator is about 450-500oC.

The fuel consumption of the plant was about 35kl/day. The cullet in the feed amounted toabout 60% of the total batch onto the furnace.

The plant team installed an indirect type batch preheating system for their furnace. In orderto keep the loss of heat of the transport system, as low as possible the preheater was locatedas close as possible to the doghouse. The ideal location was directly above the batch charger.

After this installation, the flue gas got cooled to a temperature of about 200-250oC. As aresult, the total reduction in oil consumption by the plant is about 10% of the fuel consumption.

The technique also gave an increase in furnace capacity by 10 % - 15 % without compromisingthe furnace life. If the pull rate is not increased a small increase in furnace life may bepossible.

If a plant utilizes electric boosting technique, by getting more heat into the furnace the techniquecan also reduce the requirement from electric boosting.

The cost economics of the project is as below:

Investment – Rs 4.00 million

Savings – Rs 1.50 million

Payback – 32 months

Other general factors to be considered• To prevent material agglomeration the maximum entry temperature of the flue gases

should not exceed 600°C.

• In some cases, problems with odor generation from the preheater have arisen, due toorganic fumes released during pre-drying of the cullet. The problems are caused byburning of food particles and other organics in the external cullet.

• Material preheating consumes electric energy, particularly for direct heating which requiresan Electrostatic Precipitator. These off sets a portion of the energy saving but it is notsubstantial.

• For economic reasons the temperature of the waste gas available should at least be 400- 450°C.

• Direct Cullet/batch preheating systems can theoretically be installed at any existing glass-melting furnace with greater than 60 % cullet in the batch. The use of a direct preheatercauses increased emissions of particulate matter (up to 2000 mg/Nm3) and secondary


137

Case study - 2

The installation of preheater have successfully implementedin many of the European industries and some of the expammleinstallations are as below:(All container Glass)

Direct preheating:

Four furnaces at Nienburger Glas, Nienburg, Germany.

Gerresheimer Glas, Dusseldorf, Germany.

Wiegand Glas, Stein am Wald, Germany.

Gerresheimer Glas, Budenheim, Germany.

Indirect preheating:PLM Glasindustrie Dongen BV, Dongen, Netherlands.PLM Glass Division, Bad Münder, Germany.Vetropack, St. Prex, Switzerland – no longer operating.

Edmeston EGB Filter:Irish Glass, Dublin, Ireland.Leone Industries, New Jersey, USA (oxy-fuel fired furnace).

The installations as such in India are still in the initial stages of implementation andoffer a very good potential for energy savings.

The project has a good potential to be replicated in about 100 organized sectors and200 to 250 small scale manufacturers in India.



Case study - 3

WASTE GAS HEAT RECOVERY SYSTEMS IN FURNACES

BackgroundGlass is maintained at a temperature of about 1550oC, in the tank. The hot flue gas from thefurnace leaves at a temperature of about 1600oC.

The heat in the exit flue gas can be effectively utilised by preheating the incoming air to thecombustion furnace. There are two options available for this purpose. The installation of:

1. Regenerators

2. Recuperators

Regenerators:The regenerator is designed in a way that high temperature exhaust gas is passed throughthe checker bricks, and the heat is absorbed by these bricks. After the combustion, gas is fedfor some time (15 to 30 minutes), air is fed there by switching, and the brick heat is absorbed,raising the air temperature. The air is used for combustion. This procedure is repeated atintervals of 15 to 30 minutes. Thus, two regenerators are required for each furnace.

The exhaust gas temperature is 1350 to 1450°C at the regenerator inlet, and drops 400 to500°C at the regenerator outlet. Air enters the regenerator at the room temperature, and isheated to reach 1200 to1300°C at the outlet. Then, it is used as secondary air for combustion.

Most glass container plants have either end-fired or cross-fired regenerative furnaces. All floatglass furnaces are of cross-fired regenerative design.

Preheat temperatures up to 1400 °C can also be attained leading to very high thermalefficiencies.

Cross-Fired Regenerative Systems


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A cross-fired regenerative furnaceIn the cross-fired regenerative furnace, combustion ports and burners are positioned along thesides of the furnace. The regenerator chambers are located either side of the furnace and areconnected to the furnace via the port necks. The flame passes above the molten material anddirectly into the opposite ports. The number of ports (up to 8) used is a function of the sizeand capacity of the furnace and its particular design. Some larger furnaces may have theregenerator chambers divided for each burner port.

This type of design using effectively a multiplicity of burners is particularly suited to largerinstallations, facilitating the differentiation of the temperature along the furnace length necessaryto stimulate the required convection currents in the glass melt.

End-Fired Regenerative FurnaceIn the end-fired regenerative furnace the principles of operation are the same, however, thetwo regenerative chambers are situated at one end of the furnace each with a single port. Theflame path forms a U shape returning to the adjacent regenerator chamber through thesecond port.

This arrangement enables a somewhat more cost effective regenerator system than thecross-fired design but has less flexibility for adjusting the furnace temperature profile and isthus less favoured for larger furnaces.

End-fired regenerative furnace



Side view of end-fired regenerative furnaces

Plan view of end-fired regenerative furnaceRegenerative furnaces achieve a higher preheat temperature for the combustion gases, up to1400°C compared with 800°C for recuperative furnaces, resulting in better melting efficiencies.

The generally larger size of the regenerative furnaces also makes them more energy efficientthan the smaller recuperative furnaces. This is because structural losses are inverselyproportional to the furnace size, the main reason being the change in surface area to volumeratio.

A modern regenerative container furnace will generally have an overall thermal efficiency ofaround 50 %, with waste gas losses around 20 %, and structural losses making up the vastmajority of the remainder.

Maximizing heat recovery in regenerators:Furnace geometry is constantly undergoing refinements to optimise thermal currents and heattransfer, both to improve glass quality and to save energy. The developments are oftencombined with developments in combustion systems to reduce emissions and save energy.

Normally, furnace geometry changes are only possible for new furnaces or rebuilds.

The energy recovered by regenerators may be maximized by incorporating the right type andquantity of refractory material into the regenerators.

The refractory material should possess high thermal conductivity, hence resulting in higherheat recoveries.

One of the problems faced by companies in regenerators is that, they get corroded with theexit flue gas and results in clogging of the flue gas path with particulate carry over in fluegases inside the regenerators. This ultimately reduces the heat recovery in the system. Henceone of the important factors to be considered is to select a right type of refractory materialthat can withstand corrosion.

There are a variety of checker works available nowadays and the best one needs to bechoosed for better heat recovery. The most common is the bricks are available in standardsizes of 65mm thickness with basic materials such as magnesite and chrome. These refractorymaterials are used for their resistance to handle alkaline corrosion in flue gases.


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Losses through the Crown and walls 20 – 40%

Melting Furnace

Combustion Air Recuperato

Exhasust Gas Losses Approx 40%

Energy Recovered through the preheating of the combustion air approx 30%

Energy input from Gas / Fuel oil 100%

Melting and Refining energy 20 – 40%

Blocks shaped in the form of cruciform or chimney blocks on account of their lesser thicknessare more efficient in Magnesite high alumina and AZS compositions. However, heat transfercan be improved by using specially shaped packing and fusion cast materials. For example,fusion cast corrugated cruciform will enhance the heat exchange efficiency compared tostandard brick packing and typical fuel savings of 7 % are quoted.

With better quality basic and AZS electrocast refractories, regenerator checker life can beincreased and increase upto 8 years have been improved in various factories.

In addition, these materials are very resistant to chemical attack from volatiles in the wastegas stream and show very much reduced deterioration in performance (compared to bricks)throughout the campaign. So far, around 320 installations of corrugated cruciforms have beenreported world-wide.

Increased refractory area:The energy recovered by regenerators may be maximized by increasing the surface area tospecific volume ratio. In practice, these may be organised in enlarged regenerator chambersor in separate but connected structures, giving the term multi-pass regenerators in somecases.

The law of diminishing returns applies, as the regenerator efficiency is approachingasymptotically its maximum limit. The principle limitations are the cost of the extra refractorybricks, and in the case of existing furnaces the limitation of available space and the additionalcost of modification of furnace infrastructures.

Modification of regenerator structures on existing furnaces (if this is technically and economicallyfeasible given the plant layout) can only be made during furnace reconstruction.



Case study – Install Regenerators for glass meltingfurnacesOne glass bulb making unit in southern part of India had a unit melterof capacity 16tonnes/day. The total furnace oil consumption by thefurnace is about 700lit/ton.

There was no flue gas recovery by the furnace and the temperatureof exit flue gas is about 1500oC. This can be effectively utilized topreheat the incoming combustion air.

The plant installed a new regenerative furnace of 16 ton/day capacityand achieved a saving of 1800 kl/annum of furnace oil.

Benefits (check the cost benefit as the below thing is taken from a1987 report)

There was a tremendous reduction in the specific fuel consumptionby the furnace. The new specific fuel consumption is about 310 lit/ton of glass melted.

The cost economics of the project is as below:

Investment – Rs 30.0 million

Savings – Rs 20.0 million

Payback – 18 months

Majority of the organized sectors in India have adopted this technology of regeneration in themelting furnaces. The major thrust, which needs to be applied, is towards the small-scalesectors, which constitutes about 250 glass industries.

These industries can be installed with recuperative heaters for their furnaces and thus thisarea would offer a huge energy saving potential in the energy consumption by the meltingfurnaces.

Recuperative Furnaces:The recuperator is another common form of heat recovery system usually used for smallerfurnaces. In this type of arrangement the incoming cold air is pre-heated indirectly by acontinuous flow of waste gas through a metal (or, exceptionally, ceramic) heat exchanger. Airpreheat temperatures are limited to around 800°C for metallic recuperators, and the heatrecovered by this system is thus lower than for the regenerative furnace. The lower directenergy efficiency may be compensated by additional heat recovery systems on the wastegases, either to preheat raw materials or for the production of steam.

However, one consequence is that the specific melting capacity of recuperative furnaces islimited to 2 tonnes/m2/day compared to typically 3.2 tonnes/m2/day for a regenerative furnacein the Container Glass Sector. This lack of melting capacity can be partially compensated bythe use of electric boosting.

Normally, recuperators would be ideally suited for low capacity industries (about 10TPD).Recuperators can be of either metallic/refractory type. The temperature limitations of thesetypes of recuperators are 1000oC and 1500 oC respectively.


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The maximum temperature upto which the combustion air can be preheated would be 850 -900oC. This limits the thermal efficiency of the recuperative furnace. Typically, the thermalefficiency of a recuperative furnace without heat recovery will be closer to 20 %.

Case study:One of the tank type glass-melting furnaces with a fuel consumption of 1450 lit/day wasinstalled with a metallic recuperator. The flue gas temperature from the furnace is about1100oC and the combustion air is heated to a temperature of 600oC.

The plant achieved a savings of 25% savings in fuel consumption. The cost benefit analysisof the project is as below:

Annual savings - Rs 0.88 million

Investment - Rs 0.3 million

Payback - 5 months


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Case study - 4

Improve Insulation Practices in furnace:

Background

Furnace Walls:The insulation of furnace walls requires great attention, as the wrong selection of refractorymaterial would result in decreased production quality as well as increased energy consumptions.

Presently, all modern glass-melting furnaces are lined with AZS electrocast blocks in glasscontact areas and superstructures. The refractory material has the resistance to prevent thecorrosion of glass.

But the disadvantage is that it possesses high thermal conductivity making it less energyefficient.

Therefore, the electrocast material is backed up with a solid high alumina block and insulationto minimize heat loss.

The table below shows the heat loss at different parts of the glass tank with and withoutinsulation:

HEAT LOSS (W/M2)

Without Insulation With Insulation

G.T Crown 6900-8000 1800

End wall -do- 3500

Super Structure -do- 1800

Tank Blocks 11600-15100 2800

Bottom 10500-12800 1400

Case study:A 200 tpd container glass manufacturing industry hada melting furnace with its sidewalls at a temperatureof 230oC initially. The total surface area at thistemperature was about 6 m2. The amount of heatloss with this surface temperature is 12000 kCal/h(@6100 kcal/m2h).

The plant team increased the insulation levels, byincorporating AZS refractory bricks supported with highalumina and ceramic fibre layers and reduced the

high alumina block

= 120oC

950


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surface temperature to 120oC (corres. heat loss is 950 kcal/m2h). The diagram of the setupis given in below:

Apart from reducing the surface temperature, the plant also achieved significant savings by thereduced contamination of glass by the refractory material.

Benefits: (check – calculated based on assumed surface area; also check with excelglass proposal in backup)



Payback - 8 months


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Case study - 5

Modifications in the design of crown to reduce radiation lossand improved quality of glass

a. Reduce gap in the crown of melting furnace and reduce radiation of loss

BackgroundThe refractories used in crowns should have high alkali vapor resistance, high melting point,low surface variations and high volume stability at operating temperatures.

Over the years considerable improvements have been made in the quality of super silicabricks with minimum residual quartz and better surfaces with minimum variation. It is nowpossible to build crowns with minimum mortar of around 0.3 to 0.5 mm thickness.

Low quality bricks are characterized by high roughness on its surface, with increased gapsbetween bricks of about 1 to 3mm.

With increased corrosion due to the alkaline nature of the melt the gaps gets widenedresulting huge radiation losses. This is called the ‘Rat hole concept’.

The radiation loss from such a furnace crown can be as high as 6900-8000 W/m2. Goodpotential to reduce radiation loss from these furnaces exists by suitably refurbishingthe furnace crown.

Case studyA 50TPD container glass plant had installed for the crown of the furnace, low quality bricks.The low quality brick was least resistive to the alkaline medium and also had gaps betweenthe bricks, resulting in radiation loss from the furnace. Subsequently due to corrosion, the gapswidened resulting in the development of ‘rat holes’ on the crown.

During shutdown, the plant refurbished their crown refractory with super silica bricks. Thesuper silica brick was highly resistive to alkaline medium and had minimum surface variations.This minimized the radiation loss from the furnace considerably.

The refurbishment resulted in huge savings in the furnace and the radiation loss was minimizedto 1800 W/m2.



Payback - 48 months


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Redesigning the crown to minimize contamination of glass

The raw material fed into the glass-melting furnace consists of small quantities of Na2CO3,added as flux to reduce the melting temperature of glass.

At high temperatures Na2CO3 vaporizes and condenses on the super structures. This high pHdroplet on top of refractory, corrodes the super structure, and would drop back into the meltalong with some corroded particles. This would result in quality problems in the batch, andhence would increase the reject percentage.

The latest trend in designing the crown would be to pull up one of the refractory blocks of thefurnace, making the high pH alkaline droplet, drop back into the furnace, with out corrodingthe superstructures. This would maintain the quality of the batch with reduced rejects.

EnCon projectA 100 TPD flat glass manufacturing plant had a conventional crown in the furnace. It wasfound that the quality of the melt was reduced due to the mixing of impure particles from thesuperstructure onto the glass melt.

The furnace was then redesigned during one of the shutdowns with the crown having one ofthe blocks pulled up. This made the droplets fall back into the furnace without carrying alongwith it the particle from the superstructures.

There was a considerable reduction in the rejects % in the plant and this attributed to a netenergy saving of about 2% in the plant. The refurbishment of the old worn out crown in theplant with newly designed crown amounted to about Rs 75 lakhs.

4820

Size of the crown bricks 375 x 150 x 75 / 65 2592 375 x 230 x 75 / 65 144



Case study - 6

Installation of Modern Instrumentation & control Systems forfurnaces:Instrumentation and Control, forms one of the major energy saving component in a glassindustry.

The various parameters in a melting furnace viz., the level of molten glass in the furnace, thetemperature distribution in the furnace, the oxygen % in the flue gas needs to be monitoredon a continuous basis.

This would result not only in reduce energy consumptions but also in increased productquality. The various types of controls available nowadays for the furnace are as below:

Level indicator control:Inorder to measure the level of molten glass in the tank, platinum tipped probes are beingused. This probe moves up and down through the tank furnace and he accurately gives thelevel of glass in the furnace. The feedback from the element in certain cases is interlinkedwith the feed rate to the furnace. Thus maintaining the level of glass in the furnace. The probehas an accuracy of + 1 mm.

The other methods of measuring the level of glass include the Laser based Level Indicatorcontrol (LIC) and Pneumatic LICs using LP compressed air.

Temperature indicator Control:The required temperature of glass in the furnace should be about 1550oC. This needs to beprecisely controlled inorder to reduce radiation loss from the furnace. Any slight increase inthe temperature would result in huge loss as radiation from the furnace. Normally, a toleranceof about + 5oC is allowed in the glass furnace.

The latest controls for measuring the glass temperatures include the noble metal basedthermocouples. Typically, there would be two nos. of thermocouples, one at crown and oneat bottom. The values from the thermocouples need to be counterchecked with the readingfrom an optical pyrometer.

Flue gas analyser:The other most important parameter in a glass-melting furnace is the percentage of oxygenin the flue gas. The % O2 should be monitored on a continuous basis and a value of less than2% O2 should be maintained in the flue gas. Any increase in this value would result in hugelosses from the furnace as flue gas loss.

Online oxygen analyzers should be necessarily installed in the flue gas duct of the furnacesto measure the O2 %. The signal from the analyser can also be given as a feedback to controlthe oil pump as well as the blower supplying combustion air. The values from the online oxygenanalyser should be counter checked with the values from portable oxygen analyzers.


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The above measures should be followed on a continuous basis and an energy saving ofatleast 2% in the energy consumed by the furnace can be reduced, by these methods.

Case study - 7

Redesign the mesh belt in lehr and avoid heat loss

BackgroundThe mesh belt is made of steel wire or stainless steel. When it enters the furnace and isheated the energy consumed by the mesh belt will be twice the amount consumed by theproduct. Good potential to reduce the energy consumed in the lehr exists by redesigning andreducing the mass of the mesh belt, conveying the products.

Case study:A container glass industry with a production through the lehr of 630 kg/h enters at a temperatureof 400°C into the lehr. The soaking temperature in the lehr is 550°C. The total quantity of heatrequired to heat the product with a specific heat of 0.252 is 23814 kcal/h

A mesh belt of weight 20 kg/m and 1.5 m width carries the products at an rpm of 380 mm/min. The total heat required to heat up the belt is (with Cp = 0.132) 48304 kcal/h, which istwice the value of heat required to heat the glass product.

To save this heat, the belt wire length and diameter was minimized, and the weight wasreduced, by making the pitch loose.

However, care should be taken to check the reduced strength of belt after alterations.

Replace old reciprocating compressors with centrifugal compressors having lower specificenergy consumption.

Compressed air usage in a plant is one of the major electrical energy consumers. Typically,the process air demands in the plant requires compressed air at a pressure of about 3.5 –4.0 kg/cm2.

The compressed air demand of these process users are met by positive displacement (usuallyreciprocating) compressors. The specific energy consumption of these types of compressorsis about 0.12 kW/cfm.

The compressed air requirements with pressure requirements of the order of 4.0 kg/cm2 canbe met using centrifugal compressors. These types of compressors would have lower specificenergy consumption for the same deliver pressure. The typical specific energy consumptionfor pressures of about 3.5 kg/cm2 would from 0.09 to 0.10 kW/cfm. Therefore energy savingupto 20% can be easily achieved by the installation of a centrifugal type of compressor.

Case studyA 550tpd container glass manufacturing unit has a process air demand of about 10000 cfmof compressed air at a pressure of about 3.5 kg/cm2.



The plant had four nos. of reciprocating compressors of 2500 cfm capacity each to meet thecompressed air demands. The specific energy consumption by the compressors was0.125 kW/cfm.

The plant installed two nos. of 5000 cfm centrifugal compressors to meet this process demandby replacing the reciprocating compressors. The new specific energy consumption ofcompressed air is 0.10 kW/cfm.

An energy saving of about 20% was achieved by the installation of the centrifugal compressors.

Benefits:There was a reduction in power consumption in the compressed air system. Apart from thisthe cooling requirement of the compressed air system also came down by another 50%resulting in additional savings in energy consumption.

Annual savings (compressorsavings alone) - Rs 0.52 million


Payback period - 35 months


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Case study - 8

Replace pneumatic conveying with mechanical conveyingsystem in the soda-ash conveying system

BackgroundSoda ash is being added in to the furnace as one of the primary raw material. Soda ash isusually conveyed pneumatically to the furnace from the storage area.

Typically, for this purpose dry compressed air at a pressure of 4.0 bar is utilized for thepurpose. Pneumatic conveying system consumes nearly about 3 to 4 times more power thana mechanical conveying system. Also, the conveyed air needs to b separated from theconveyed material using a dust separation system, which also consumes additional power.

Good potential to reduce power consumption in this area exists by replacing pneumaticsystems with mechanical belt conveyor and bucket elevator systems.

Case studyIn a float glass plant of capacity 600 TPD, soda ash was conveyed to the furnace pneumaticallyusing compressed air at a pressure of 4.0 bar. There were two nos. of 1200cfm compressorsbeing operated for this purpose. The total power consumption by the compressors was about150 kW.

The total quantity of soda ash conveyed is about 150TPD.

The replacement of the pneumatic system was carried out and the energy consumption wasreduced by one-third of the energy consumption by the pneumatic conveying system.

BenefitsThe cost-economics of the proposed energy saving project will be as follows:



Payback - 19 months

Other projects

Oxy fuel firing systems to reduce fuel consumption in the furnace:This technique of oxy-fuel firing involves the replacement of the combustion air with oxygen.The elimination of the majority of the nitrogen from the combustion atmosphere reduces thevolume of the waste gases. Therefore, energy savings are possible because it is not necessaryto heat the atmospheric nitrogen to the temperature of the flames.


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Good potential to reduce oil consumption exists by reducing this remaining 3/4th portion ofcombustion air. Fuel consumption would reduce to 1/5th of initial consumption.

Moreover, the formation of thermal NOx is greatly reduced, because the only nitrogen presentin the combustion atmosphere is the residual nitrogen in the oxygen, nitrogen in the fuel etc

The principal deterrents to the increased use of oxygen enrichment of fossil fuel firing are thecost of oxygen and the possible effect of the higher flame temperatures on the furnace life,particularly on the silica crown roof.

Typically, the cost of supplying O2 when compared with the cost of reduced fuel firing wouldbe 10% costlier.

The project becomes more attractive when the O2 plant is set up nearby to the glass plant.The project can be contemplated by higher capacity plants or by cluster of smaller plants.Then the project becomes more attractive.

The project has been successfully implemented in countries like United States of America andthe other European countries. The major reason being the stringent environmental regulationsfollowed in those regions. The plants have also achieved substantial benefits by theimplementation of the project.

In India, however, Oxy-fuel works out to be quite costly and as is mentioned above, the projectcould be considered where totally new furnaces are being put up, wherein the cost ofregenerators can be eliminated.

The performance of refractories in oxy-fuel furnaces is still a gray area and considerabledevelopments have to be made for a foolproof solution.

Installation Of Sand Beneficiating Unit At Raw Material SiteBeneficiation is a process of washing the raw material with water inorder to eliminate unwantedmaterial. Typically in India, the iron oxide content in the raw material is about 0.1 to 0.2%. Theoptimum allowable limit in the raw material varies depending upon the quality of glass.

Iron oxide content in the raw material also turns out to be advantageous when it the batchrequires a certain composition of iron oxide.


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Many plants in India have set-up captive beneficiation unit in their factory site. This involvestransportation of unwanted material along with raw material to the factory and results in increasedtransportation costs.

There is a good potential to eliminate this cost by setting up beneficiation unit at the rawmaterial site. Thereby a saving of about 10% on the transportation cost can be achieved.

This project would not involve a separate investment by the plant, but should be taken carerom the inception of the plant.



Supplier Address

Preheaters :Zippe Industrieanlagen GmbH,Alfred-Zippe-Strasse,D – 97877 Wertheim, Germany,P.O Box 1665, D – 97866 Werthim,GermanyTel: + 49 9342 8040Fax: + 49 9342 804138Email: [email protected]

SORG (Melting furnaces, preheaters)Nikololaus Sorg GmbH & Co KGPO Box 152097805 Lohr am MainGermanyTel: 0 9352 / 5 07-0Fax: 0 93 52/5 07-196 / 507-204-507-234email : [email protected]

Indian representative for Zippe & SorgMascot Engg. CompanyWorld Trade CentreCuffe ParadeTel: + 91 22 2187165Fax: + 91 22 2187166Email: [email protected], regerators, recuperators, refractorymaterials

Vesavius VGT – DYKOWieesenstr, 6140549 Dusseldorf – GermanyTel: +49-211-502900Fax: +49-211-502659Email: [email protected]

Refractories:

Carborundum Universal Ltd – cross checkaddressTiam House Annexe,28 rajaji Road, Chennai600 001, IndiaTel: +91 44 2511652Fax +91 44 2510378

Glass Fabrication equipment manufacturerOilvotto10051 Avigliana (Torino) ItalyTel: +39 011 9343511Fax: +39 011 9343593Email: [email protected] Representative for OlivottoCV Chalam & Consultants

FullerIngenieurburoDipl-Ing(FH) Herman FullerSchulstrabe 39D – 94518 SpiegelauTel. +49 – 0 –8553518Fax +49 – 0 –8553514Email: [email protected]. f-gt.deInstrumentation & Control

Glass Service IncRokytrive,60,75501,VsetinCzech replublicEmail: [email protected] suppliersBOC Gases/India Oxygen ltdOxygen House, P43 Taratala road,Kolkatta700-088, IndiaTel +33 91 2478 4709Fax + 33 91 478 4974


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Ceramics

Per Capita Consumption 0.09 ceramic sq.m per annum

Sanitary : 16 – 17 Million pieces /annum

Growth percentage 11% per annum in last 3 years

Energy Intensity 20 – 25% of manufacturing cost

Energy Costs Rs.2350 million (US $ 47 million)

Energy saving potential 15% of the energy costRs.350 million (US $ 7 million)

Investment potential onenergy saving projects Rs.725 million (US $ 14.5 million)


162Energy Conservation in Ceramic Industry

1.0 IntroductionThe Ceramic industry is one of the age-old industries and has evolved over the centuries, fromthe potter’s wheel to a modern industry with sophisticated controls. This is one of the fastgrowing industries, with a projected growth rate of 8%. The average energy cost as apercentage of manufacturing cost is 20 to 25%.

2.0 Growth of Ceramic Industry2.1 Ceramic Tile Industry

There are at present 14 units in the organised sector with an installed capacity of 12 lakh MT.Some of the units have either closed or merged with the existing units. It accounts for about2.5% of world ceramic tile production. The ceramic tiles industry has grown by about 11%per annum during the last three years. Its demand is expected to increase with the growthin the housing sector. Indian tiles are competitive in the international market. These are beingexported to East and West Asian Countries.

2.2 Sanitary ware Industry

Sanitary ware are also manufactured both in large and small-scale sectors with variance intype, range, quality and standard. This industry has been growing by about 5% perannum during the last two years. There is significant export potential for sanitary ware.These are presently being exported to East and West Asia, Africa, Europe and Canada.Sanitary ware demand amounted to nearly 80m. pieces worth US$1.1bn in 2000. Indiarepresented 21% of the volume and only 10% of value.

The whole market is expected to grow by about 7-8% in the next five years, reachingnearly 110 m. pieces in 2005. The fastest growing countries will include Bangladesh, India,Vietnam, China and Sri Lanka.

2.3 Pottery ware Industry

Pottery ware signifying crockery and tableware are produced both in large scale and the smallscale sectors. There are 16 units in the organised sector with a total installed capacity of43,000 tonnes per annum.

3.0 Per Capita ConsumptionPer-capita ceramic tile consumption - 0.09 sq.m/annum

Per-capita sanitary ware consumption - 16-17 M pieces/annum

4.0 Energy IntensityThe ceramic industry is highly energy intensive. The energy consumed by the ceramicindustry is worth about US $ 47 million per year.

The main fuel used by the ceramic industry is LPG and natural gas. The other fuels used arefurnace oil, LSHS, LDO and HSD.

The energy cost as a percentage of manufacturing cost, is presently around 20-25%.


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The expenditure on energy ranks only next to the raw material in the manufacture of ceramic.With the ever-increasing fuel prices and power tariffs, energy conservation needs no specialemphasis.

5.0 Energy Saving potentialThe various energy conservation studies conducted by CII, indicate an energy savings potentialof 15%, equivalent to an annual savings of about US $ 7 million. The estimated investmentrequired to achieve the savings potential is US $ 14.5 million.

The ceramic industry is highly energy intensive and is one of the major energy consumerin the country. Energy costs account for nearly 20 to 25% of the manufacturing cost andhence, energy conservation is strongly pursued as one of the attractive options for improvingthe profitability in the Indian Ceramic Industry.

5.1 Target specific energy consumption figures

Kilns and dryers are the major energy consumers of ceramic industry. As this constitutesto 80-90% of the total thermal energy bill, the specific energy consumption of the kilns hasbeen highlighted.

A typical comparison of specific energy consumption of different types of kilns is as follows:

Type of Ceramic In Periodic Kilns (Kj/Kg) In Tunnel Kilns (Kj/Kg)

Fire bricks(fired at 1200-1400oC) 6000-8000 2500-3500

High alumina refractories(fired at 1400-1600oC) 12000 3500

Basic refractories(fired at 1600-1750oC) 12000-16000 6000-7000

Major factors that affect the energy consumption in all types of ceramic industry

The major factors that affect the energy consumption in the ceramic industry are as follows:

• Types of kilns and dryers

• Capacity utilisation of kilns and driers

• Combustion control systems

• Type of heat recovery system

• Type of insulation used at kilns and driers

• Types of presses

• Types of spray driers



6.0 Manufacturing process of ceramicsNaturally occurring inorganic substances are heat-treated after adjustment of the grain sizeand moisture, and some of them are completely molten to be formed into ceramics; whileothers are formed, heat-treated and made into the ceramic products in the sintered stateimmediately before being molten.

The former product formed in the molten state is known as glass, and the latter productfinished in the sintered state includes pottery, refractory, sanitary ware, tiles and cement.These ceramics are called traditional ceramics. By contrast, extremely fine particles of high-purity inorganic substances such as alumina (Al2O3), Silica (SiO2), Zirconia (ZrO2) and siliconNitride (Si3N4) are sintered at a high temperature and made into ceramics; they are calledadvanced ceramics. These advanced ceramics are used in electronic parts and mechanicalparts. The following describes the traditional ceramics production process:

6.1 Broad Classification of Ceramics

The Ceramic units can be classified based on the product, into three broad categories as:

• Electro Porcelain

• Tiles & Sanitary ware

• Refractory

Process Description

The process description in manufacturing of the above three categories of ceramic productsis as follows :

6.2 Electro Porcelain

The main raw materials used in this process are quartz, feldspar, china clay and ball clay. Inaddition, small quantities of fusible salts, such as calcium carbonate, barium carbonate, zincoxide, etc. are used to prepare the glaze melt.


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Jaw crushers and hardening mills are used, to pulverise the quartz and feldspar to 45 micronfineness. The clay, if hard, is ground in ball mills. The crushed raw material is then mixed withclay in blungers and a homogeneous slip is passed through screens and ferro filters toremove the impurities.

Filter presses are used to remove the water. The cakes are then sent through de-airing pugmills and the extruded mass is used to make solid core or moulded insulators, as per therequirements.

Hollow and solid core electro-porcelains are dried by electro-osmosis initially, and then inhumidity driers, after turning on lathes to the required shape. The formed wares are dried inbatch driers, using conventional heat sources.

The dried wares are glazed and then fired in the kilns to about 1250-1300oC. The insulatorsare fitted with metal caps and are tested for porosity and desired electro-mechanical qualities.The accepted ones are then sent for packing and despatch.

The process flow diagram of electro-porcelain is shown in the below:

6.3 Sanitary-ware and tiles

The main raw materials used in the process are quartz, feldspar, silica sand (as substitute forquartz) and clay. In addition, small quantities of homogenising materials are used to prepareglaze.

Quartz and feldspar are crushed in jaw crusher and then fed to a ball mill. The fineness ofthe material is reduced to, around 50 microns.

The crushed raw materials is then mixed with powdered clay in blungers. A magnetic drumand filter chamber are installed to remove impurities. The slip, that is formed, is kept agitatedin agitators to homogenise and then stored in silos.



For glazed preparation, the ball clays are ground in smaller ball mills along with water andother ingredients.

The slip is poured into the moulds by hand held hose. The cast wares are then dried in driers,from an initial moisture content of 15% to 0.5%.

The dried wares are glazed in several spray glazing booths, where compressed air is used.

The glazed wares are then fired in the kilns upto a temperature of 1200oC. The output fromthe kiln is inspected before packing and despatch.

The process flow of tiles industry is almost similar to sanitary ware except for the followingchanges :

After homogenisation, the material is dried in a spray drier. The dried material is pressed withpresses. The pressed product is passed through drier and fired in a kiln at 1150oC to 1300oCto get the final product.

The process flow diagram of sanitary-ware and tiles are shown below :

6.4 Refractories

Refractory manufacturing can be broadly divided into three sections namely:

• Raw material preparation section

• Brick making or press section

• Firing/drying


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In raw material preparation, crushing of raw material (from stores) to a desired size and mixingof raw material to the required composition is carried out. In brick making or press section,brick is made to the desired shape/weight in presses. The formed bricks are fired in kilns.

The process flow diagram of refractories is shown below :

7.0 Energy Saving schemesAn exhaustive list of all possible energy saving projects in the Ceramic industry is given below.The projects have been categorised under short-term, medium term and capital-intensiveprojects.

The projects which have very low or marginal investments and have an energy savingpotential of upto 5% has been categorised as short-term. The projects which requiresome capital -investment having a simple payback period of less than 24 months and havingan energy saving potential of upto 10% has been categorised as medium-term.

The short-term and medium-term projects are technically and commercially proven projectsand can be taken up for implemented very easily.

There are several projects, which have very high energy saving potential (typically 15% ormore), besides other incidental benefits. These projects have very high replication potentialand contribute significantly to improving the competitiveness of the Ceramic industry. However,some of these projects require very high capital-investment and hence has been categorisedseparately under case studies.



8.0 Energy Saving schemes8.1 House-Keeping Measures – Energy Savings Potential of 5%

A. Electrical

1. Install delta to star convertors for lightly loaded motors







8. Optimise TG/DG sets operating frequency

9. Optimise TG/ DG sets operating voltage

10. Improve operating power factor of diesel generator

11. Balance system voltage to avoid unbalance in motor load

B. Kiln

12. Install auto interlock between the brushing dust collection blowers and the glazing lines

13. Avoid air infiltration and operate the Vertical Shaft Kiln (VSK) exhaust fan with dampercontrol

14. Improve combustion efficiency of VSK by optimising excess air levels

C. Spray Drier

15. Arrest air infiltration in spray drier system

16. Replace LPG with Diesel firing in the spry drier

D. Vertical Drier

17. Switch off chiller circuit when hydraulic press is not in operation

18. Reduce idle operation of hydraulic press pump by installing suitable interlocks

E. Utilities

19. Optimise pressure setting of air compressors




23. Avoid/ minimise compressed air leakages by vigorous maintenance

24. Install level indictor controllers to maintain chest level

25. Install hour meters on all material handling equipment, such, pulpers, beaters etc.


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8.2 Medium Term Measures - Savings Potential upto 10%

A. Electrical

1. Install Automatic voltage stabilizer for lighting feeder

2. Replace copper ballast with high frequency electronic ballast in all fluorescent lamps.

3. Replace old motors with energy efficient motors

B. Kiln

4. Convert electrical heating to thermal heating system for LPG vaporizer

5. Install variable frequency drive for rapid air cooling fan

6. Segregate combustion and atomizing air fans in Kiln

7. Install variable frequency drive for hot air fan in kiln

8. Install variable frequency drive for smoke air fans

9. Improve insulation of vertical shaft kiln (VSK) to reduce radiation losses

10. Replacement with correct size combustion air blower in Kiln

11. Loading of acid bricks on top of refractory bricks on a continuous basis to maximize boxformation

C. Spray Drier

12. Install variable frequency drive for spray drier exhaust fan

13. Replacement with correct size combustion air blower in kiln

D. Vertical Drier

14. Install VFD for press b/f fan & optimize the pressure drop across bag filter

15. Install soft starter cum Energy saver for friction screw press

8.3 Case Studies- Savings Potential upto 15%

This chapter includes 9 actual case studies, which have been implemented successfully in theCeramic industry

Each of the individual case studies presented in this chapter includes.

• A brief description of the equipment / section, where the project is implemented.

• Description of the Energy Saving Project

• Benefits of the energy Saving Project

• Financial analysis of the project

A diagram of the system or photograph of the project is also included, wherever applicable.

The data collected from the plant is presented in its entirety. However the name of the plantis not revealed to protect the identity of the plant. Similar projects can be implemented byother units also to achieve the benefits.



A word of caution here. Each plant is unique in its own way and what is applicable in one plantmay not be entirely applicable in another identical unit. Hence these case studies could beused as a basis and fine-tuned according to the individual plant requirement before taking upfor implementation.


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Case Study 1

Insulation of the Top Portion of the Ring Chamber Kiln withInsulating Powder

BackgroundGenerally, the top portion of the ring chamber kilns lacks proper insulation due to the constructionintricacies. The normal trend is to have a low weight (Minimum layer of insulating bricks) onthe top portion of the ring chamber kiln.

As a result of this, the surface temperature on the top portion of the ring chamber kiln is high,leading to higher radiation losses. This case study highlights an example of minimising theradiation losses from the top portion of a ring chamber kiln.

Previous StatusIn one of the refractory brick industry, the measured kiln surface temperatureof a ring chamber kiln were as follows

Sides 50 to 60oC (Average)

Top portion 110 to 120oC (Average)

This indicates that the radiation heat losses from the top portion is high anda substantial scope to reduce the heat losses atleast to the level of that of

the sides.

Energy Saving ProjectThe top Portion of the ring chamber kiln was thoroughlycleaned and was filled with 75 to 100 mm thick layer ofinsulating powder. The application of the insulating powderdid not significantly add to the weight of structure.

Implementation Status and time frameFilling the top portion of the ring chamber kiln with insulating powder in stages of 25 mm thicklayers carried out during the implementation. The total implementation activity was completedin 4 months time. The plant team did not face any problem during and after implementation.

Benefits of the ProjectThe insulation of the top portion of the kiln drastically reduced the surface temperature from110oC to 50oC, resulting in a lower fuel consumption.



Financial AnalysisThe annual energy saving achieved was Rs. 0.40 million. The Investment made wasRs. 0.20 million, which has got paidback in 6 months.

Benefits of insulation of top portion of ring chamber kiln• Reduction in surface temperature from 110°C to 50°C

• Fuel savings





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Case Study 2

Provision of Insulation for the Furnace Shell Electric arc furnaceinsulated with alumina bricks on the inner side of the shell

BackgroundIn the ceramic fibre manufacturing industry, melting furnace is themajor consumer of electrical energy. The melting of ceramic rawmaterial is carried out in an electric arc furnace. The raw materialsin powder form are fed into the furnace where it gets fused by theelectric arcs. Later, the fused material is blown by compressed air toform ceramic fibres.

Heat Balance of Arc FurnanceThe arc furnace consists of a steel shell. The temperature of fusionvaries from 1200 to 1250oC. To avoid damage of the steel shell,water cooling panels are provided to keep the shell temperaturebelow the softening point. The usage of water panels is an importantsafety requirement, but unfortunately carries away enormous amountof heat energy from the arc furnace. This results in higher energyconsumption of the arc furnace in a typical ceramic fibre industry.

Previous StatusTo estimate the amount of heat losses, the arcfurnace heat balance was developed. The summaryof the heat balance of the furnace is as follows:

Item Power kw % of Total Power

Actual heating (for melting) 115 31Loss through water 160 43Core reactor / transformer combination 55 15Radiation loss and others 40 11Total 370 100

It is clear from the heat balance that the major heat loss is through cooling water. It was alsofound that, out of the 160 Kw heat loss through cooling water, 60 – 65 Kw was for coolingthe shell. The balance 100 kw heat losses was through cooling water used for coolingelectrodes, clamps, cables, etc.,


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Energy saving projectThe furnace was insulated by providing one layer of special insulated bricks (high Aluminabricks) on the inner side of the shell. This reduced the heat loss to shell cooling waterconsiderably, thereby reflecting in the overall reduction of energy consumption.

BenefitsThe major benefit of this project was the minimisation of heat loss from furnace shell. Thecooling water flow also reduced due to the minimised heat loss.

The specific energy consumption reduced from 4.1 Kw / Kg of ceramic fibre to 3.75 Kw/kgof ceramic fibre produced, after implementation. This has resulted in an overall savings of0.35 kw / Kg of ceramic fibre produced.

Financial AnalysisThe annual savings achieved was Rs. 1.08 million. This investment made wasRs. 0.14 million, which was paid back in 2 months.

Benefits of insulation on the inner side of steel shell

• Minimised heat loss

• Reduced specific energy consumption

• Reduced shell cooling water consumption





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Case Study 3

Installation of Additional Insulating Layers for the Ring ChamberKiln DoorsThe ring chamber kiln normally has a temporary constructed door for loading and unloadingof refractories. Conventionally the temporary door is constructed by sealing with a single layerof insulating bricks after completion of raw refractory loading.

In most of the cases, the single layer insulation is inadequate leading to higher heat lossesthrough the temporary door. This has led to the development of multi-layer insulating bricks

for minimising the heat losses through the temporary doors.

A typical door of a ring chamber kiln

Previous StatusThe ring chamber kiln had 12 doors, through which the raw bricks (tobe fired) were loaded inside the kiln. Once the raw bricks are fullyloaded, the doorway was closed by constructing a single layer ofinsulating brick and sealing with insulating powder. The surfacetemperature of the temporary door was measured to be 80 – 110oC,resulting in high radiation losses.

Energy Saving ProjectThe practise of constructing single layered insulating brick for thetemporary door was changed to a multi-layer (3 Layers) insulating

brick construction. An air gap was also maintained between the layers. The concept isschematically shown here.

Concept of the proposalThe provision of multi-layer insulating brick with air gaps, acts as an additional insulation forthe temporary door, resulting in minimisation of heat losses.

Benefits of the ProjectThe provision of additional layers of insulating bricks at the doorway reduced the heat loss fromthe door sides drastically. The outside surface temperature of the doors was around 50oC afterthe new construction.



Financial AnalysisThe annual energy saving achieved was Rs. 0.30 million. The investment made wasRs. 0.10 million which has got paidback in 4 months.

Benefits of multilayer of insulating brick for door way• Door surface temperature reduction from 100°C to 50°C

• Fuel savings





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Case Study 4

Optimisation of Kiln Loading

BackgroundCeramic products like tiles, sanitary ware, crockery,insulators, etc., are glazed in Kilns, which is amajor consumer of thermal energy. Theoptimisation of product loading in the kilns canresult in substantial energy savings.

The raw wares, after pressing / moulding is coatedwith ceramic material and then fed into the kiln forglazing. The raw wares are stacked in the kilncars and then pushed into the kiln. The stackingpattern plays a vital role in energy consumption ofthe kilns.

Conventionally, for ease of handling, the raw wares are stacked with huge spaces betweenthem. The space provided is also determined by the contour of the raw wares. The minimisationof space between the raw wares by proper planning can facilitate improved loading of the kiln,leading to energy savings.

Previous StatusThe energy consumption figures of a sanitary ware unit, having 50-60 standard products withfixed shapes/contour is as shown below:

Oil consumption Production Specific Energy Litres / month Tons / Month Consumption Litres / ton

Kiln 1 119360 378.48 315.36Kiln 2 34519 86.52 398.97

Energy Saving ProjectThe plant team developed a new supporting structure so as to load the kiln to the maximum.The gaps between the wares were minimised to increase the loading. In some cases two tier/ three tier system was adopted to maximise the loading.

Concept of the ProjectIn any kiln, there are fixed losses viz., radiation losses, kiln car heating etc., irrespective of theloading. When the load factor is very high, the fixed energy losses get distributed to a largervolume of production resulting in lower specific energy consumption.

Optimised load on kiln car

Kiln


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BenefitsThe benefits of this project were two fold:a. Increased production and lower specific energy consumption.b. Less inventory of raw wares and hence the moulds.

The operating parameters before and after modification are shown below :

Description Kiln 1 Kiln 2

Before After Before After

Oil consumption Litres / month 119360 121844 34519 32827

Production Tons / Month 378.48 401.27 86.52 100.07

Specific Oil Consumption Litres / ton 315.36 303.64 398.97 328.05

Reduction in Specific OilConsumption Litres/ton - 11.72 - 70.92

Financial AnalysisThe annual saving achieved by this project was Rs. 2.70 million. This had an investment ofRs.0.30 million for the support structure, which was paid back in 2 months.

Benefits of optimising load on kiln• Increase in production

• Lower specific energy consumptionCost benefit analysis• Annual Savings - Rs. 2.70 millions




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Case Study 5

Installation of Low Thermal Mass (LTM) Cars in Tunnel Kiln

BackgroundA typical LTM kiln car

In a ceramic industry, kiln is one of the majorconsumer of energy. Conventionally, the ceramictile and sanitary ware industry use the open flametunnel kiln, to fire the products. The open flametunnel kiln is a continuous type kiln, wherein, theraw product is fed on one side and on the otherside the finished product is taken out.

The raw product undergoes firing, drying & coolingcycles, as it moves over from the front end to theback end of the kiln. The material movementthrough the tunnel is by kiln cars, run on rails.

The kiln cars are like train bogies designed to hold the products. The Kiln cars are constructedwith refractory and insulating bricks. Due to their high thermal mass, Kiln cars consumeconsiderable amount of heat energy supplied to the kiln. Normally, the heat absorbed by kilncars is as high as 40 - 50% of the total heat energy supplied to the Kiln.

The thermal mass reduction of the kiln cars can give tremendous energy savings. Low thermalmass materials (LTM) are now being used for kiln car construction, which reduces the thermalmass considerably.

Previous StatusIn one of the ceramic sanitary ware industry, an open flame tunnel kiln was used for firingapplications. This kiln was using LPG as fuel with a direct firing mode. The operating parameterswere as follows:

Cycle No. of cars Throughput@ LPG Specific Gastime(hours) No./day 240 kg /car(kg/day) consumption Consumption

MT / day MT / Ton

13 102 24480 3.36 0.137

Energy Saving ProjectThe following modifications were made to reduce the weight of the kiln cars :

• Previously refractory bricks were used as supporting pillars for holding the racks. This wasreplaced with Hollow Ceramic Coated Pipes

• Introduction of ceramic fibre blankets at the base of the car instead of refractory brick base



• Use of cordierite (Hollow) blocks to hold the rawwares instead of solid refractory mass

The car furniture weight was reduced from 287 Kg/car to 220 Kg/car (23% weight reduction)

Concept of the ProjectThe use of low thermal mass materials (cordieriteetc.) in kiln cars resulted in thermal mass reduction,thereby resulting in fuel savings.

The other advantages of LTM materials are Fuelconservation, Increased capacity and longer servicelife. The incidental advantages due to LTM materials are less Thermal shock resistance, Easeof assembly and a good mechanical strength.

Implementation, problem faced and time frameThe implementation of this project was done in phases; so as to minimise the production loss.This was mainly due to limited availability of kiln cars. The plant team did not face any majorproblems during the implementation of this project.

The time taken for the implementation was one month.

BenefitsThe benefits were multifold, which are as follows :

• An increase in the production from 24.48 MT to 28.8 MT (17.6%)

• Reduction in the cycle time from 13 Hrs to 11 Hrs, resulting in increased no. of carshandled per day ( 102 to 120 cars per day)

• Fuel savings of 0.58 MT / day.

The summary of operating parameters before and after the modification is as follows

Description Before Conversion After Conversion

Cycle time (hours) 13 11

No. of cars No./day 102 120

Throughput (kg/day) 24480 28800

LPG consumption MT / day 3.36 3.36

Specific Gas Consumption MT / Ton 0.137 0.117

Throughput increase MT/Day - 4.32

LPG savings MT/Day - 0.58

Hollow Corderite holding structure with ceramic coated pipe supports

Hollow corderite Ceramic fiber

Hollow ceramic pipe


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Financial AnalysisThe Annual energy saving achieved was Rs. 13.14 million. This required an investment of Rs.12.5 million, which was paid back in 12 months.

Benefits of LTM cars• Increase in production

• Reduction cycle time

• Fuel savings





187

Case Study 6

Installation of Recuperators at the Cooling End of Kiln andUtilising the Hot Air Produced for Drying Raw Wares

BackgroundIn the ceramic industry, the raw materials aremixed through mixers, pressed and thenconverted to raw wares through moulds. Themoulded material has to be dried in batch driersbefore loading on to the kiln cars. Thetemperatures inside the dryers are maintainedat 55 to 60oC so as to evaporate the moisture inthe moulded material.

Conventionally ceramic plants use leco/coal asfuel, to generate hot air for drying. Some plantseven use electrical heating system or fuels likefurnace oil, LPG etc., for drying.

In modern plants recuperators are provided to recover the heat from the exhaust gases of theKiln. Thus the hot air generated by indirect heat exchange with Kiln exhaust air is used fordrying purposes. This resulted in the elimination of usage of fuel or electrical heaters in thedrying moulds.

Previous StatusIn one sanitary ware unit, leco was used as a fuel for generating hot air for the drying purposes.The leco consumption was around 1300 kgs per day.

Energy Saving ProjectA recuperator was installed at the exhaust of the kiln. The hot air generated by indirect heatexchange was fed to the driers. This resulted in elimination of leco fired hot air generator.

The schematic of the modification is highlighted in the figure.

BenefitsThe implementation of this project resulted in total stoppage of leco fired hot air generator,leading to a saving of 1300 kgs/day of leco.

Financial AnalysisThe annual saving achieved by this project was Rs. 1.52 million. The investment made wasRs. 3.00 million, which was paid back in 24 months.



Benefits of recuperators• Waste heat from kiln cooler utilised• Elimination of fuel for drying raw wares





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Case study 7

Utilisation Of Exhaust For Kilns Vertical Driers

BackgroundThe Raw material is poured into the mould through the hopper and then pressed in thehydraulic press. The Green tiles from the press are then fed through the vertical drier to furtherreduce the moisture content. The temperature required in the vertical drier is about 150oC.

The low moisture content tiles are then fed through the roller kiln for firing at a temperature ofabout 1200oC. Generally the exhaust gases from the kiln are at a temperature of 200-250oC.

Previous StatusIn one of the ceramic tiles industry, on a continuous basis about 3000 – 3500 kg/hr at atemperature of 240°C was getting vented from the kiln exhaust.

The vertical driers located close to the kiln needed hot air at a temperature of 150°C fordrying.

Energy Saving Project

240°C 3000 – 3500 kg/hr

HAG

��

Proposed Line

Kiln

E


191

There was a good potential to utilise this heat from the kiln exhaust and reduce the energyconsumption in the vertical drive. These sort of projects are being adopted in similar units.Thekiln exhaust line was connected to the suction line of the vertical drier.

The schematic of the modification is highlighted in the figure.

Financial AnalysisThe overall benefits that achieved by implementing this project was Rs.1.5 Million. Theinvestment required including instrumentation was Rs.5.0 Million, which got paid back in 2years.

Benefits of recuperators• Reduced 50% of the heat consumption in the vertical drier

• Waste heat from kiln utilized





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Case study 8

Install Variable Frequency Drive For Circulating Air Fans InVertical Drier

BackgroundThe circulating air fan is utilized to circulate hot air from the hot air generator to the verticaldrier. A fraction of air is vented out. Fresh air is added into the system by a fan as well asby air infiltration due to suction of circulating air fan.

The fresh air addition happens depending on the temperature inside the drier. If the temperaturegoes up, the fresh air addition increases. Moreover, the circulation air rate is constant thoughthe fuel-firing rate is varied depending on the temperature inside the drier.

Good potential to vary the circulation of fan depending on the temperature inside the drier.This ensures maintaining constant temperature in the drier and reduces the fresh air addition.

Previous statusTwo Vertical driers were used for different kilns in the plant. Constant temperature in the drierswas not maintained which resulted in additional fresh air consumption of around 8400Kg/h.

Hence there was a good potential to vary the circulation air quantity depending on thetemperature.

Energy Saving ProjectVariable Frequency Drive was installed in the circulating air fan in Vertical Driers. The speedof the fan was varied depending on the temperature inside the drier.

Financial AnalysisInstallation of Variable Frequency Drive for circulating air fans in Vertical Dreirs # resulted inan annual energy saving of Rs 0.695 Million. This required an investment of Rs 0.65 Millionand had a simple payback period of 12 months.

Benefitsa. Reduction in power consumption of the circulating air fan by at least 25%

b. Reduction in thermal energy consumption





195

VD – 1

VD – 2

HAG

HAG HAG



Case study 9

Replace conventional tunnel kiln with energy saving roller kilnfor sanitary ware firing

BackgroundIn a ceramic industry, kiln is one of the majorconsumer of energy. Conventionally, the ceramictile and sanitary ware industry use the open flametunnel kiln, to fire the products. The open flame tunnelkiln is a continuous type kiln, wherein, the rawproduct is fed on one side and on the other side thefinished product is taken out.

Previous StatusIn one of the ceramic sanitary ware industry, an open flame tunnel kiln was used for firingapplications.

Energy Saving ProjectThe conventional tunnel kiln was replaced by roller kiln for the production of sanitary stonewareproducts, made in a large variety of shapes and sizes. The products, which are placed on heatresistant ceramic plates, are transported on ceramic rollers through the roller kiln. Productsspend about 10 hours in this kiln compared with 25 hours in a tunnel kiln where products aretransported using wagons. The products are fired at a maximum temperature of 1250 °C.

Energy consumption details Tunnel Kiln Roller Kiln

Per Kg dry product 0.342 m3 0.131 m3

Per piece 4026 m3 1.64 m3

Per year 2,380,000 m3 914,000 m3

The PrincipleThe unfired sanitary stoneware products are placedon heat resistant ceramic plates (see Figure).These are then transported on rollers, first throughthe drying section and subsequently fired in thefiring section. The products pass through the kilnover ceramic rollers in about 10 hours. The speedof the drive for the rollers can be adjusted to theappropriate residence time. The roller kiln consistsof a firing section and a cooling section.

Schematic slice of the roller kiln


197

The products are fired at a maximum temperature of 1250°C. The burners and all the coolingair inlets and outlets can be adjusted individually. The advantage of the application of this typeof roller kiln for sanitary stoneware products is the quick firing process with the overall processtime reduced from 25 to 10 hours compared to a tunnel kiln. The new kiln also offers thepossibility of firing products which vary in shape, colour and size.

Financial AnalysisInstallation of roller kiln resulted in an annual energy saving of Rs 6.74 Million. This requiredan investment of Rs 14.37 Million and had a simple payback period of 26 months.

Benefitsa. Reduction in energy consumption by at least 62%

b. Reduction in process time of 15 hours





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Copper

Per Capita Consumption 400 gms


Energy Costs Rs.5000 million (US $ 100 Million)

Energy saving potential Rs 750 million (US $ 15 million)

Investment potential onenergy saving projects Rs.1500 million (US $ 30 Million)


200Energy Conservation in Copper Smelters

1.0 IntroductionCopper is the eighth most abundant metal in the Earth’s crust. It is mined in at least 63countries including India. Major producers of copper are Chile, the USA, Canada, Indonesia,Australia, Russian Federation, Peru, China, Poland, Mexico and Zambia.

Copper has the highest conductivity of all commercial metals. It is easily recyclable.

Copper is used for conducting heat and electricity, roofing, plumbing and piping, timberpreservation, coins and scientific instruments. Almost every electrical device has a coppercomponent.

The demand for copper is increasing and is used extensively in many areas such asautomobiles, construction industries, architectural applications, new generation super-conductorsand co-axial fibre optic cables.

1.1 Copper Production in IndiaThe present copper production in India is about 3.6 to 4.0 Lakh TPA. The percapita consumptionof copper is about 400 gms as against world average of 3 kgs and North America’s 15 kgs.

Due to the increase in use of copper in different fields, the consumption of copper in India isincreasing. The copper production has increased considerably after 1996. Many smelts unitsare planning to increase their capacity.

1.2 Major PlayersIn India copper ore is available in the states of Jharkand, Madhya Pradesh and Rajasthan.Hindustan Copper Limited (HCL) is the integrated producer of primary copper in India and wasestablished in 1967.

Hindustan Copper Limited (HCL) has copper mines at Khetri,Kolihan in Rajasthan, RakhaCopper Project in Jharkhand and Malanjkhand Copper Project in Madhya Pradesh. HCL hasbeen involved in exploration, mining, beneficiation, smelting and refining of copper.

Sterlite Copper, A unit of Sterlite Industries India Limited has set up a smelter plant in 1996 atTuticorin, Tamil Nadu. The smelter is having a capacity of 1,75,000 TPA. It also producessulphuric acid and phosphoric acid. The plant receives copper ore from Australia. It also hasa refinery unit at Silvassa.

Indo Gulf, through Birla Copper, has set up a copper Smelting and Refining complex at Dahejin Bharuch district of Gujarat in 1999. The plant produces Copper Cathodes, Continuous CastCopper Rods & Precious Metals. Apart from copper products, Sulphuric Acid, PhosphoricAcid, Di-Ammonium Phosphate, other Phosphatic Fertilizers and Phospho - Gypsum are alsoproduced at this plant. The plant has increased its smelter capacity from 1,00,000 TPA to1,80,000 TPA in the year 2000.


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Table 1.1: Production capacity and locationsS.No Plant Location Product Capacity

1 Hindustan Khetri Copper Copper cathode, 31000 TPA CopperCopper Limited Complex, Rajasthan Sulphuric Acid, cathode

Phosphoric acid

2 Indian Copper Copper Cathode, 16500 TPAComplex, Sulphuric Acid, Copper CathodeJharkhand Gold, Silver,

Palladium, Selenium,Tellurium, NickelSulphate, CopperSulphate

3 Malanjkhand Mine – Copper 20000 MTcopper Project concentrate concentrate /

Annum

4 Taloja Copper Continuous cast 60000 TPAProject, copper rodsMaharashtra

Hindustan Zinc Chanderiya Lead- Copper cathode 2100 TPALimited Zinc Smelter,

Rajasthan

5 Sterlite Copper Tuticorin, Copper Cathodes, 1,75,000 TPATamil Nadu sulphuric Acid

and Phosporic acid

6 Silvassa Refined Copper 1,00,000 TPA

7 Birla Copper Dahej, Copper Cathodes, 1,80,0000 TPADist Bharuch, Continuous CastGujarat Copper Rods,

Precious Metals,Sulphuric Acid,Phosphoric Acid,Di-AmmoniumPhosphate, otherPhosphaticFertilizers andPhospho – Gypsum

1.3 Energy Intensity of Copper smeltersCopper smelting is highly an energy intensive process. It requires both electrical and thermalenergy. The energy component of manufacturing is about 45% to 55%.



The major electrical energy consumers in a copper smelter are compressors, Fans & blowers,pumps and heater loads. The average electrical load requirement for a 2.0 million tons perannum plant is about 24 MW.

The copper smelters also utilize thermal energy through the fuels such as Furnace Oil, Diesel,LPG and coal.

The specific electrical energy consumption varies from 1190 to 1250 units/ton of copper. Thespecific thermal energy consumption is 1.1 to 2.0 Gcal/ton of copper depending on the typeof plant. The overall specific energy consumption varies from 2.1 to 2.8 Gcal/ton of copper.

As copper is produced from sulphite and concentrate ores, a large amount of Sulphur di-oxideis generated as a by-product. Due to this, copper smelter complexes have other plants likesulphuric acid, phosphoric acid and fertilizer plants. The total energy consumption of coppercomplexes in India is about Rs.5000 million (US$ 100 million)

1.4 Energy Saving Potential and InvestmentThe various energy conservation studies conducted by CII – Energy Management Cell andfeedback received from various industries through questionnaire survey indicate an energysaving potential of 15%. (Excluding waste heat recovery potential)

This is equivalent to an energy saving potential of about Rs.750 million. The estimatedinvestment required to realize this savings potential is Rs.1500 million.

The copper smelters in India have power generation potential of about 30 MW through wasteheat recovery. The investment opportunity in this alone is Rs.750 million.

2.0 Process Description - Smelting and ConvertingCopper is manufactured through the process of smelting and converting the sulphide ores ofcopper. All the Indian manufacturers except Hindustan copper import copper concentrate fromother countries. Hindustan Copper Limited has captive copper mines in the states of MadhyaPradesh, Rajasthan and Jharkhand.

The Pyrometallurgical processing of the copper concentrate includes the processes of smelting,converting, and fire refining.

The block diagram of the copper manufacturing is as below:

Energy

Oxygen

Copper Concentrate

Flux Copper Anodes

Sulphuric Acid

SO2

Sulphuric Acid

Rock Phosphate

Pure Copper

Phosphoric Acid

Copper Smelter

Sulphuric Acid Plant

Phosphoric Acid Plant

Refinery


203

SmeltingSmelting consists of melting the sulfide concentrate in an oxidizing atmosphere, which producesa copper rich (35-70% Cu) molten sulfide phase called matte. The other products in thesmelting process are a low copper silicate slag, and flue gas with sulphur di oxide (SO2).

The capture of SO2 is environmentally important and economically significant due to theproduction of Sulphuric acid (H2SO4.). Smelting is carried out either in a reverberatory or flashfurnace. Flash furnaces are replacing older reverberatories and account for approximately 75%of the world’s current smelting capacity.

The slag and matte products are separated in a rotary holding furnace and the slag granulatedinto a pit with removal of the slag to a storage bin being carried out by a mechanical grab.Matte is transferred to the converters by ladle.

ConvertingConverting is a two step process in which matte is made into “blister” copper. The first stageof converting is the removal of iron in a slag and the generation of flue gas containing SO2.The second stage involves the further oxidation of the remaining copper sulfide to liquid or“blister” copper. Converting has traditionally been performed batch style. Recent developmentshave led to continuous converting, but these technologies are not widely used.

The final pyrometallurgical step is fire refining. Fire refining consists of an oxidation stepfollowed by reduction. The “blister” copper is oxidized to lower the sulfur content of the copperto approximately 0.001%. Following oxidation, oxygen is removed by the introduction of areducing agent such as natural gas or ammonia. The final oxygen content is typically between1500 and 3500 ppm.

Anode FurnaceThe removal of sulfur and oxygen is imperative to ensure a flat, thin casting needed for the lastprocess in the production of pure copper, electrorefining. Most industrial casting involves theuse of an anode casting wheel. The molten copper from fire refining is poured into a tiltabletundish where the amount of copper is weighed to ensure proper anode weights.

After achieving the desired weight, the copper is poured into an anode shaped mold on thecasting wheel. There are twenty to thirty such molds on the wheel. The wheel is then rotatedand copper is poured into the next mold. As the process continues, the copper anode is cooledwithin the mold due to water cooling of the wheel and water spray on top. After about a one-half rotation, the anodes are removed from the mold.

Some smelters use a continuous caster instead of a casting wheel. The continuous casteruses two water cooled steel belts (one on top, the other on the bottom) and stationary edgedams to contain the molten copper. As the belts rotate, the copper is moved through the casterand cooling occurs. When the copper leaves the caster, it is a solid continuous strip with thecorrect anode thickness. Anodes are made from the strip by shearing. The copper anodes arethen sent to copper refinery for refining to cathode copper (99.999% copper).

Sulphur dioxide

Sulphur dioxide (SO2) is emitted from the copper smelters as a by-product of the smeltingprocess. This is converted to sulphuric acid, which is either sold or sent to fertilizer plant forthe production of fertilizer.



Phosphoric Acid

The sulphur dioxide emitted as by-product from the smelting process and sulphuric acid fromsulphuric acid plant is reacted with rock phosphate and phosphoric acid is produced.

3.0 Energy Saving Schemes

3.1 List of Energy Saving Projects

3.1.1 Concentrate Handling & Smelters

Short Term

1. Reduction of Idle Running Hrs.of Feed Conveyors by Automation

2. Replacing exisiting pump with correct size pump for Rotary Holding Furnace - HygineVenturi Scrubber fan

3. Installation of correct size pump for Slag Granulation pump / cooling tower pump

4. Reduce false air entry into the gas duct and reduce fan power consumption

5. Utilise the heat of smelter furnace exhaust gases to preheat the blower air

6. Install waste heat recovery system for Anode Furnace exhaust and utilise to preheatcombustion air

Medium Term

1. Installation of Variable Speed Drive for smelting furnace Induced Draught Fan

2. Installation of Variable Fluid Coupling For Converter plant ID Fan

3. Installation of Auto Inlet Guide Vane (IGV) operation for Converter Blower.

4. Installation of Variable Frequency Drive for lime recirculation at scrubber exhaust systemof Anode furnace

5. Replacing old fan with an energy efficient fan for direct exhaust fan at Anode furnace

6. Replace existing main firing burner with high efficiency burners in the Anode Furnaces

7. Avoid radiation losses through feed door by covering the openings in the Anode Furnaces

Long Term

1. Installation of Variable Fluid Coupling for Rotary Holding Furnace - Hygiene Venturi Scrubberfan

2. Installation of Double charge casting system to decrease preheating time

3. Install a waste heat recovery system and generate steam and power from Smelter exhaustgas

4. Install vapour absorption machine (VAM) refrigeration system in Sulphuric Acid Plant byutilising the heat of smelter furnace exhaust gases


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3.1.2 Sulphuric Acid PlantShort Term

1. Effective Utilisation of Acid Coolers in Sulphuric Acid Plant to Reduce Cooling towerPumps Load

2. Replacing existing pump with correct size pump in Sulphuric Acid Plant Cooling waterpump and matching with the requirement

Long term

1. Installation of variable fluid coupling for SO2 blower at Sulphuric Acid Plant

3.1.3 Phosphoric Acid PlantShort Term

1. Optimising the size of Cold Well Pumps in Phosphoric Acid Plant

2. Improvement Of Boiler Efficiency in Phosphoric Acid Plant

Medium Term

1. Installation of Variable Speed Drive for Gypsum Slurry Pump in Phosphoric Acid Plant

2. Installation of Variable Speed Drive for return Acid Pumps, HH Cloth Wash Pump anddilute cake wash pump in Phosphoric Acid Plant

3.1.4 Utility AreasShort Term

1. Reduction in Oxygen plant venting and saving energy

2. Installation of Temperature Indicator Controllers for Cooling Tower Fans in ISA,SAP,PAP

3. Reduction of compressed air usage in the plant

4. Replacing existing lime plant and spray pond make up pump with smaller size pump andavoid the final effluent transfer pump

5. Installation of guide vane control system to control the blower capacity

6. Installation of correct head pump for raw water pumping, soft water pumping system

7. Segregating cooling water requirements of compressors & smelter plant

8. Utilisation Of Vent Compressed Air In Oxygen Plant

Medium Term

1. Replace old inefficient compressors with energy efficient compressors

2. Installation of variable frequency drives for screw compressor

3. Installation of Variable speed drives for cooling tower fans

4. Conversion of V-belt drives to flat belt drives in compressors and blowers



Long term

1. Replacing electrical heating with steam heating for FO heaters and LPG vaporizer –Reduction of energy cost

2. Utilisation of waste heat from captive power plant and avoiding operation of phosphoricacid plant boiler

3.1.5 Electrical SystemsShort Term

1. Replacing copper chokes with Energy Efficient Electronic chokes in fluorescent lamps

2. Installation of energy efficient lamps in place of low efficacy lamps

3. Convert delta to star connection in lightly loaded motors

4. Installation of automatic voltage stabilizer for the main lighting feeder and operating at 210volts

Medium Term

1. Installation of automatic power factor controllers and maintaing high PF

2. Installation of separate lighting transformers and optimising the lighting voltage

3. Replace old rewound motors with energy efficient motors

4. Installation of Soft Starter cum Energy saver for lightly loaded motors

Long Term

1. Installation of on-load tap changer (OLTC) for the main transformer and optimising thevoltage

2. Installation of harmonic filtes and reducing Total Hormonics Distortion


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Case study – 1

Install waste heat recovery system for ISA furnace exhaustgases to generate steam & Power

BackgroundPyrometallurgical processing of the concentrate consists of smelting, converting, and firerefining.

Smelting consists of melting the sulfide concentrate in an oxidizing atmosphere, which producesa copper rich (35-70% Cu) molten sulfide phase called matte. The other products in thesmelting process are a low copper silicate slag, and flue gas with sulphur di oxide (SO2).

The flue gases generated in the smelting process is at a very high temperature of about1200°C. The major portion in the flue gas is sulphur di oxide.

There is a tremendous potential to tap this waste heat. In view of the dust concentration,cohesive nature of dust and presence of SO2 in the exhaust gas, suitable dust collectionsystem to be installed.

Present StatusAt a concentrate feed of 50 TPH, about 2,40,000 m³/hr of flue gas is leaving the ISA furnaceat around 1200°C.

Energy Saving ProjectThere are different options available to utilize the waste heat from the copper smelters. Differentenergy saving opportunities are tried in other countries and are working well. Similar potentialis available in Indian copper smelters also.

Alternative-1

Installation of a Mechanical Dust Collector (MDC) followed by a Waste Heat Recovery Boiler(WHRB) to generate 15 TPH of steam at 11 Ata. This steam can also be used to meet thesteam requirements of the Phosphoric Acid Plant (PAP).

Alternative – II

Installation of a Mechanical Dust Collector (MDC) followed by a Waste Heat Recovery Boiler(WHRB) to generate 15 TPH of steam at 42 Ata. This steam can be use in an extraction-cum-back pressure turbine. About 2 TPH shall be extracted at 11 ksc and balance 13 TPH will goto the back-pressure mode at 2 ksc. This back-pressure steam can be utilised for processsteam requirements.

Alternative - III

Install a Mechanical Dust Collector (MDC) followed by a Waste Heat Recovery Boiler (WHRB)to generate 15 TPH of steam at 42 Ata. This steam can be made to pass through a condensingturbine to generate 6.5 MW of power. This is about 20% of total power requirement of the plant.



Implementation MethodologyThe proposed ISA furnace exhaust gas heat recovery shall be a separate stream, parallel tothe existing stream.

Whenever, the proposed stream gets choked with dust and requires shutdown for cleaning,this stream can be by-passed. The existing stream can then be brought on-line and theproduction can be continued, without a shutdown.

BenefitsAlternative - I

The estimated annual savings that can be achieved by implementing this alternative isRs.47.80 million. The investment required (estimated) will be around Rs.24.00 million, whichwill get paid back in 6 months.

Alternative - IIThe estimated annual savings that can be achieved by implementing this alternative isRs.90.00 million. The investment required (estimated) will be around Rs.60.00 million, whichwill get paid back in 8 months.

Alternative - IIIThe estimated annual savings that can be achieved by implementing this alternative is Rs.122.00million. The investment required (estimated) will be around Rs.130.00 million, which will getpaid back in 13 months.

Note:This project though straightforward and simple has not been implemented in any of the plantsin India. It is a proven project in other industrial sectors and in other countries.

Replication PotentialOverall waste heat recovery potential for generating power from copper smelters in India isabout 30 MW. The investment potential is around Rs. 750 million.





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Case study – 2

Install Vapour Absorption Machine (VAM) for refrigerationsystem in Sulphuric Acid Plant (SAP) by utilising the heatof ISA furnace exhaust gasesBackgroundChilled water system, having a heat load of about 400 TR is used in Sulphuric Acid Plant ina copper smelter complex. Vapour compression system is used for generating the chilledwater. The specific energy consumption is about 0.70 kW/TR. The temperature requirementof chilled water is 12°C.

In copper smelters waste heat available is very high. The generation of chilled water throughvapour absorption machine (VAM) is more economical, more so, when steam is generatedthrough waste heat. In copper smelters, the furnaces let out very high amount of heat throughflue gas. By utilizing this waste heat, the chilled water requirement of the plant can be met byusing vapour absorption machines.

Previous Status

Vapour compression system of about 400 TR was used in sulphuric acid plant. Waste heatat 1100°C was let out from the furnace.

Energy Saving ProjectInstallation of Vapour Absorption Machine (VAM) for refrigeration system in Sulphuric Acid Plant(SAP) by utilising the waste heat of smelter furnace exhaust gases

Implementation MethodologyThis project is not implemented in any of the copper smelters. But it is very easy to implementand implemented in many chemical plants. Recommended to install a vapour absorptionmachine of 400 TR using the aste heat from the smelter furnace exhaust gases.

The smelter furnace exhaust gases can be used to generate steam in a waste heat recoveryboiler (WHRB), which will supply steam of about 2.5 TPH to VAM. Before the flue gases enterthe air preheater, the temperature of the flue gases has to be reduced, by passing through adedicated small gas cooler. The gases are then passed through a mechanical dust collector(MDC), so as to reduce the dust concentration.

The proposed system, is a separate exhaust gas dust, parallel to the existing duct. The gasespassing through this new duct will be used for the preheating of blower air. Whenever thereis a choking of the new duct, this is used as by-pass andthe gases are passed through the existing duct.

Benefits

The annual savings potential is about Rs.6.00 million. Thetotal investment required is Rs.11.10 million, which willpay back in 23 months.





211



Case study – 3

Installation of Variable Fluid Coupling for SO2 blower atSulphuric Acid Plant

BackgroundSmelting consists of melting the sulfide concentrate in an oxidizing atmosphere, which producesa copper rich (35-70% Cu) molten sulfide phase called matte, a low copper silicate slag andflue gas with sulphur di oxide (SO2).

The sulphur di oxide in the flue gas is sent to sulphuric acid plant for the production of sulphuricacid. A high capacity fan handles the sulphur di oxide from smelter plant.

The capacity utilisation of the SO2 blower varies depending on convertor operation in thesmelter. The load on the blower is higher when ISA furnace and the convertor are in operation.When ISA furnace alone is running, the capacity utilisation is less.

The capacity of the blower was controlled by motorized valve. Operation of a blower with valvecontrol is energy inefficient practise. An energy efficient way of controlling the capacity of ablower is by varying the RPM of the blower.

Previous StatusThe capacity of the blower was adjusted by inlet guide vane control of the blower. The pressuredrop across the suction damper was:

• When ISA & convertor in operation = 21%

• When ISA furnace alone in operation = 44%The power consumption of the blower during high flow was 2300 kW.

-151MM -770MM -969MM

Mixer

Quencher

Vent.. Humidif.

ESP

Mixer

-156MM

-10 to –20 MM

2300 kW

2728 MM


213

Energy Saving ProjectThe plant team installed a variable fluid coupling for the SO2 blower and avoided the operationof inlet guide vane

Implementation MethodologyAfter installation of the variable fluid coupling, the speed of the fan was controlled manuallybased on the ISA plant and converter plant operation. The implementation was done in aphased manner and the closed loop operation of the VFC was put into effect in a months time.

BenefitsThe annual saving achieved was Rs. 7.30 million. Theplant team invested Rs. 5.00 million for the variable fluidcoupling and controls, which paid back in 9 months.

Replication PotentialThis project has a replication potential in four more plants.





215

Case study – 4

Installation of Variable Frequency Drive for ISA furnace ID fan

BackgroundIn a copper smelter, a 132 kW ID fan handles ISA furnace exhaust gases. The capacityrequirement of the fan varies depending on the draft level and gas quantities. Damper controlwas practiced in ID fan of the furnace to meet the capacity variation.

Operation of a fan with valve control is an energy inefficient practice. An energy efficient wayof controlling the capacity of a blower is by varying the RPM of the blower.

Previous StatusThe ID fan of the smelter furnace wasconsuming 63 kW of power. The pressuredrop across damper of the fan was 46%.The higher pressure drop was due to theexcess capacity available in the fan.Also, the fan flow and the drought wasvarying with the process conditions.

Energy Saving ProjectA 132 kW variable frequency drive wasinstalled for the smelter furnace ID fan. The speed of the fan was reduced based on the actualrequirement. The loss across the damper was eliminated.

Implementation MethodologyAfter the installation of VFD, the damper of the fan was kept open at 100%. The VFD reducesthe speed of the fan based on the drought. The control signal for the VFD is from the pressuretransducer and operates in closed loop.

BenefitsThe annual savings achieved was Rs.1.42 million. The investment for the VFD and controlswas Rs. 0.87 million, which paid back in 8 months.





217

Case study – 5

Install Variable Fluid Coupling for Rotary Holding Furnace (RHF)- HVS FAN

BackgroundIn a copper smelter, RHF – HVS fan is used for handling the exhaust gases. The capacityrequirement of the fan varies depending on the draft level and gas quantities. Damper controlwas practiced in ID fan of the furnace to meet the capacity variation.

Operation of a fan with valve control is energy inefficient practise. An energy efficient way ofcontrolling the capacity of a blower is by varying the RPM of the blower.

Previous StatusThe RHF – HVS fan was consuming 250 kW of power. The pressure drop across damper ofthe fan was 35%. The higher pressure drop was due to the excess capacity available in thefan. Also, the fan flow and the drought was varying with the process conditions.

An energy efficient way of capacity variation of a fan is to install a variable speed arrangementsuch as variable fluid coupling and adjust the RPM of the fan depending on the requirement.

Energy Saving ProjectA variable fluid coupling was installed for the RHF – HVS fan. The speed of the fan wasreduced based on the actual requirement. The loss across the damper was eliminated.

Implementation Methodology & DifficultiesAfter the installation of VFC, the damper of the fan was kept open at 100%. The VFC reducesthe speed of the fan based on the drought. The control signal for the VFC is from the pressuretransducer and operates in closed loop.

For implementation of this project, the motor and fan base has to be modified and VFC isinstalled in between fan and motor. This project was implemented during the stoppage of theplant. The time required for implementation is about 15 days.

BenefitsThe annual saving achieved was Rs. 1.32 million. The investment for the variable fluidcoupling was Rs. 1.00 million, which paid back in 10 months.

Replication PotentialThis project has a replication potential in four moreplants.





219

Case Study-6Replacing Electrical Heating with Steam Heating for F.O Heatersand LPG VaporiserBackgroundIn copper smelters, Furnace Oil (FO) and LPG are used as fuel in ISA furnace, rotary holdingfurnace and converters. Electrical heaters are used at various locations of the plant for heatingthe furnace oil at different sections of the plant and also vaporising the LPG. The plant alsohas a furnace oil fired boiler at phosphoric acid plant.

The variable cost of electrical power is Rs.3.50/unit and the landed cost of furnace oil isRs.10.50/litre. The cost comparison of electrical heating and steam heating was analysed.

The cost of electrical heating is Rs.4000/MM kCal and the cost of thermal heating is onlyRs.1500/MM kCal.

This indicates that electrical heating is atleast 2.5 times costlier than oil fired heating for thesame quantity of heat output. The cost of heating operation can be reduced, by replacingelectric heating with the cheaper steam heating.

Previous StatusIn one of the copper smelters, electrical heating was used for heating furnace oil and vaporisingLPG.

The capacity of heaters at various locations and the average consumption is as below:

Sl no. Location of heater Capacity of Average Averageheaters operating Load

(in Nos. x kW) time(in %) (in kW)

1 FO Main storage tank 3 x 24 40 29

2 LPG Vaporiser 3 x 36 50 54

3 Anode furnace day tank 2 x 54 20 11

4 Line heaters 2 x 54 35 28

Total capacity 396 122

The average load of electrical heaters was around 122 kW on a continuous basis.

Energy Saving ProjectReplacing electrical heating with steam coil heating for F.O heaters and LPG vaporizer.

Implementation statusThe plant team replaced all the electrical heaters with steam coil heaters for all the FurnaceOil heating and LPG vapouriser in a phased manner.

BenefitsThe implementation of this project resulted an annual savings of Rs. 2.00 million. The investmentmade was around Rs.1.00 million. The simple payback period was 13 months.


221

Case Study –7

Installation of Variable Fluid Coupling for converter blower

BackgroundConverting in a smelter is a two step process in which matte is made into “blister” copper. Thefirst stage of converting is the removal of iron in a slag and the generation of flue gas containingSO2. The second stage involves the further oxidation of the remaining copper sulfide to liquidor “blister” copper.

The converter blower supplies air to the converter. In one of the copper smelters, converterblower was operated for 11 to 12 hrs/day. Out of which for 5 to 6 hrs/day air was vented out.Generating the air and venting out is energy inefficient practice.

The venting of air from the converter blower was mainly due to the excess capacity of theblower.

Previous StatusIn a 1.0 million tons per annum copper smelter, converter blower was operated with ventingof air. Generating the air and venting out is energy inefficient practice.

Energy Saving ProjectThe plant has installed a Variable fluid coupling for the converter blower, which was consumingan average power of 1200 kW. The energy loss due to venting of air was completely avoided.

Implementation Status & DifficultiesAfter the installation of the VFC, the converter blower speed is reduced based on the actualrequirement. Closed loop system is used for varying the speed of the blower.

For implementation of this project, the motor and fan base has to be modified and VFC isinstalled in between fan and motor. This project was implemented during the stoppage of theplant. The time required for implementation is about 15 days.

BenefitsThe annual savings achieved was Rs. 1.20 million. The investment made wasRs. 0.8 million which will paid back in 10 months.





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The annual savings in furnace oil was Rs. 3.60 million. This required an investment (for their pre-heater) of Rs. 1.00 million, which paid back in 3 months.

Case study 8

Utilise heat of smelter furnace exhaust gases to preheat thecombustion blower air and reduce oil consumption

BackgroundIn a 1.75 MTPA capacity copper smelter, smelter furnace is used for smelting the concentrate.Furnace oil is used in the furnace. Combustion air is supplied by FD fan, which sucks air fromthe atmosphere. The exhaust gas from the furnace was let out at a very high temperature ofabout 1100°C. By preheating the combustion air, using the exhaust gas, the furnace oilconsumption was reduced. Air preheaters are used for recovering the heat from flue gas.

Previous Statusthere is a choking of the new duct, this can be by-passed and the gases can be passedthrough the existing duct.

Energy saving ProjectUtilise heat of smelter furnace exhaust gas to preheat the combustion blower air and reduceoil consumption.

Implementation methodologyThe plant team installed a air preheater and the combustion air was pre heated upto 200 °C.Before the flue gases enter the air preheater, the temperature of the flue gases was reduced,by passing through a dedicated small gas cooler. The gases were then passed through amechanical dust collector (MDC), so as to reduce the dust concentration. The implementedsystem has a separate exhaust gas dust, parallel to the existing duct. The gases passingthrough this new duct will be used for the preheating of blower air. Whenever there is a chokingof the new duct, this can be by-passed and the gases can be passed through the existing duct.

Benefits





225

Case Study – 9Install waste heat recovery system for anode furnace exhaustand utilise to preheat combustion air

BackgroundIn the anode furnace, refining of Blister Copper (98.5% Cu) to Anode Copper (99.9% Cu)takes place. This conversion has two phases – an oxidation phase (about 45 – 60 min)followed by a reduction phase (about 180 – 200 min). The heat required for the refiningprocess is provided by the firing of FO and LPG.

The flue gases coming out of the furnace combustion chamber at an average temperature ofabout 450°C. The air required for combustion was sent through a blower at 40°C.

There was a good potential to utilise the waste heat of flue gases to preheat the combustionair and save energy.

Previous StatusCombustion air at 40°C was used at Anode furnace. The exhaust gas temperature from theanode furnace was about 450°C.

Energy Saving ProjectPreheating combustion air from the exhaust gas and reduce oil consumption.

Implementation MethodologyThe plant has installed a waste heat recovery systems (air-to-air H.E) for the anode furnaceand the combustion air was preheated to 200°C. This has resulted in fuel savings.

BenefitsThe annual savings achieved was Rs. 1.08 million. The investment made by the plant wasRs.0.50 million and got paid back in 6 months.





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4.0 List of Suppliers/ ContractorsName of Company and Address Area of expertise

MIM Holdings Limited ISA Technology, Copper smelter(A . B . N . 009814019) Level 1.3, technology supplierMIM Plaza410, ANN StreetBrisbane,Australia

Outokumpu Harjavalta Metals Outokumpu Engg Contractor OyOyHarjavalta (Flash smelting process)Teollisuuskatu, 1Harjavalta, FIN-29200Finlandhttp://www.outokumpu.comJukka Järvinen Pentti Ahola+358 2 535 8111+358 2 535 8207

Chematics International Co. Limited Sulphuric Acid PlantFromson Equipment Division77, Railside RoadDon mills street, Ontario, CanadaPostal Code M3A 1B2Ph:001 416 447 5541Fax.:001 416 447 5541

M/s Hydro Agri, Rotterdam Phosphoric Acid PlantMassluisedijk,103,3133, Ka VLQQRDINGHENNetherlandPostal code:3133 KATel:31-10-248-2279Fax:31-10-248-2221

Hindustan Dorr-Oliver Limited Consultant for phosphoric acid plantDorr-Oliver HouseChakala, Andheri EastMumbai – 400 099Tel.: 022 – 2832 5541, 2832 6416/ 17/18Fax: 022 – 2836 5659Email: [email protected] : www.hind-dorroliver.com

Kvaerner Powergas Limited (Mumbai) Basic and detailed engineering, projectPowergas House 177 Vidyanagari Marg management, procurement, inspection/Kalina, Mumbai 400 098 expediting, construction supervision forTelephone: +91 (0) 22 691 5901 petrochemicals, chemicals, synthetic fibres,Telefax: +91 (0) 22 691 5934 ferrous and non ferrous metals,E-Mail: http://www.kvaerner.com industries.



Name of Company and Address Area of expertise

ME Engineering Limited Waste Heat Recovery systemsSai Chambers for copper smelters15 Mumbai Pune Road,Wakadewadi,Pune 411 003,IndiaTel: 00-91-20-5511010Fax: 00-91-20-5511234www.me-engineering.co.uk

Thermax House, Waste Heat Boilers, Vapour4, Mumbai Pune Road,Shivajinagar, Absorption MachinesPune 411 005Tel : (020) 5512122Fax : (020) 5511226Email : [email protected]

Thermal Systems (Hyd) Pvt. Ltd. Waste Heat Recovery Steam GeneratingPlot No.1, Apuroopa TownshipI Systems for S.A. Plants, Nitric Acid,DA, Jeedimetla Ammonia, Hydrogen plants andHyderabad - 500 055 metallurgical plantsTel: 040 - 309 8272/ 8273Fax: 040 - 309 7433

L & T, Baroda Power plant and waste heat recovery

Bharat Heavy Electricals Limited Supplier power plant equipmentsBHEL Building, Siri Fort RoadNew Delhi – 110 049Tel: 011 – 26493031Fax: 011 – 26493021

Voith Supplier of Variable Fluid Coupling

Greaves Supplier of Variable Fluid Coupling

Air Products, USAINOX Air Products ltd. Supplier of industrial gases56, Jolly Maker ChambersNo.2, Nariman Point, Mumbai - 400 021Telephone: +91 (0)22 2020345 / 6314 / 7374Fax: +91 (0)22 2025588

Praxair India Limited Supplier of industrial gasesPraxair House No. 8, Ulsoor RoadBangalore 560042IndiaTel.: +91.80.555.9841Fax: +91.80.559.5925

Air Liquide Engineering India (PVT) Ltd. Oxygen Plant3-5-874, plot no.15, hyder gudaHyderabad


229

Paper

Per Capita Consumption 5 kg


Energy Intensity Rs 1500 million (US $ 300 million)

Energy Costs 25% of manufacturing cost

Energy saving potential Rs.300 Million (US $ 6 Million)

Investment potential on energysaving projects Rs.500 Million (US $ 10 Million)


230Energy Conservation in Pulp and Paper Industry

1.0 IntroductionPaper has a long history, beginning with the ancient Egyptians and continuing to the presentday. After hand-made methods dominated for thousands of years, paper production becameindustrialised during the 19th century.

Originally intended purely for writing and printing purposes, a wide variety of paper grades anduses are now available to the consumer.

Paper is a natural product; manufactured from a natural and renewable raw material, wood.The advantage of paper is that it is biodegradable and recyclable. In this way, the paperindustry is sustainable, from the forest through the production of paper, to the use and finalrecovery of the product.

It’s almost impossible to imagine a life without paper. In fact, paper is such a versatilemedium, its uses are only limited to the imagination.

2.0 Growth of Paper IndustryThe pulp and paper industry plays an important role in a country’s economic growth.

2.1 World ScenarioThe world’s paper and board production, which was about 15 Million tons in 1950, has grownsteadily to reach about 326 million tons in 2001. This accounts for nearly 3.5% of world’sproduction and 2% of the world trade.

The compound annual growth rate (CAGR) of the world paper industry is 2.8%.

USA is the leading producer of paper with over 100 million tons, which accounts for nearly1/3rd of the world’s paper production.

The capacity additions in the paper sector have been taking place of late in the Asian region.

The growth of the paper industry, region-wise is depicted in the graph below:

3.10%2.50%

4.40%

3.10%

2.10%

6.50%

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

7.00%

A frica A sia A ustra lia Europe LatinAmerica

NorthAmerica


231

2.2 Indian ScenarioThe Indian pulp and paper industry is over a hundred years old. It has grown in installedcapacity from a paltry 0.15 million tons in the early fifties to the present level of 4.65 milliontons (a growth of more than 30 times).

The Indian paper industry is a mix of large integrated plants (> 25000 tons per annumcapacity), medium size plants and small size paper plants based on waste paper. The capacitiesof the mills range from 500 tons/annum to 2.00 lakh tons/ annum.

There are about 515 registered paper mills in India, while the numbers of mill, which are inactual operation, are about 380.

The breakup of the mills, capacity-wise is as follows:

• Small (upto 10000 TPA) : 285 numbers and 1.90 million tons

• Medium (< 20000 TPA) : 65 numbers and 1.00 million tons

• Integrated (> 20000 TPA): 30 numbers and 2.50 million tons

These mills produce various types of paper products, such as, writing & printing paper, kraft,paperboard, newsprint etc.

The mills are located all over India. The region-wise break-up of number of mills and capacityis highlighted below:

Region Mills in terms of Mills in terms numbers of production

Numbers % %

East 44 11.6 23.6

West 128 33.7 29.7

South 65 17.1 25.0

North 143 37.6 21.7

The installed capacity of the paper plants in India (2000-2001) is 5.41 million tons of paperand 1.1 million tons of newsprint.

The total annual production figures are 4.65 million tons of paper and 0.46 million tons ofnewsprint, accounting for about 86% & 42% actual capacity utilisation respectively.

2.3 Major players in IndiaThe major integrated pulp and paper industries in India, in terms of installed capacity, aregiven below:

1. A P Rayon Limited, Kamalapuram, Andhra Pradesh

2. Balakrsihna Industries Limited, Kalyan, Maharashtra

3. Ballarpur Industries Ltd., Illure, Maharashtra



4. Ballarpur Industries Ltd., Ballarpur, Maharashtra

5. Ballarpur Industries Ltd., Daulatabad, Orissa

6. Ballarpur Industries Ltd., Yamunanagar, Haryana

7. Ballarpur Industries Ltd., Gaganapur, Orrisa

8. Bilt Graphic Paper Ltd., Pune, Maharashtra

9. Century Pulp & Paper, Lalkua, Uttar Pradesh

10. Emami Paper Mills Limited, Balgopalpur, Orissa

11. Global Boards Limited, Mahad, Maharashtra

12. Grasim Industries Limited, Mavoor, Kerala

13. Harihar Polyfibers, Kumaraptanam, Karnataka

14. Hindustan Newsprint Ltd., Newsprintnagar, Kerala

15. Hindustan Paper Corporation, Cachar, Assam

16. Hindustan Paper Corporation, Nagaon, Assam

17. ITC Limited, Bhadrachalam Paper Boards, Sarapaka, Andhra Pradesh

18. ITC Limited, Unit – Tribeni, Chandrahati, West Bengal

19. J K Corp Limited, Jaykaypur, Orissa

20. Mukerian Papers Limited, Mukerian, Punjab

21. Nath Pulp and Paper Mills Ltd., Aurangabad, Maharashtra

22. Orient Paper Mills, Amlai, Madhya Pradesh

23. Orient Paper Mills, Brajrajnagar, Orissa

24. Pudumjee Pulp & Paper Mills Ltd., Pune, Maharashtra

25. Rama Newsprint and Papers Limited, Surat, Gujarat

26. Rama Paper Mills Limited, Kiratpur, Uttar Pradesh

27. Rohit Pulp & Paper Mills Ltd., Udvada, Gujarat

28. Ruchira Papers Limited, Kala Amd, Himachal Pradesh

29. Satia Paper Mills Ltd., Rupana, Punjab

30. Seshasayee Paper & Boards Ltd., Erode, Tamil Nadu

31. Shreyans Industries Limited, Ahmedgarh, Punjab

32. Star Paper Mills Limited, Saharanpur, Uttar Pradesh

33. Tamilnadu Newsprint and Papers Limited, Karur, Tamil Nadu

34. The Andhra Pradesh Paper Mills Ltd., Rajahmundry, Andhra Pradesh

35. The Central Pulp Mills Ltd., Songadh, Gujarat

36. The Mysore Paper Mills Ltd., Bhadravati, Karnataka

37. The Sirpur Paper Mills Ltd., Sirpur Khagaznagar, Andhra Pradesh

38. The West Coast Paper Mills Ltd., Dandeli, Karnataka

39. Varinder Agro Chemicals Ltd., Barnala, Punjab


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3.0 Per Capita ConsumptionThe Indian per capita consumption of paper is 5 kg, in comparison to the Asian averageof 21 kg, World average of 55 kg and US average of 330 kg.

The per capita consumption of paper in the different parts of the world are depicted graphicallybelow:

The planning commission forecasts a per capita consumption of 5.4 kg by 2010 AD. So theIndian pulp and paper industry has got a tremendous growth potential estimated at about 8%.

4.0 Energy IntensityThe paper industry is highly energy intensive and is the sixth largest consumer of commercialenergy in the country.

The main fuel used in the pulp and paper industry is coal.

The other fuels used are furnace oil, LSHS, rice husk and coffee husk. LDO and HSD arealso used in diesel generators.

Large paper plants generate part of their own power through cogeneration, while smallerplants depend exclusively on purchased power.

The energy cost, as a percentage of manufacturing cost, which was about 15% is presentlyabout 25%. This is mainly due to the increase in energy prices. Energy costs account fornearly 23-25% of the overall manufacturing cost.

The total annual purchased energy consumption of the Indian Paper Industry is about 52Million Giga Cal, which is equivalent to about Rs.15000 million.

The expenditure on energy ranks only next to the raw material in the manufacture of paper.With the ever-increasing fuel prices and power tariffs, energy conservation is strongly pursuedas one of the attractive options for improving the profitability in the Indian pulp and paperindustry.

5 19 28.4 34 39.6

331.7

215.8249.9

0

50

100

150

200

250

300

350

India

Indonesia

China

Thailand

Brazil

Japan

USA UK



The specific energy consumption comparison of Indian paper industry vis-a-vis the internationaltrends is as follows:

Parameter Units Norm Indian Mills International Mills

Steam MT/ MT of FNP Avg. 11-14 6.5-8.5Best 7.5 6.0

Power KWh/MT of FNP Avg. 1500-1700 1150-1250Best 1200 -1300 900-1000

Water m3/ MT of FNP Avg. 150 50Best 75 25

Total energy GCal/ MT of FNP Avg. 52 -Best - -

The typical break-up of steam and power of the various Indian mills vis-à-vis the internationalmills is as below:

Steam consumption (MT/MT of FNP)Section Indian Mills International Mills

Digestor 2.50-3.90 1.9-2.3(now 0.5)Bleach Plant 0.35-0.40 0.20-0.25Evaporator 2.50-4.00 1.50-2.30Paper Machine 3.00-4.00 0.70-2.00Soda Recovery Plant 0.50-1.10 0.30-0.50Generator 0.02-1.20 0.45-0.70

Total 11.0 - 14.0 6.5 - 8.5

Power consumption (kWh/MT of FNP)Section Indian Mills International Mills

Digester 58-62 43-46Bleach Plant 88-92 66-69Paper Machine 465-475 410-415Soda Recovery Plant. 170-190 127-135Stock Preparation 275-286 164-172Utilities & Others 246-252 160-165Chippers 112-128 92-98Washing & Screening 145-155 116-123

Total 1500-1700 1150-1250


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5.0 Energy Saving PotentialThe various energy conservation studies conducted by the CII – Energy Management Cell andfeedback received from the various industries through questionnaire survey and plant visits,indicate an energy savings potential of 20%.

This is equivalent to an annual savings potential of about Rs.3000 million. The estimatedinvestment required to realize this savings potential is Rs.5000 million.

The pulp and paper industry has an attractive cogeneration potential of over 100 MW,in addition to the existing cogeneration plants.

5.1 Major factors that affect energy consumption in paper millsThe major factors that affect energy consumption in the Indian pulp and paper industry areas follows:

• Level of capacity utilisation

• Quality and type of paper produced

• Number and multiplicity of machinery

• Paper machine runnability and number of paper breaks

• Finishing losses

• Boiler type & pressure levels

• Level of cogeneration power generation

• Type of raw material preparatory section- Type of chippers/ cutters- Type of conveying system

• Digester system- Type of pulping technology (extended delignification preferred)- Installation of blow heat recovery- Optimal bath liquor ratio

• Washing section- Utilisation of advanced washers, such as, flat belt wire washers, double wire press, DD washer and Twindle press- Screening section- Installation of advanced screening equipment- Type of refiners- Type of centri-cleaners (use of low pressure drop centri- cleaners reduces the pumping power consumption)

• Paper machine press section- Type of press- % moisture after press section



- On-line moisture control- Type of hood system

• Evaporation section- Type of evaporator and number of stages- Steam economy achieved (minimum should be 6)

• Extent of condensate recovery

• Type of river water pumping system and overall water consumption

• Levels of instrumentation

• Extent of utilisation of variable speed drives, such as, variable frequency drives (VFD),variable fluid couplings (VFC), DC drives, dyno-drives etc.

These are the various major factors, which affect the specific energy consumption in paperplants.

5.2 Target specific energy consumption figuresThe overall specific energy consumption norms, for large integrated paper plants, producingwriting and printing paper, using 100% wood pulp and operating on sulphate process, shouldbe as highlighted below:

• Steam = 8.00 MT/MT of finished paper• Power = 1300 kWh/MT of finished paper• Water = 100 m3/MT of finished paper

The break-up of the target specific steam, specific power and specific water consumptionfigures in the different sections of the plant are as follows:

Specific steam consumption break-up (MT/MT of FNP)Section Steam

Pulping & washing 0.9

Bleaching 0.3

Black Liquor Evaporation 2.0

Chemical recovery boiler 0.8

Recausticising & Lime kiln 0.5

Paper machine 1.9

Deaerator 1.4

Miscellaneous 0.2

Total 8.0


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Specific power consumption break-up (kWh/ MT of FNP)Section Power

Chippers 10

Digester house 55

Washing and Screening 105

Bleaching plant 105

Stock prep., Paper m/c and Finishing 575

Power boilers 170

Intake well + Water treatment plant 60

Recovery (Evaporator, recovery boiler,causticisers and lime kiln) 100

Effluent treatment plant 70

Lighting and workshop etc. 50

Total 1300

Specific water consumption break-up (100 m3/MT of FNP)Section Water

Pulp Mill 30

Paper machine 20

Boilers incl. WTP and Cooling tower 30

Chemical recovery area 10

Miscellaneous 10

Total 100

6.0 Raw material profileThe paper units can be classified based on the raw material into three broad categories as:

• Wood based (Bamboo, hardwood etc.)

• Agro- based (Bagasse, rice & wheat straw, jute etc.)

• Waste paper based

The break-up of the paper mills based on raw material usage in India mills and Internationalmills are highlighted below:



Raw Material Usage Indian Mills International Mills% of total mills % of total mills

Agro-based residues 31 4

Wood based 37 57

Waste paper based 32 39

7.0 Process descriptionNearly 80% of the Indian paper mills use the sulphate process for pulping. Hence, thesulphate process description is given below.

For waste paper based plants, the main sections are the stock preparation and paper machinesection. This has been covered in the process description.

Kraft sulphate processThe raw materials used for pulp making are hard woods like eucalyptus, bamboo and bagasse.These fibrous materials are mainly composed of cellulose and lignin.

By cooking these raw materials with chemicals like NaOH and Na2S, the lignin is removed inthe form of black liquor, while the cellulose is separated in the form of pulp.


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Chipper houseHard wood logs are cut into smaller size by band saw. After wetting these logs with waterspray (to remove sand particles), they are fed into chippers to get chips of small size (1/2"to 1").

DigestersThe chips are fed into digesters, where white liquor (a mixture of NaOH : Na2S with ratio of80 : 20) is added. The contents are circulated. Then it is steamed for two hours and cookedat 170°C. The total batch time is about 5 hours in a batch type digestor. After cooking thecontents are blown to a blow tank.

WashingWashing is done next to free soluble impurities and at the same time to remove black liquor,thereby recovering maximum amount of spent chemicals.

Usually, washing is practised in counter current fashion, involving 3 or 4 stages of washingusing rotary drum filters. The washed pulp is then sent for bleaching and the recovered weakblack liquor is sent to the evaporators.

BleachingBleaching is done to increase the brightness of pulp. Lignin, which is the colouring matter inthe pulp, is converted to chlorolignin and is dissolved in water.

Bleaching is done in four stages:

• Chlorination

• Alkali extraction

• Hypochlorite bleaching

• Final washing

Washing is also done after each stage of bleaching. After the final washing, the bright pulpis sent for stock preparation.

Stock preparationHere, refining is done to give paper the desired properties. This can be done in double discrefiners or conical refiners. After refining, the stock is subjected to sizing, loading and colouring.

Paper machineAfter the stock preparation, the pulp suspension is sent to the paper machine, where the pulpis converted into sheets of paper. The paper is drawn out from the other end and rolled intobundles or cut into the required sizes.



Soda recoveryThe black liquor from the washers is concentrated in the evaporators and fired in the sodarecovery boilers. After firing, the residue (green liquor) is treated with chemicals to get whiteliquor, which is reused in the digesters.

8.0 Energy saving schemesAn exhaustive list of all possible energy saving projects in the pulp & paper industry is givenbelow. The projects have been categorised under short-term, medium term and capital-intensiveprojects.

The projects which have very low or marginal investments and have an energy saving potentialof upto 5% has been categorised as short-term. The projects which require some capital -investment having a simple payback period of less than 24 months and having an energysaving potential of upto 10% has been categorised as medium-term.


There are several projects, which have very high energy saving potential (typically 15% ormore), besides other incidental benefits. These projects have very high replication potentialand contribute significantly to improving the competitiveness of the paper industry. However,these projects require very high capital-investment and hence has been categorised separately.

8.1 List of all possible energy conservation projects in a typical pulp andpaper industry

8.1.1 House-Keeping Measures – Energy Savings Potential of 5%A. Chipper, Pulp Mill & Soda Recovery1. Avoid idle running of chippers, conveyors, etc. by installing simple interlocks.

2. Ensure optimum loading of chippers

3. Avoid fresh water for pulpers and beaters and use back water

4. Interlock agitators with pumps at storage chests

5. Providing timer control for agitators for sequential operation

6. Optimise fresh water consumption in pulp mill washers e.g., alkali washer back water inchlorine washer and chlorine washer back water in brown stock washed pulp.

7. In multiple effect evaporators, use stand-by effect also so as to improve the steameconomy.

B. Stock Preparation & Paper Machine1. Optimise loading of refiners and beaters

2. Interlock agitators with pumps at storage chests

3. Minimise recirculation in receiving chest and machine chest

4. Optimising excess capacity/ head in pump by change of impeller or trimming of impellersize


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5. Avoiding pump operation by utilisation of gravity head

6. Optimise capacity of vacuum pumps by RPM reduction

7. Install level indicating controllers for couch pit pumps

8. Optimising pressure of high pressure pump used for wire cleaning and deck showers

C. Co-Generation, Steam & Condensate Systems1. Monitor excess air levels in boilers and soda recovery boilers

2. Arrest air infiltration in boiler flue gas path, particularly economiser and air preheatersection

3. Plug steam leakages, however small they may be

4. Always avoid steam pressure reduction through PRVs. Instead, pass the steam throughturbine so as to improve cogeneration

5. Insulate all steam and condensate lines

6. Monitor and replace defective steam traps on a regular basis

7. In case coal has higher percentage of fines, ensure wetting is done.

8. Monitor boiler blow down; use Eloguard for optimising boiler blow down

9. Installation of flash vessels for heat recovery from hot condensate vapours

10. Monitor the blow-down quantity of water in cooling towers and the quality of water

11. Install chlorine dosing and HCl dosing for circulating water.

D. Electrical Areas1. Install delta to star convertors for lightly loaded motors









E. Miscellaneous1. Replacement of Aluminium blades with FRP blades in cooling tower fans




5. Install level indictor controllers to maintain chest level

6. Install hour meters on all material handling equipment, such, pulpers, beaters etc.



8.1.2 Medium Term Measures - Savings Potential upto 10%A. Chipper, Pulp Mill & Soda Recovery1. Mechanical unloading system in chipper house

2. Install belt conveyor for conveying wood chips instead of pneumatic conveyors. In caseof space constraint, install cleated belt conveyors

3. Install auto slip power recovery systems for chipper motor

4. Install VSD for cutters and chippers

5. Install two stage preheating in digesters (combination of MP steam and LP steam)

6. Replace steam doctor by high pressure shower in brown stock washers

7. Retrofit additional effect in multiple effect evaporators

8. Install water ring vacuum pumps instead of steam ejectors in evaporators, depending onthe cost of steam.

B. Stock Preparation & Paper Machine1. Stopping broke deflaker when broke refiner is in operation

2. Install new correct size high efficiency pumps

3. Install new high efficiency fans & blowers in boiler

4. VSD for displacement pump, discharge pump, hot fill pump and warm fill pump of washingand screening plant

5. Replace eddy current drive with VFD for washing and bleaching

6. Install suspension type agitators to keep the pulp in suspension during pumping

7. Optimising the capacity of vacuum pumps by RPM reduction or bleed-in control

8. Optimise the suction line size of water ring vacuum pumps

9. Install pre-separators for water ring vacuum pumps

10. Install mixing type agitators to mix different types of pulp

11. Introduce double dilution system

12. Install double disc refiners instead of conical refiners

13. Install VSD for paper machine fan pumps

14. Install VSD for tanks dilution pumps

15. Install VSD for mould fan pumps

16. Install VSD for flat box vacuum pump to avoid bleeding or throttling

17. Avoid interconnection of high and low vacuum sections

18. Optimise suction pipe line size for water ring vacuum pumps

19. Install pre-separators and extraction pumps for water ring vacuum pumps

20. Install dual speed motors for couch pit agitator and press pit agitator

21. Install VSD for MG machine/MF machine hood fans

22. Replace steam ejector with water ring vacuum pump in evaporator section

23. Install cascade condensate system in paper machine area


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24. Install flash steam recovery system for paper machines

25. Reel pulper operation optimized by effective utilization of winder pulper

26. Optimizing operation of hydraulic system of calender

27. Automatic operation of hood and ventilation system

C. Co-Generation, Steam & Condensate Systems1. Install automatic combustion control system/ oxygen trim control system in steam boilers

and soda recovery boilers

2. Install economiser/air preheater for boilers

3. Use of cheaper fuels, like bamboo dust, wood barks, pith etc.

4. Install boiler air preheater based on steam to enhance cogeneration

5. Install high temperature deaerator (120°C to 140°C) with suitable boiler feed water pumpto enhance cogeneration

6. Install heat recovery from boiler blow down

7. Convert medium pressure steam users to LP steam users to increase co-generation

8. Reducing moisture content of wet pith using screw presses for burning in boilers

9. Install condensate recovery systems in digesters, paper machines, evaporators and airheaters

10. Install automatic blow down system for boilers

11. Install sonic soot blowers in place of steam operated soot blowing system

12. Install VSD for SA fan, FD fan and ID fan

13. Install VSD for boiler feed water pump

14. Install VSD for clarified water pumps

15. Install VSD for raw water/recycle water pumps

16. Install VSD for roots blower (agitation purposes)

17. Install VSD for final effluent discharge pumps

18. Replace dyno-drives with VSD in coal feeder

19. Install VSD for vibrating screen, lime feeder and mud filters in recovery boiler

D. Electrical Areas1. Install maximum demand controller to optimise maximum demand

2. Install capacitor banks to improve power factor

3. Installation of thyristorised rectifiers

4. Replace rewound motors with energy efficient motors

5. Install energy efficient motors as a replacement policy

6. Thyristor room AC units provided wit timer control

7. Replace HRC fuses with HN type fuses

8. Replace 40 Watts fluorescent lamps with 36 Watts fluorescent lamps



9. Replace conventional ballast with high efficiency electronic ballasts in all discharge lamps

10. Install SV lamps at wood and coal yard areas instead of MV lamps

11. Install LED lamps for panel indication instead of filament lamps

12. Install CFL’s for lighting in non-critical areas, such as, toilets, corridors, canteens etc.

13. Installation of neutral compensator in lighting circuit

14. Optimise voltage in lighting circuit by installing servo stabilisers

15. Minimising overall distribution losses, by proper cable sizing and addition of capacitorbanks

16. Replace V-belts with synthetic flat belts

E. Air Compressors1. Ensure air compressors are loaded to a level of 90%

2. Set compressor delivery pressure as low as possible

3. Monitor pressure drop across suction filter and after filter

4. Segregate high pressure and low pressure users

5. Replace heater - purge type air dryer with heat of compression (HOC) dryer for capacitiesabove 500 cfm

6. Replace old and inefficient compressors with screw or centrifugal compressors

F. DG System1. Use cheaper fuel for high capacity DG sets

2. Increase loading on DG sets (maximum 90%)

3. Increase engine jacket temperature (max. 85 o C) or as per engine specification

4. Take turbocharger air inlet from outside engine room

5. Installation of steam coil preheaters for DG set fuel in place of electrical heaters

6. Replace multiple small size DG sets with bigger DG sets

G. Miscellaneous1. Floating type aerator in place of fixed aerators

2. High efficiency diffuser aerators instead of conventional aerators

3. Treatment of effluent through activated sludge lagoon resulting in stopping of aerators

4. Use of ETP filter cakes in boilers

5. Solar water heating for canteen and guest house

6. Reuse of water from hydratreater

8.1.3 Long Term Measures - Savings Potential of 10-15%A. Chipper, Pulp Mill & Soda Recovery1. Install high capacity chippers with mechanized feeding

2. Install extented delignification cooking process


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3. Install oxygen delignification

4. Installation of TDR’s in place of beaters

5. Install medium consistency pumping

6. Replace brown stock washing with double wire press system

7. Install high efficiency washing system such as, Flat belt/wire washer, Double wire press,Twin roll press

8. Install VSD for primary, secondary and tertiary centri-cleaners, pumps of unbleached andbleached pulp.

9. Introduce ClO 2 and H 2 O 2 bleaching stages

10. Install pressure screens in pulp mill and avoid centri-cleaners

11. Install 7-effect evaporator instead of conventional triple-effect evaporator

12. Installation of falling film evaporator

13. Install 2-stage steam heating in black liquor pre-heater

14. Install soda recovery plant in medium sized paper plants

15. Install causticiser and rotary lime kiln

16. Increase in TAA to get higher solids concentration in black liquor

17. Installation of plate heat exchanger in evaporator section

B. Stock Preparation & Paper Machine1. Replace conical refiners with double disc refiners

2. Install conical port high efficiency vacuum pumps in place of flat port vacuum pumps

3. Replace centrifugal screens with pressure screen

4. Segregate high-vacuum & low-vacuum sections of the paper machine and connect todedicated systems

5. Segregation of high-head and low head users in cooling towers and process areas

6. Install tri-nip press section in paper machine to reduce drying load

7. Install computerised automatic moisture control system for paper machines

8. Install paper machine hood heat recovery system

9. Convert small steam turbines in paper machine area to DC or AC drive so as to enhancecogeneration.

C. Co-Generation, Steam & Condensate Systems1. Convert chain grate/spreader stoker boilers to FBC

2. Install co-generation system for medium sized paper plants

3. Install vapour absorption system to utilise LP steam and enhance cogeneration

4. Install cascade condensate recovery system in paper machine

5. Install cascade evaporators in soda recovery plant

6. Maximising solids concentration in Recovery boiler

7. Rotary feeder for lime kiln feeding system



8. Install steam-generating system from DG exhaust, if DG is run on a continuous basis

9. Install scoop type syphons in the dryer cylinders of paper machine instead of conventionalsteam & condensate system with rotary joints

10. Install hood recovery systems in paper machine to minimise steam consumption

D. Miscellaneous1. Replacement of Aluminium bus bars with Copper bus bars in caustic chlor unit

2. Replacement of Mercury cell bottom

3. Installation of DCS monitoring and targetting system for better load management

4. Installation of harmonic filters


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Case Study No.1

Replacement of Dyno-drives with Variable Frequency Drives(VFD’s) in Washer Drum Drives

BackgroundThe contents of the digester, after cooking, are blown down to a blow tank. The blown pulpis then washed, to remove the dissolved lignin and chemicals.

Usually, washing is practised in counter current fashion, involving 3 or 4 stages of washing,using rotary drum washers. The washed pulp is then sent for bleaching and further processing.The rotary drum washers are operated under vacuum, utilising a barometric column. Thesedrum washers are driven by a variable speed system, to achieve the desired speed variation,according to the throughput of the plant.

Previous statusIn one of the old integrated paper plants, the washer drum drives were originally supplied withAC commutator motors. As these commutator motors had frequent maintenance problems,these were replaced with dyno-drives.

The dyno-drives, though have lesser maintenance problems, are inefficient at lower speeds.As the washers were operating at 50 - 60% of the rated speed for majority of the time, thereplacement of these drives with more efficient drives, such as, variable frequency drives(VFD) can result in substantial energy savings.

Energy saving projectThe dyno-drives of the washers were replaced with variable frequency drives (VFD’s).

Concept of the projectThe dyno-drives are very inefficient at lower speeds. The dyno-drives also require specialattention and maintenance, because of its semi-open construction.

The variable frequency drives (VFD) are more efficient at lower/all speeds and require lessermaintenance, in comparison to dyno-drive.

Implementation status, problems faced and time frameThe dyno-drives in both the washer drums were replaced with 22.5 kW variable frequencydrives (VFD’s). A VFD can achieve the exact speed variation requirement energy efficientlydepending on the process requirement.

The problem faced during the implementation stage was the frequent tripping of the VFD’s.The supplier studied this and suitable remedial action was taken, to solve the problem. Theentire project was executed in 3 months time.



Benefits achievedThe replacement of dyno-drives with VFD’s, resulted in a net reduction in power consumption.The net power saving achieved was 36,024 units/year (equivalent of 5.23 kW). The othermajor advantage is, the precise speed variation, which can be achieved.

Financial analysisThe annual energy saving achieved was Rs.0.11million. This required an investment ofRs.0.25 million and had a simple payback period of 28 months

Replication potentialThis project has very high replication potential in majority of the medium size paper mills in thecountry and integrated paper mills also.


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Case Study No.2

Installation of Variable Frequency Drive (VFD) for Fan Pump

BackgroundThe pumps in a paper plant, are major consumers of electrical power. The pumps are usedfor pumping water & pulp through out the plant - in the pulp mill, stock preparation section,paper machine and water pumping sections.

One such important pump, is the fan pump, which pumps the dilute stock to the papermachine, through the centri-cleaners.

The quantity of the stock being pumped by the fan pump varies, according to the quality andgrade of the paper produced in the paper machine. The production of high GSM paperrequires lower fan pump capacity, while the production of lower GSM paper needs higher fanpump capacity. Hence, normally the fan pump is designed for the maximum capacityrequirement. Thus, the fan pump will be operating at lower capacity, whenever high GSMpaper is produced.

Conventionally, the fan pump is controlled by throttling the discharge valve or by re-circulatinga part of the discharge, during such low capacity requirements.

The operation of a centrifugal pump with valve throttling or re-circulation is energy in-efficient,as a part of the energy supplied to the pump, is either lost across the valve or wasted for re-circulation.

The latest trend is to install variable frequency drive (VFD) and control the varying capacityrequirements, by varying the speed of the pump.

Previous statusIn a large integrated paper plant having one of the paper machines of 50 TPD capacity, theconsistency of the pulp varied from 0.6% to as high as 1.0%. The quantity of the dilute stockto be pumped also varied accordingly, between 180 m3/h and 125 m3/h.

A fan pump of the following specifications, is used to pump the stock:

• Capacity : 240 m3/h

• Head : 35 m

• Motor rating : 50 HP

This capacity and head were designed with a safety margin on the maximum requirement inmind. Hence, the valves in the delivery line of the fan pump had to be throttled and more so,when the high GSM paper was produced.

The operation of a pump with valve throttling is energy inefficient, as a part of the energysupplied is lost across the valves.


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Energy saving projectThe fan pump was installed with a variable frequency drive (VFD) and the speed was variedto meet the varying capacity requirements. The valves were kept fully open, during thecontinuous operation of the pump.

Concept of the proposalThe operation of a pump with valve throttling is an energy inefficient method of capacitycontrol, as a part of the energy is lost across the valves.

The best energy efficient way of capacity control, for such varying process conditions, can beeffectively achieved with a variable frequency drive (VFD).

Implementation status, problems faced and time frameThere were no problems faced during the implementation of this energy saving scheme. Thetime taken for the implementation was 6 months.

Benefits achievedThe installation of VFD for the fan pump, resulted in the following:

• Avoiding discharge valve throttling

• Exact matching of the process requirements

• Energy savings

The net power reduction achieved on installation of VFD for the fan pump was 54 kW.

Financial analysisThe annual energy saving achieved was Rs.0.25 million. This required an investment ofRs.0.50 million and had a simple payback period of 24 months.

Replication potentialThis project has very high replication potential in majority of the medium size paper mills inthe country and a few of the integrated paper mills also.

On a conservative estimate, this project can be taken up for replication in about 100 papermills in the country.





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Case Study No.3

Replacement of Suction Couch Roll by Solid Couch Roll in thePaper Machine

BackgroundThe paper machine performs the important function of converting the low consistency pulp todry paper. The water removal is initially done by high-speed drainage, suction through flatvacuum boxes, suction couch & mechanical presses and drying in steam cylinders.

The latest paper machines have been installing the modern presses and reducing the loadon the steam drying section.

Another project, which has been taken up by some of the plants, is the replacement of thesuction couch with the solid couch.

The concept of this project, is based on utilising the method, which removes the maximumquantity of water, with the least quantity of energy. This is particularly applicable, to plantsbased on long fibre agro-pulp, which have a low drainage.

Previous statusIn a medium size agro-based paper plant, the major portion of water from the wet end, isremoved by suction couch roll. The moisture removal is effected by a vacuum pump of 200kW rating. This is a highly energy intensive process.

Energy saving projectThe suction couch roll was replaced by a solid couch roll, for the efficient removal of moisturein the wet end of the paper machine.

Concept of the projectAgricultural residue fibres have very low diameter and low water drainage rate. The quantityof water removed by the suction couch is very low and the energy consumption wasdisproportionately high.

The inlet consistency to the suction couch roll was around 18% and outlet consistency afterthe suction couch roll was between 18.5 - 19.0%. To remove this moisture of 0.5 - 1.0% atthe suction couch roll, a vacuum pump of 200 kW rating was being used.

The operation of a vacuum pump can be avoided, by the installation of a solid couch roll. Theadditional water load, i.e., 0.5 - 1.0%, can be well taken care by the press part, without posingany adverse effect on the working of the press part.



Implementation status, problems faced and time frameThe suction couch roll was replaced with a solid couch roll, for the removal of moisture in thewet end of the paper machine. There was an initial apprehension that, whenever a breakoccurred at the wet end, it was due to the solid couch roll.

However, once the plant team got familiar with the running of the paper machine with a solidcouch roll, there were no further problems faced. The entire project was implemented in 2months.

Benefits achievedThe operation of the 200 kW vacuum pump was completely avoided with the implementationof this proposal.

Financial analysisThe annual energy saving achieved was Rs.2.67 million. This will require an investment ofRs.1.00 million and had a simple payback period of 5 months.

Replication potentialThis project has good replication potential in the agro-waste based small and medium sizepaper mills. These mills typically have the suction couch roll for water drainage instead of themodern presses.





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Case Study No.4

Installation of Seven Effect Free Flow Falling Film (FFFF)Evaporator

BackgroundMultiple effect evaporators are installed in the liquor line between the brown stock washersand the soda recovery boiler to efficiently remove large amounts of water from the liquor, sothat, the recovery boiler produces steam from this liquor economically.

The multiple effect evaporator is fed black liquor at 12-14% solids and concentrated tobetween 40-55% solids. Most of the paper plants use the short tube or long tube verticalevaporators, having five to seven effects, the first two effects being contained in one evaporatorbody.

These conventional evaporators have the following disadvantages:

• A large heating area is required, since the units are broad.

• Requires hydrostatic head

• Has a high pressure drop

• Tendency to scale

The latest trend among the large integrated paper plants, is the installation of free flow fallingfilm evaporators. They are characterised by higher steam economy and better operationalperformance.

Previous statusA large integrated paper plant had a conventional quintuple effect short tube vertical evaporatorsystem for the concentration of black liquor. The black liquor flow rate was about2500 m3/h.

The steam economy achieved was 2.8 tons of water evaporation per ton of steam. Theseevaporators had frequent operational problems, leading to increased mechanical down time.Also the chemical losses were more due to the frequent water boiling.

The installation of FFFF evaporators can result in higher steam economy, reduced down timeand improved operational performance.

Energy saving projectThe quintuple effect short tube vertical evaporators were replaced with 7 - effect free flowfalling film (FFFF) evaporators.

Concept of the projectThe FFFF evaporators are characterised by the following advantages over the conventionaltypes:


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• In this type, the feed liquor is introduced at the top tube sheet and flows down the tube wallas a thin film.

• Since the film moves by gravity, a thinner and faster moving film forms. This results inhigher heat transfer coefficients and reduced contact times.

• As a large heat transfer area can be packed into a given body, they occupy less floorspace.

• Heat transfer coefficients are high.

• There is no elevation in boiling point, due toabsence of hydrostatic pressure

• Very high steam economy, of the order of 6

• There is no static head to affect thetemperature driving force. This allows use ofa lower temperature difference for units tooperate. Hence, a superior evaporatorperformance is achieved.

Implementation status, problems faced and time frameThe latest 7 - effect free flow falling film evaporator, was installed in place of the conventionalshort tube vertical evaporator. There were no problems faced during the implementation ofthis project and the implementation was completed in 12 months.

Benefits achievedThe installation of 7-effect FFFF evaporator resulted in achieving a steam economy of 6. Anet saving of about 97000 MT of low-pressure steam was achieved as a result of thismodification. The modification also resulted in reduced down time and improved operationalperformance.

Financial analysisThe annual steam savings achieved amounted to Rs.28.50 million. This required an investmentof Rs.36.90 million, which had an attractive simple payback period of 16 months.

Replication potentialThere are only few installations of seven stage evaporators, particularly, the falling filmevaporators in the paper industry.

Hence, this project has very high replication potential in majority of the integrated paper millsin the country.

On a conservative estimate, this project can be taken up for replication in about 10 integratedpaper mills in the country.


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Case Study No.5

Recovery of Chemicals from Spent Liquor Obtained fromCounter Current Washing of Unbleached Pulp in a MediumSize Paper Mill

BackgroundThe chemical recovery systems (evaporators, recovery, boilers etc.,) are an integral part ofany large integrated paper plant. The black liquor can be fired in the soda recovery boilersto generate steam. The sodium salts recovered in the process is reused in the digesters.

Chemical recovery systems have been well proven and operating for many years in the largeintegrated plants.

The installation of such chemical recovery systems in the medium size paper plants is generallyconsidered financially unattractive. But one leading medium size paper plant has taken leadin this direction.

They have installed a fluidised bed reactor to recover the chemicals from spent liquor andconvert them into sodium carbonate pellets. These pellets are commercially sold, resulting inadditional revenue generation.

Previous statusIn an agro-based medium size paper plant, the spent liquor obtained from the counter currentwashing of unbleached agro-pulp, was getting mixed with wastewater and let out to effluenttreatment plant.

This increases the load on the effluent treatment plant, as it is not possible to bring down theSodium ratio in the effluent. The recovery of this spent liquor will not only reduce the effluentload, but also recovers the valuable chemicals, which can be sold.

Energy saving projectA fluidised bed reactor was installed, to recover chemicals from spent liquor, obtained fromcounter current washing of unbleached pulp.

Concept of the projectSpent liquor obtained after counter current washing of unbleached pulp has sodium lignate.Spent black liquor is concentrated to 45% solids content to have autocombustion in thereactor.

The heat from flue gases makes the concentrated black liquor to convert into dry solids.When these dry solids are burnt, organic portion of solids are converted mostly into carbondioxide and water vapour and generate heat. While sodium compounds present is convertedinto very useful chemical- sodium carbonate pellets.



As mentioned above it is an exothermic reaction, therefore no auxiliary fuel is required oncecombustion of solids present in spent liquors gets started. Sodium carbonate is used in themanufacture of glass, sodium silicate etc.

Implementation status, problems faced and time frameA chemical recovery plant, to recover the chemicals from spent black liquor, obtained from thecounter current washing of the unbleached agro-pulp, was installed.

The entire quantity of weak black liquor, which was earlier sent to the effluent treatment plant,is now processed in the soda recovery plant. This reduced the effluent load and related powerconsumption.

The major problem faced during the implementation of this project was the de-fluidisation ofthe bed in the fluidised bed reactor. The problem was diagnosed and found to be due to thehigh chloride content in the wheat straw. The pre-treatment of the wheat straw, with water oflow chloride contents, reduced the chloride contents in the wheat straw. This eliminated theproblem of de-fluidisation.

The entire project was implemented in 12 months time.

Benefits achievedThe following benefits were achieved on the installation of chemical recovery system:

• Chemical recovery (Sodium Carbonate)

• Savings in power at the effluent treatment plant

• Savings in Urea and DAP at the effluent treatment plant

The summary of the financial benefits is as follows:

Income (per month) Expenses (per month)

Additional revenue generated by Fixed expenses (personnel, repairs &sale of Na2CO3 = Rs. 3.78 million maintenance, financial etc.,) = Rs. 0.88 million

Saving in power, urea and DAP Variable expenses (diesel, power, steam etc.,)at ETP = Rs. 0.36 million = Rs. 2.74 million

Total benefits = Rs. 4.14 million Total expenses = Rs. 3.62 million

Net monthly benefits = Rs. (4.14 - 3.62) million = Rs. 0.52 million


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Financial analysisThe net annual energy saving achieved was Rs.6.20 million. This required an investment ofRs. 12.60 million, which had a simple payback period of 24 months.

Replication potentialThe installation of such chemical recovery systems in the medium size paper plants is generallyconsidered financially unattractive.

But considering the other spin-off benefits, like additional revenue from pellets and hugeintangible benefits, such as, reduced load on ETP & related environmental benefits, thisproject can have good replication potential in all the medium size paper mills.

On a conservative estimate, this project can be taken up for replication in about 50 mediumsize paper mills in the country.





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Case Study No.6

Installation of Variable Frequency Drive (VFD) forBoiler ID Fan

BackgroundThe capacity requirements of the boiler ID fans, vary with the boiler operating conditions. Insuch highly fluctuation conditions, the right sizing (capacity and head) of the fans is verydifficult. Some excess margins are added, to take of such uncertainties and safetyconsiderations. The excess capacity/head of a fan, is conventionally, controlled by a damper.

In a typical paper plant, the coal fired boiler, was operating with damper control. The varyingcapacity requirements, can be exactly matched in an energy efficient manner, by the installationof variable frequency drives.

Previous statusIn a large integrated paper plant, the varying capacity requirements of the coal fired boiler -ID fan was achieved with damper control.

The operation of a fan with damper control is an energy inefficient practise, as substantialenergy is lost across the damper.

The installation of a variable frequency drive (VFD) can, not only result in exact matching ofthe varying capacity requirements, but also result in achieving energy savings.



Energy saving projectVariable frequency drives were installed for the coal-fired boiler ID fan and the soda recoveryboiler ID fan.

Concept of the projectThe operation of a fan with damper control is an energy inefficient practise, as substantialenergy is lost across the damper. The energy efficient method of capacity control is to varythe RPM of the fan, to exactly match the varying capacity requirements.

The installation of a variable frequency drive can achieve this objective resulting in maximumenergy savings, in all speed ranges.

Implementation status, problems faced and time frameA variable frequency drive was installed for the coal-fired boiler ID fan.

There were some minor problems of tuning the variable frequency drive during the initialstages.

The supplier’s service engineer rectified these problems. The implementation of the entireproject was completed in 3 months time.

Benefits achievedThe benefit of installing a variable frequency drive, for the coal-fired boiler ID fan is as follows:

Parameter Units ID fan Power Cons.

Power consumption without VFD kW 185

Power consumption with VFD kW 150

Power savings achieved kW 35

Financial analysisThe annual energy saving achieved was Rs.0.56 million. This required an investment ofRs. 0.70 million and had an attractive simple payback period of 15 months.






Replication potentialThe project has very high replication potential in almost all the medium size paper mills andsome of the integrated paper mills.

Several integrated paper mills have installed variable fluid coupling (VFC) for the boiler (bothcoal-fired and soda recovery) ID fans.

The comparative performance and cost-benefit analysis of the various variable speed devices,decides the best selection of the type of variable speed drive (VSD) to be installed for the IDfans.

Amongst the various VSD’s available, a variable frequency drive (VFD) will offer the maximumenergy savings and as well as maximum operational flexibility. Hence, it is advisable toreplace VFC with VFD.

For example:• One of the integrated paper plants, by installing VFD for their soda recovery boiler ID fan,

the plant was able to achieve a power reduction of 72 kW at 80% motor speed and 27 kWat 95% motor speed, as compared to VFC.

• The plant achieved an annual energy saving of Rs.1.08 million. This required an investmentof Rs.1.50 million, which had an attractive simple payback period of 17 months.

Similar to the boiler ID fans, VFD’s have also been installed successfully for the boiler FD fansand SA fans.


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Case Study No.8

Conversion of Spreader Stoker Boilers to Fluidised Bed Boilers

BackgroundThe paper plant is a major consumer of thermal energy in the form of steam. This steamrequirement is met by a battery of boilers fired by a solid fuel (coal) and also partly by theSoda Recovery Boiler (SRB) in the case of the integrated plants.

In the older paper plants, the boilers were the conventional stoker boilers. These boilers werecharacterised by:

• Higher unburnts in ash

• Lower thermal efficiency

The latest trend has been to install the fluidised bed boilers or conversion of the existing chain/ spreader stocker boilers, which have the following advantages:

• Coal having high ash content/ low calorific value can be used

• Biomass fuels can also be used

• Lesser unburnts in ash

• Higher thermal efficiency

Hence, the older plants are also in a phased manner, converting their old stoker-fired boilersto fluidised bed boilers. This case study describes one such project implemented in a paperplant.

Previous statusA large integrated paper plant, had four numbers of spreader stoker boilers, operating to meetsteam requirements of the plant. These spreader stoker boilers, were designed for highcalorific value coal (4780 kCal/kg) with low ash content.

Due to non-availability of this type of coal, these boilers had to be fired with coal of lowcalorific value and high ash content. This resulted in the capacity down-gradation and loss inefficiency. The steam generation was only 14 TPH, as against the design rating of 30 TPH.The boiler efficiency achieved was only 65%.

Energy saving projectThe plant team modified two of the spreader stoker boilers into fluidised bed combustionboilers.

Concept of the proposalIn addition to the benefits of fluidised bed combustion mentioned earlier, they also enable theuse of biomass fuels, such as saw dust, generated in the chipper house.



Implementation status, problems faced and time frameTwo of the four spreader stoker boilers were converted to fluidised bed combustion boilers.This conversion to fluidised bed combustion boilers, enabled the use of saw dust, which isgenerated in the chipper house.

There were no major problems faced during the implementation of this project. Theimplementation was taken up in two stages and was completed in 18 months time.

BenefitsThe steam generation capacity increased to 27 TPH and the thermal efficiency improved to78%, with this modification. The improved thermal efficiency has resulted in an annual coalsaving of 5639 MT.

Additionally, the use of saw dust (calorific value of about 3000 kCal/kg) has resulted in anannual coal savings of 3600 MT.

Financial analysisThe annual benefits achieved were Rs.10.50 million. This required an investment of Rs.27.00million (for the conversion of two spreader stoker boilers to fluidised bed combustion boilers),which had a simple payback period of 31 months.

Replication PotentialThis project can be replicated in majority of the older paper mills, both medium size andintegrated paper mills, particularly, those plants which is looking at augmenting its boilercapacities and adopting high pressure cogeneration systems.





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Case Study No.9

Conversion of MP Steam Users to LP Steam Users to MaximiseCogeneration

BackgroundThe paper industry is a major consumer of power and steam. In all the integrated plants andin a few medium sized plants, the co-generation system is installed to meet the power andsteam needs of the plant simultaneously.

This system facilitates the generation of cheaper power, fully meets the steam requirementand partly the power requirements of the plant. The balance power requirement is met, eitherfrom the grid or through condensing turbine, in the plant itself at a higher cost.

Hence, the paper plant should make every effort to increase the co-generation power to theextent possible.

The generation of power from the turbine depends on the pressure level of the extraction. Thelower the pressure, the higher will be the generation of power per unit of steam extracted.Hence, efforts should be made to replace the HP (High Pressure) / MP (Medium Pressure)steam with LP (Low Pressure) steam to the extent possible.

One such case study involving replacement of MP steam with LP steam and implemented inan integrated paper plant is described below.

Previous statusOne of the large integrated paper plants in the country, had an extraction-cum-back pressureturbine for the generation of power. The turbine specifications were as follows:

• HP steam pressure = 42 ata

• MP steam pressure = 12 ata

• LP steam pressure = 5.5 ata

The MP steam consumers, such as, malony filter, furnace oil preheaters in boilers and thesteam air preheaters consume MP steam. The heating requirements in these areas, can beeffectively met by LP steam.

The conversion of these MP steam users to LP steam users, can help in maximising thecogeneration.

Concept of the proposalThe detailed analysis of the temperature requirement of the various above listed MP steamusers, indicated that the LP steam can be used for providing the required heat, without anyproblem.


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The comparison of power generation with MP steam and LP steam are as follows:

• 1 MT of HP steam extracted as MP steam generates 67 kWh

• 1 MT of HP steam extracted as LP steam generates100 kWh

Hence, replacement of 1 MT of MP steam with 1 MT of LP steam can aid in generating about23 kWh of extra power.

Implementation status, problems faced and time frameThe MP steam users, such as, the malony filter, furnace oil preheater and the steam airpreheater were converted to LP steam users.

There were no particular problems faced during the implementation of this project. Theimplementation of the project was completed in 1 month time.

Benefits achievedBy the conversion of the identified MP steam users to LP steam users, there was an additionalannual power generation of 16.73 lakh kWh.

Financial analysisThe additional annual benefit achieved (on account of increased power generation) wasRs.1.67 million. This did not require any major investment, as LP steam header was availableclose to all these users.

Replication PotentialThis project has very good replication potential in almost all the paper plants have a commercialcogeneration system.


• Investment - negligeble


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Case Study No.10

Utilisation of Bamboo Dust along with Coal Firing in the CoalFired Boilers

BackgroundCoal is used conventionally, as the basic fuel forcombustion in the boilers for steam generation.The steam requirements of the entire plant aremet, by steam generated in these coal-firedboilers. This is supplemented by steamgeneration from the soda recovery boilers.

Previous statusIn an integrated paper plant, two coal-fired boilersmet the majority of the steam requirements ofthe entire plant. There was lot of bamboo dust

generated in the chipper house, which was being sold-off to outside parties.

Energy saving projectThe bamboo dust was fired along with coal in the boilers.

Concept of the projectThis is an excellent cost reduction and waste disposal method.

Even though, there are several proven cases of utilisation of alternate forms of fuel, includingwaste fuels and low cost fuels, coal continues to be the most preferred fuel in most of thepaper plants, particularly the large integrated paper plants.

As the cost and ash content of the coal available to the paper sector is on the raising trend,the use of supplementary fuels, such as, bamboo dust, rice husk, bagasse etc., have gainedincreasing prominence.

This has assumed greater relevance, as the available coal resources are also fast dwindling.

Implementation status, problems faced and time frameChipper dust was used along with coal as fuel, in the coal-fired boilers, on a trial basis. Oncethe operational stability was achieved, the chipper dust was used to supplement the coal firingon a continuous basis, except during the rainy season.

During the rainy seasons, the plant team faced serious firing problems, due to the highermoisture content in the chipper dust. It was hence decided to stop the use of chipper dustas supplementary fuel during the rainy season.

The time taken for the complete implementation of the project was 2 months, which alsoincluded the initial trials conducted.



Benefits achievedWith the use of bamboo dust as supplementary fuel to the coal firing in the coal-fired boilers,there was a net annual reduction in coal consumption by 3312 MT.

Financial analysisThe annual energy saving achieved was Rs.4.14 million. This required only a minimalinvestment to transport the bamboo dust available in the chipper house to the boiler house.

Replication potentialThe project has excellent cost reduction and waste disposal potential. This coupled with theincreased use of agro-wastes, such as, wet & dry pith from bagasse, groundnut shells,coconut shells, paddy husk etc., has tremendous long-term benefits.


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Case Study No.11

Installation of High-Efficiency Turbine Pumps for Raw WaterIntake

BackgroundWater is an essential commodity for the pulp & paper industry, from both energy andenvironmental point of view.

The overall water consumption of the Indian pulp and paper industry varies from 175 - 250m3/ton of finished paper (depending on the product) in large integrated paper plants.

Previous statusIn one integrated paper plant, six pumps installed at the raw water intake well met the rawwater requirements of the entire plant. The pumps were of the following specification:

Three pumps Three pumps

• Capacity = 772 m3/h • Capacity = 522 m3/h

• Head = 35 m WC • Head = 35 m WC

• Motor rating =125 HP • Motor rating = 75 HP

• Design efficiency = 86.5% • Design efficiency = 80%

To meet the normal plant requirements, the operating pattern of the pumps were as follows:

• 3 pumps of 125 HP, run for 24 hrs/day


• 1 pump of 75 HP, kept as stand-by pump, to take care of any exigencies.

On detailed analysis of the pumps, it was observed that the three 125 HP pumps wereoperating very close to the design efficiency. On the other hand, the two 75 HP pumps wereoperating much below their best efficiency points.

The design efficiencies were not being achieved, on account of ageing and wear out ofimpellers.

Energy saving projectThree new high-efficiency river water turbine pumps were installed, in place of the existing 75HP pumps.

Concept of the projectThe design efficiencies were not being achieved, on account of ageing and wear out ofimpellers. The latest turbine pumps for river water intake have operating efficiencies as highas 87%.


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Substantial energy savings can be achieved by the installation of high efficiency turbine pumps.

Implementation status, problems faced and time frameThree new high-efficiency, 125 HP turbine pumps were installed, in place of the old 75 HPturbine pumps. To meet the raw water requirements of the entire plant, the operating patternof the pumps changed to:

• Three 125 HP pumps, run for 24 hrs/day

• One 125 HP pump, run for 12 hrs/day

• Two 125 HP pumps, kept as stand-by

No problems were faced during the installation of the new pumps, since there was a stand-by pump available. The new pumps were installed one-by-one. The total time taken forimplementation of this project was 8 months.

Benefits achievedThe total power consumption (measured by a common energy meter) of the 5 pumps inoperation, before modification, was on an average 8000 units per day.

After the installation of new high efficiency turbine pumps for raw water intake, the total powerconsumption (measured by a common energy meter) of the four pumps in operation was onan average about 7000 units/day. Thus, there was a net reduction in power consumption byan average of 1000 units/day (equivalent to 41.7 kW).

Financial analysisThe annual energy saving achieved was Rs.1.05 million. This required an one-time investmentof Rs.0.52 million and had a very attractive simple payback period of 6 months.

Replication potentialWater is an essential and power intensive utility for effective functioning of a paper mill.Hence, efficient operation of pumps is very important, not only from the process point of view,but also from cost point of view.

The project has excellent replication potential, in majority of the integrated and medium sizepaper mills, which are dependent on rivers for raw water intake.





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Case Study No.12

Installation of Variable Frequency Drive (VFD) for Process WaterPump

BackgroundIn a typical paper plant, the centrifugal pumps are major consumers of electrical energy. Thecapacity requirements of a centrifugal pump vary with the operating conditions and processrequirements.

Normally, the pumps are designed to operate at their maximum capacity and meet the peakload demand of the plant. However, these conditions do not arise all the time. Due to thevariation in demand, the system pressure also varies.

For example, when the header pressure varies between 3 kg/cm2 and 4 kg/cm2 (assuming therequired pressure is 3 kg/cm2) the header pressure will approach 4 kg/cm2, during the periodof low demand.

This indicates generation of higher pressure, when it is not required, and a potential for savingenergy to the extent of 25% [(4-3)/4 x 100] during low demand condition exists.

Previous statusIn a large integrated paper and paperboard plant, the process water pump was catering tothe water requirements in the plant.

The process water requirement was continuously varying, leading to fluctuations in the systemheader pressure between 3.0 and 4.0 kg/cm2.

The installation of a variable frequency drive can exactly match the process requirements andmaintain a constant pressure of 3 kg/cm2, resulting in energy savings.

Energy saving projectA variable frequency drive was installed for the process water pump, with a pressure indicatorcontroller (PIC) in a closed loop.

Concept of the projectA variable frequency drive (VFD) can exactly match the process requirements by varying theRPM. The PIC will continuously monitor the header pressure and give a signal to the VFDpanel to increase / decrease the RPM.

Whenever the process demand decreases, the header pressure increases above 3 ksc. ThePIC will sense this increase in pressure and will give signal to the VFD panel to reduce theRPM, to match the set point and vice-versa.



Implementation status, problems faced and time frameA variable frequency drive was installed for the process water pump, with a PIC in a closedloop. There were some minor problems of tuning the variable frequency drive during the initialstages.

The supplier’s service engineer rectified these problems. The implementation of the projectwas completed in 3 months time.

Benefits achievedThe benefit of installing the variable frequency drives, for the boiler ID fans and process waterpump are as follows:

Parameter Units Power cons. ofprocess water pump




Financial analysisThe annual energy saving achieved was Rs.1.15 million. This required an investment of Rs.0.7 million and had an attractive simple payback period of 8 months

Replication potentialVariable speed drives are finding increasing application, not only from energy point of view,but also from process point of view. The application purely depends on the variation indemand and also the flexibility of operation desired.

In fact, some of the latest plants have almost 250-300 variable speed drives, a drive foralmost any application you can think of!!

Hence, variable speed drives have excellent application potential.





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Energy saving projectThe bamboo dust was fired along with coal in the boilers.

Concept of the projectThis is an excellent cost reduction and waste disposal method.

Even though, there are several proven cases of utilisation of alternate forms of fuel, includingwaste fuels and low cost fuels, coal continues to be the most preferred fuel in most of thepaper plants, particularly the large integrated paper plants.

As the cost and ash content of the coal available to the paper sector is on the raising trend,the use of supplementary fuels, such as, bamboo dust, rice husk, bagasse etc., have gainedincreasing prominence.

This has assumed greater relevance, as the available coal resources are also fast dwindling.

Implementation status, problems faced and time frameChipper dust was used along with coal as fuel, in the coal-fired boilers, on a trial basis. Oncethe operational stability was achieved, the chipper dust was used to supplement the coal firingon a continuous basis, except during the rainy season.

During the rainy seasons, the plant team faced serious firing problems, due to the highermoisture content in the chipper dust. It was hence decided to stop the use of chipper dust assupplementary fuel during the rainy season.

The time taken for the complete implementation of the project was 2 months, which alsoincluded the initial trials conducted.

Benefits achievedWith the use of bamboo dust as supplementary fuel to the coal firing in the coal-fired boilers,there was a net annual reduction in coal consumption by 3312 MT.

Financial analysisThe annual energy saving achieved was Rs.4.14 million. This required only a minimal

investment to transport the bamboo dust available inthe chipper house to the boiler house.

Replication potentialThe project has excellent cost reduction and waste disposal potential. This coupled with theincreased use of agro-wastes, such as, wet & dry pith from bagasse, groundnut shells,coconut shells, paddy husk etc., has tremendous long-term benefits.


• Investment - negligible


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Case Study No.11

Installation of High-Efficiency Turbine Pumps for Raw WaterIntake

BackgroundWater is an essential commodity for the pulp & paper industry, from both energy andenvironmental point of view.

The overall water consumption of the Indian pulp and paper industry varies from 175 - 250m3/ton of finished paper (depending on the product) in large integrated paper plants.

Previous statusIn one integrated paper plant, six pumps installed at the raw water intake well met the rawwater requirements of the entire plant. The pumps were of the following specification:

Three pumps Three pumps

• Capacity = 772 m3/h • Capacity = 522 m3/h

• Head = 35 m WC • Head = 35 m WC

• Motor rating =125 HP • Motor rating = 75 HP

• Design efficiency = 86.5% • Design efficiency = 80%

To meet the normal plant requirements, the operating pattern of the pumps were as follows:



• 1 pump of 75 HP, kept as stand-by pump, to take care of any exigencies.

On detailed analysis of the pumps, it was observed that the three 125 HP pumps wereoperating very close to the design efficiency. On the other hand, the two 75 HP pumps wereoperating much below their best efficiency points.

The design efficiencies were not being achieved, on account of ageing and wear out ofimpellers.

Energy saving projectThree new high-efficiency river water turbine pumps were installed, in place of the existing 75HP pumps.

Concept of the projectThe design efficiencies were not being achieved, on account of ageing and wear out ofimpellers. The latest turbine pumps for river water intake have operating efficiencies as highas 87%.



Substantial energy savings can be achieved by the installation of high efficiency turbine pumps.

Implementation status, problems faced and time frameThree new high-efficiency, 125 HP turbine pumps were installed, in place of the old 75 HPturbine pumps. To meet the raw water requirements of the entire plant, the operating patternof the pumps changed to:

• Three 125 HP pumps, run for 24 hrs/day

• One 125 HP pump, run for 12 hrs/day

• Two 125 HP pumps, kept as stand-by

No problems were faced during the installation of the new pumps, since there was a stand-by pump available. The new pumps were installed one-by-one. The total time taken forimplementation of this project was 8 months.

Benefits achievedThe total power consumption (measured by a common energy meter) of the 5 pumps inoperation, before modification, was on an average 8000 units per day.

After the installation of new high efficiency turbine pumps for raw water intake, the total powerconsumption (measured by a common energy meter) of the four pumps in operation was onan average about 7000 units/day. Thus, there was a net reduction in power consumption byan average of 1000 units/day (equivalent to 41.7 kW).

Financial analysisThe annual energy saving achieved was Rs.1.05 million. This required an one-time investmentof Rs.0.52 million and had a very attractive simple payback period of 6 months.

Replication potentialWater is an essential and power intensive utility for effective functioning of a paper mill.Hence, efficient operation of pumps is very important, not only from the process point of view,but also from cost point of view.

The project has excellent replication potential, in majority of the integrated and medium sizepaper mills, which are dependent on rivers for raw water intake.





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Case Study No.12

Installation of Variable Frequency Drive (VFD) for Process WaterPump

BackgroundIn a typical paper plant, the centrifugal pumps are major consumers of electrical energy. Thecapacity requirements of a centrifugal pump vary with the operating conditions and processrequirements.

Normally, the pumps are designed to operate at their maximum capacity and meet the peakload demand of the plant. However, these conditions do not arise all the time. Due to thevariation in demand, the system pressure also varies.

For example, when the header pressure varies between 3 kg/cm2 and 4 kg/cm2 (assuming therequired pressure is 3 kg/cm2) the header pressure will approach 4 kg/cm2, during the periodof low demand.

This indicates generation of higher pressure, when it is not required, and a potential for savingenergy to the extent of 25% [(4-3)/4 x 100] during low demand condition exists.

Previous statusIn a large integrated paper and paperboard plant, the process water pump was catering tothe water requirements in the plant.

The process water requirement was continuously varying, leading to fluctuations in the systemheader pressure between 3.0 and 4.0 kg/cm2.

The installation of a variable frequency drive can exactly match the process requirements andmaintain a constant pressure of 3 kg/cm2, resulting in energy savings.

Energy saving projectA variable frequency drive was installed for the process water pump, with a pressure indicatorcontroller (PIC) in a closed loop.

Concept of the projectA variable frequency drive (VFD) can exactly match the process requirements by varying theRPM. The PIC will continuously monitor the header pressure and give a signal to the VFDpanel to increase / decrease the RPM.

Whenever the process demand decreases, the header pressure increases above 3 ksc. ThePIC will sense this increase in pressure and will give signal to the VFD panel to reduce theRPM, to match the set point and vice-versa.



Implementation status, problems faced and time frameA variable frequency drive was installed for the process water pump, with a PIC in a closedloop. There were some minor problems of tuning the variable frequency drive during the initialstages.

The supplier’s service engineer rectified these problems. The implementation of the projectwas completed in 3 months time.

Benefits achievedThe benefit of installing the variable frequency drives, for the boiler ID fans and process waterpump are as follows:

Parameter Units Power cons. of processwater pump




Financial analysisThe annual energy saving achieved was Rs.1.15 million. This required an investment ofRs. 0.7 million and had an attractive simple payback period of 8 months

Replication potentialVariable speed drives are finding increasing application, not only from energy point of view,but also from process point of view. The application purely depends on the variation indemand and also the flexibility of operation desired.

In fact, some of the latest plants have almost 250-300 variable speed drives, a drive foralmost any application you can think of!!

Hence, variable speed drives have excellent application potential.





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Case Study No.13

Installation of Centralised Compressed Air System

BackgroundA centralised compressed air system has a single large / multiple number of compressors atone location. On the other hand, a decentralised compressed air system has multiple numbersof compressors, distributed over various locations.

Centralised compressor system is preferred in cases, where large capacity requirements atidentical pressure levels. In addition, they also have the following advantages

• The unloading operation of multiple compressors at different locations is avoided, therebysaving substantial energy.

• This eliminates the requirement of stand-by compressors resulting in avoiding the investmenton stand-by equipment at the design stage

• Leads to usage of high capacity compressor, which are generally more efficient, comparedto smaller ones.

Previous statusA large integrated paper plant, had two compressed air units, catering to the compressed airrequirements of the entire plant. These units were located at two different locations(decentralised).

The decentralised system necessitates the operation of multiple compressor units. This leadsto increase in both power consumption and mechanical maintenance problems.

Energy saving projectThe feasibility of installing a centralised compressed air system, in place of the decentralisedsystem was considered.

Concept of the projectFrom the energy efficiency point, a good compressed air system layout is the one which,offers the process the maximum plant efficiency and economy of operation.

Process variables, maintenance, location, capacity of the utilities and the energy consumptionmust all be considered for this purpose.

A centralised compressed air system has the following advantages over the decentralisedcompressed air system:

• Reduced power consumption

• Reduced manpower

• Better maintenance control



Implementation status, problems faced and time frameThe old compressed air pipelines were replaced with new pipelines, to reduce the leakagelosses and line friction losses. Further, the compressors were located at one central locationfor ease of operation and maintenance.

As compressed air is very vital for the efficient operation of instruments, the major problemthe plant team faced for the implementation of this project was the non-availability of a shut-down.

The major modifications could be carried out, only during the entire plant shut-down. Theimplementation of the project was completed in 18 months time.

Benefits achievedThere was a substantial reduction in the leakage losses and significant savings of power.There was a net reduction in power consumption by 53 kW, with the above modification. Themaintenance costs also have reduced considerably.

Financial analysisThe annual energy saving achieved was Rs.0.4 million. This required an investment ofRs. 0.7 million (for pipeline modification, civil works for relocation) and had an attractivesimple payback period of 20 months.

Replication potentialThe project has good replication potential in several integrated paper plants, considering theextent of compressed air distribution. The project also can be taken up in majority of themedium size paper mills.





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Case Study No.14

Installation of Heat of Compression (HOC) Air Dryers

BackgroundCompressed air is an important utility in process and engineering industries. Instrumentationapplications require dry air. Any moisture present in the compressed air will condense at thepoint of utilisation, causing damage to the instrumentation valves.

Drying of compressed air is achieved through various methods. However, the latest trend isto install heat of compression (HOC) dryers.

Heat of compression dryer is a major technological improvement, having the following distinctadvantages:

• Utilises the heat in compressed air for regenerating the dessicant

• Electrical heaters are eliminated

• No purge air losses

Low atmospheric dew point is achieved, depending on the dessicant used

Previous statusA large integrated paper and board plant had compressed air requirements of about 112 m3/min. About 50 m3/min of the compressed air was being dried using heater reactivated (lambda)type air dryer.

The heater was rated for 32 kW heating capacity. The purge air loss in the dryer was about10% of the total quantity of air being dried.

This type of air dryer in addition to being highly energy intensive, also leads to substantialquantity of compressed air losses.

Energy saving projectThe heater reactivated compressed air drier was considered for replacement with heat ofcompression (HOC) dryer, to reduce the operating cost of the drying unit.

Implementation status, problems faced and time frameAn HOC dryer was installed alongside the existing dryer and utilised for drying of compressedair. The dessicant used was activated alumina, which can give an atmospheric dew point of- 40°C.

Some minor problems were encountered during the implementation of this project and necessaryrectification measures were carried out. These are as follows:

• Due to the attrition of the dessicant, carry-over of the dessicant powder was observed.Entire quantity of the dessicant was removed, filtered and topped-up.


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• Solenoid valves, which operate the four-way valves, were not connected properly. Therouting of air was traced at different cycles and the valves were rectified.

• Heating and cooling cycle times were not properly set, leading to improper regeneration.This was studied and successfully corrected.

The project was commissioned during the shut down of the plant and was completed in 3months time.

Benefits achievedSubstantial power savings were achieved, on account of the elimination of heater operation.Also, compressed air losses were totally avoided, as there are no purge losses in HOC dryers.

Financial analysisThe annual energy saving achieved was Rs.0.7 million (Rs.0.34 million - on account of powersavings and Rs.0.36 million - due to elimination of purge losses). This required an investmentof Rs.1.48 millon, which had a simple payback period of 25 months.

Precautions to be taken for HOC dryer• Select the dessicant, depending on the required dew point, life of dessicant and cost of

dessicant

• If the temperature (at the discharge of the compressor) of air is less than 135°C, as in thecase of screw/ centrifugal compressors, additional heaters are required for regeneration ofthe dessicant

• Since air carries some dust, two after-filters need to be installed, one being a stand-by

Replication potentialAlmost all the paper plants, small, medium and integrated (barring a few), have reciprocatingtype air compressors and dessicant heated type or refrigerated type of drier.

This offers an excellent potential for increased adoption of HOC dryers by the Indian paperindustry.





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Case Study No.15

Installation of Blind Drilled Rolls (Dri-Press Rolls) instead ofConventional Press Rolls in Press Section of Paper Machine

Background

The press section, has a very important role in the drying process and hence, steamconsumption of paper machine.

the overall Chipper is the first major equipment in a paper plant. These chippers are used toproduce wood chips, from the raw materials like hard wood, bamboo etc., for further processingin the digester house.

Many of the old paper plants, in general, have conventional press rolls for de-watering. Thisled to non-uniform moisture removal, which in turn affected the throughput through the system.This resulted in very high specific steam consumption in the paper machine.

The recent technological advancements in water removal and increased runnability of papermachines have led to the development of the blind drilled rolls (or Dri-Press rolls).

The blind drilled rolls enable more efficient water removal than any other de-watering technique.

The installation of blind drilled rolls is gaining increasing popularity, especially among the largeintegrated paper plants.

Previous statusIn a large integrated paper plant, the press section had the conventional press roll. Thedryness achieved with the press roll was about 40-42%.

This system had the following disadvantages:

• Lower throughput

• Increased de-watering requirement

• Higher downtime due to higher breakages at wet end

• Higher purging requirements

• High specific steam consumption

The installation of Dri-press rolls, can result in higher throughput and lower specific energyconsumption.

Energy saving projectThe conventional press rolls were replaced with blind drilled rolls.

Advantages of the projectThese rolls have the following advantages:



• Higher dryness – The holes are precision drilled to optimize available land area and providinguniform sheet de-watering

• Dynamic nip conditions

• Higher throughput

• Improved sheet quality

• Reduced steam consumption

• Reduced downtime and labour costs

• Eliminates the need for purge showers

• Extended felt-life

• Elimination of crushing

• Elimination of marking

Hence, blind drilled rolls can be installed in the press section to achieve maximum energyefficiency.

Implementation status, problems faced and time frameThe plant team replaced the conventional press rolls with blind drilled rolls in the two papermachines in phases.

Initially, one paper machine was taken up for replacement and its performance was closelymonitored. On achieving satisfactory operating results, the second machine was replaced.

There were no major problems faced during the implementation of this project. Theimplementation of this project was completed during the planned shutdown.

Benefits achievedThe dryness with blind drilled rolls (for writing & printing paper) improved to 44-46%, ascompared to 40-42% with conventional press rolls, thereby, achieving 2-6% improvement indryness.

This results in equivalent savings in steam or fuel consumption. Besides, there was tremendousimprovement in machine runnability.

Financial analysisThe annual energy saving achieved was Rs.0.90 million. This required an investment ofRs. 2.4 million, which had a simple payback period of 32 months.





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Case Study No.16

Installation of Extended De-lignification Pulping Process insteadof Conventional Pulping

BackgroundThe pulping in pulp & paper industry is conventionally carried out in vertical stationary digestors.These digesters are operated at a temperature of 170°C and 8 ata pressure. The steam isdrawn from 12 ata header or the medium pressure steam extraction from turbine.

The total batch time (Lid-to-lid) varies between 5 – 7 hrs, depending on furnish, black liquorratio and steam pressure & temperature.

The vertical digesters are highly energy intensive, consuming typically about 1.4 -1.5 tons ofsteam/ ton of FNP. Also, during blowing operation, substantial amount of heat loss takesplace, besides, loss of chemicals and increase of effluent load.

The latest technological advancements pulping have led to the adoption of extendeddelignification pulping process.

The extended delignification pulping process is not only energy efficient, but also environmentfriendly. The system has the following features:

• Majority of heat is recycled in the system. The recycled heat is stored in the form of hotblack liquor and white liquor

• Pulp is blown at lower temperature, resulting in lower heat loss from the system

• Alkali rich white liquor addition takes place only at 115°C. This makes it more reactive withalkali and aids in making the cook more selective leading to extended delignification.

• After cooking is over, the final displacement is performed with washer filtrate, eliminatingthe need for one stage of washing

The installation of extended delignification pulping process can result in substantial benefits,especially among large integrated paper plants.

Previous statusIn a large integrated paper plant, the digestor house had conventional vertical stationarydigestors, having a combined capacity of 250 Tons of BD pulp/day.

The operating parameters were as follows:• Steam consumption = 1.42 tons / ton of FNP• Batch time = 6 hours (avg. time)• Kappa number = 21-22• Yield = 45.3%• Washing loss = 16 kg/ ton of pulp (as sodium sulphate)• Black liquor conc. = 14.2%• Ash retention = 7%• Paper breakage = 3.3%


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Energy saving projectThe conventional vertical digesters were replaced with extended delignification pulping process.

The major advantages of the project are:

• Upto 75% reduction in steam demand

• Higher brightness levels can be achieved due to low Kappa numbers

• Considerable savings in bleaching chemicals

• Uniform and better pulp quality (15-20% increase in tear/ tensile strength), resulting in bettermachine runnability and efficiency

• Increased yield - atleast 46% possible

• Reduction in washing loss leading to reduction of make-up chemicals

• Reduced load on effluent treatment plant

• Due to in-digestor washing, one stage of washing gets eliminated

• Low screen rejects due to uniform cooking

• Lower black liquor viscosity allows feeding the boiler at 75+% solids

• Reduction of steam demand in evaporators

Implementation status, problems faced and time frameThe plant team replaced the conventional vertical digestors with 3 new digestors of 80-tons/day of BD pulp capacity, based on rapid displacement heating pulping process.

There were no major problems faced during the implementation of this project. Theimplementation of this project was taken up parallel to the old pulp mill, to ensure that, theplant shutdown was kept minimal.

Benefits achievedThe operating parameters were as follows:

• Steam consumption = 0.70 tons / ton of FNP

• Batch time = 4 hours (avg. time)

• Kappa number = 12-13

• Yield = 46%

• Washing loss = 10 kg/ ton of pulp (as sodium sulphate)

• Black liquor conc. = 16%

• Ash retention = 10%

• Paper breakage = 1.5%

The reduction in chemical consumption was about 50%.



Financial analysisThe total annual savings achieved was Rs.140 million. This required an investment ofRs.500 million, which had a simple payback period of 42 months.

Replication potentialThere is only one plant in India, which has installed the extended delignification pulpingprocess. Hence, the replication potential for this project is enormous.





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Case Study No.17

Improved Paper Machine Design to Improve Production

BackgroundThe success of a paper mill is determined not only on the basis of quality and quantity of paperproduced, but also on productivity. Efficiency of paper machine plays a vital role in achievingrunnability and hence, productivity.

There are a number of limiting factors, which affect the efficiency and economics. Typically,agro-fibres have lower strength, which in turn affect the machine runnability. Also, use of agro-fibres results in lower water drainage and higher power consumption.

The identification of limiting factors and modifications to overcome them, becomes extremelynecessary to optimise the productivity of the paper machine, without affecting the quality ofpaper.

Previous statusIn an agro-residue based paper mill, renewable agro-waste, such as, wild grasses and strawswere being used for making high quality writing & printing paper.

This system had the following features:

• Stationary showers in head box

• Wire return roll driven by a separate motor, causing unequal tension, leading to creasingof fabric

• Speed of machine restricted, due to lower diameter of dandy roll, only 700 mm dia leadingto limited production

• HDPE tops for paper machine

• Perennial problem of shadow marking in press part due to suction pickup roll

• SLDF screen for dryer part

• Static current problem in between calender and pope reel

A critical study was conducted to modify its paper machine, to improve its efficiency in termsof quality and productivity.

Energy saving projectThe plant team applied various modifications, right from head box to dryer part in papermachine.

The details of the modifications are as follows:

• Energy efficient rotary showers installed in head box, in place of stationary showers

• Wire circuit provided with an additional roll to improve wrap on FDR

• Motor used for wire return roll removed


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• Diameter of dandy rolls increased to 1200 mm to increase speed of paper machine, enhanceproduction and provide for water-marks

• Ceramic tops installed in place of HDPE tops in paper machine

• Suction pick-up roll modified to suction cum BDR to avoid shadow marking and ensurebetter sheet dryness

• Speed difference between wire and pickup roll reduced, resulting in improved life of pickupfelt life

• SLDF screen replaced with woven screen for better sheet flatness and prevent screenmarking

• Static current remover installed between calender and pope reel

Implementation status, problems faced and time frameThe plant team carried out the modifications on the paper machine in phases. The measureswere taken up one-by-one to observe the benefits. On achieving satisfactory operating results,the other measures were taken up. There were no major problems faced during theimplementation of this project.

Benefits achievedThe following benefits were achieved:

• Shower modification in head box resulted in better foam killing and reduced breaks due tofoam lumps

• Additional role avoided the wire slippage and consequent fabric damage

• Increase in speed of machine from 250 m/min with 115 RPM dandy roll to more than 350m/min with 95 RPM dandy roll

• Elimination of fabric creasing, shadow marking problems

• Increased felt and wire life

• Increase in ash retention by over 1%

• Sheet dryness improved from 10.5% to 16% after suction box

• Constant moisture level at pope reel

• Consistency in grammage

Financial analysisThe total annual savings achieved on account of the various modifications wasRs.18.30 million.

Replication potentialAs about 31% of the paper mills are based on agro-residue, and also majority of the papermills are looking at capacity augmentation without any major investments, the de-bottleneckingroute could be a major opportunity to increase their competitiveness. Hence, this project hasvery good replication potential, particularly in the older mills having multiple number of smallerpaper machines.


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Larsen & Toubro Limited Raw material handling & preparationIndustrial Machinery Heavy Engineering Division Pulping of wood & non-wood materialKansbahal Dist. Sundargarh – 770034 Waste paper treatment & de-inkingTel. : 0661 - 22280241/ 0101/ 0145 Secondary fibre generationFax : 0661 - 22280243/ 0557 Stock preparation & approach flowEmail : [email protected] Paper & boards machine from headbox

Winder and auxiliary systems

Enmass Andritz Private Limited Design, manufacture, supply and service ofIV Floor, Guna Building Annexe Recovery boilersNew No. 443, Old No. 304 Falling film evaporatorsAnna Salai Chennai – 600 018 Lime kilnsTel. : 044 – 24338050/ 51 RecausticizersFax : 044 – 24322412 Desilication plantEmail : [email protected] :

Kvaerner Pulping S.A. (Pty) Ltd Supplier of machines and systems toPostnet Suite 235, Private Bag X504 chemical and recycled pulp industriesNorthway 4065, Durban Republic Supplier of pollution control systemsSouth Africa ZA and specialised process technologyTel. : +27 (0) 31 303 8940Fax : +27 (0) 31 303 8949Email : [email protected] : www.akerkvaerner.com/fiberline

Mechano Paper Machines Ltd. Total solutions for pulp & paperNew Jessore Road Ganganagar machines Kolkatta – 700 132Tel. : 033 – 2538 3744Fax : 033 – 2538 4952

Sulzer Pumps India Limited All types of centrifugal pumpsNo.9, MIDCThane-Belapur Road, MC pumpsDighaNavi Mumbai – 400 708 Wear resistant pumpsTel. : 022 – 55904321 Acid resistant pumpsFax : 022 – 55904302Web : www.sulzerpumps.comName of Company and Address Area of expertise

Hindustan Dorr-Oliver Limited Pulp & paper mill equipmentDorr-Oliver House Chakala, Liquid-solid separationAndheri East Mumbai – 400 099 Environmental pollution controlTel. : 022 – 2832 5541, 2832 6416/ 17/18 Water treatmentFax : 022 – 2836 5659Email : [email protected] : www.hind-dorroliver.com

9.0 List of Contractors/ Suppliers




The Eimco-KCP Limited Solids-liquid separation equipment likeRamakrishna Buildings rotary vacuum filters, thickeners, clarifiers,239, Anna Salai Chennai – 600 006 classifiers etc.Tel. : 044 - 28555171 Water & waste water treatment plantsFax : 044 – 28555863Email: [email protected] : www.ekcp.com

FFE Minerals India Limited Material handling systemsFFE Towers, 27 G N Chetty Road Classification, filtration andT Nagar Chennai – 600 017 thickening technologiesTel. : 044 – 28220801/ 02, 28252840/ 44 Crushing and grindingFax : 044 – 28220803 Calcination, roasting, sintering, dryingEmail : [email protected]

Alfa Laval India Ltd. EvaporatorsMumbai -Pune RoadDapodi Pune - 411 012Tel. : (020) - 24116100 / 27107100Email : [email protected] : www.alfalaval.co.inContact : Mr Neeru Pant

Johnson India Steam engineering and consultancy3, Abirami Nagar, G.N. Mills PostCoimbatore – 641 029Tel. : 0422 - 2442692Fax : 0422 - 2456177email: [email protected]

Elof Hansson (India) Pvt. Ltd. Paper plant machineryOld No.11, New No.23, II Main Road Paper plant ChemicalsR A Puram Chennai – 600 028Tel. : 044 - 24617901/ 902/ 903/ 904Fax : 044 – 24617907/ 908Email : [email protected]

Pap-Tech Engineers & Associates Controls for paper machine pH, FlatR-22/301, Khaneja Complex box vacuum, Couch pit, Dry end pulperMain Market, Shakarpur and RefinerNew Delhi – 110 092 Consistency controlTel. : 011 – 22232003, 22219130 QCS/PLC/SCADA automationFax: 022 – 22219130, 22422664 Basis weight control valve packageEmail : [email protected] Cascade control of steam & condensateWeb : www.paptechinstruments.com

Ruby Macons Limited Screening equipment789/4, III Phase Road, GIDCVapi – 396 195Tel. : 0260 – 2410901 to 908Fax : 0260 – 2410910Email : [email protected] : www.rubymacons.com


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Rhetoric Technologies (P) Ltd. Turnkey projectsR-22/301, Khaneja Complex Suction pick-up roll cum press rollMain Market, Shakarpur internals for bi-nipNew Delhi – 110 092 Auto guide for felt and wireTel. : 011 – 22232003, 22219130Fax : 022 – 22219130, 22422664Email : [email protected] : www.paptechinstruments.com

Porritts & Spencer (Asia) Ltd. Complete range of paper113/114 A, Sector 24 machine clothingFaridabad – 121 005Tel. : 0129 - 25233721/ 22/ 23Fax : 0129 – 25234424Email : [email protected]

Parason Machinery (I) Pvt. Ltd. Stock preparation equipment”Parasons House”, Venkatesh Nagar and systemsOpp. Jalna Road Hi-consistency pulperAurangabad – 431 001 Forming machineTel. : 0240 – 2339234/ 35/ 36/ 37Fax : 0240 – 2332944Email : [email protected] : www.parasonmachinery.com

Ambica Paper Machineries Centri-cleaner system7, Karunasagar Estate High density cleanerOpp. Anil Starhc Prod. Ltd., Shower pipes & nozzlesAnil Road Ahmedabad – 380 025 Oscillating showersTel. : 079 - 22201089, 22201298Fax : 079 – 22202668Email : [email protected] : www.ambicamachineries.com

Swetha Engineering Limited Drum chippers, chip screens, rechippers121 – 133, Tass Industrial Estate Digesters, Blow tanks, Liquor preheatersAmbattur Chennai – 600 098 Blow heat recovery systemTel. : 044 - 26252191/ 3191 Screw pressesFax : 044 – 26250836 UTM pulpersEmail : [email protected] Agitators Multi effect evaporators

Indo Gears and Machinery (India) Tri Disc refiners48, New Arya NagarChowk Meerut RoadGhaziabad – 201 001Telfax : 0120 – 22714877




Nash Water Technology Private Limited67-UPS, Lake RoadKaggadaspura Extn.C V Raman Nagar Bangalore - 560 093Tel. : 080 – 25246374Fax : 080 – 25246445

Nash International Company Water ring vacuum pumpsNo. 1 Gul Link Singapore 629371Rep. of SingaporeTel. : (65) 861 6801Fax : (65) 861 5091Email : [email protected] : www.nasheng.com

PPI Pumps Pvt. Ltd. Water ring vacuum pumps4/2, Phase 1, GIDC Estate, VatvaAhmedabad – 382445Tel. : 079 – 25832273/4, 25835698Fax : 079 – 25830578Email : [email protected] : www.prashant-ppi.com

Dandy Rolls India Pvt. Ltd. Dandy rollsA – 179, 4th Cross, I Stage Industrial Estate, Auto guidesPeenya Bangalore – 560008Tel. : 080 - 28394381Fax : 080 -28398112

SWIL Limited Dandy rolls & brackets27 –A, Camac Street Kolkkata – 700 016 Shower systemsTel. : 033 - 22473375 to 78 Synthetic fabric clothingFax : 033 – 22473378 Metallic wire cloth

Gala Equipment Limited Vibro-screensA-59, Road No.10 Wagle Industrial AreaThane – 400 604Tel. : 022 – 25820746/ 8934, 25800252Fax : 022 – 25820771Web : www.galagroup.com

Lathia Rubber Mfg. Company Pvt. Ltd. Blind drilled rollsSaki Naka, Kurla-Andheri Road Industrial rubber/ ebonite rollersMumbai – 400 072Tel. : 022 – 28519140Fax : 022 – 28513797


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10.0 List of Consultants


Indian Companies v Project consultancy in paper plants &SPB Projects and Consultancy Limited power plantsEsvin House, Perungudi v Management servicesChennai – 600 096Tel. : 044 – 24961056/ 1079/ 0359Fax : 044 – 24961625Email : [email protected]

TCE Consulting Engineers Limited v Preliminary planningTata Press Building v Detailed project reports414, Veer Savarkar Marg v Basic and detailed engineeringMumbai – 400 025 v Procurement, inspection & expeditingTel. : 022 - 24374374, 24302419 v Project managementFax : 022 – 24374402 v Construction supervisionEmail : [email protected] v Assistance in start-up testing andWeb : www.tce.co.in commissioningContact : Mr M G YagneshwaraGroup Commercial Manager

Development Consultants Limited v Preliminary planning and surveying24-B, Park Street Kolkata - 700016 v Detailed project reportsTel. : 033 - 22267601, 22497603 v Basic and detailed engineeringFax : 033 - 22492340/3338 v Procurement, inspection & expeditingEmail : [email protected] v Project construction and management

v Structural engineeringv Technical management

Engineers India Limited v Preliminary planningEngineers India Bhavan v Detailed project reports1, Bhikaji Cama Place New Delhi – 110 066 v Basic and detailed engineeringTel. : 011 - 26186732, 26102121 v Procurement, inspection & expeditingFax : 011 – 26194760, 26178210 v Project managementEmail : [email protected] : www.engineersindia.comContact : Mr D K Gupta, General Manager – Mktg.

UHDE India Limited v Preliminary planningUHDE House, LBS Marg v Detailed project reportsVikhroli (W) Mumbai – 400 083 v Basic and detailed engineeringTel. : 022 - 25783701, 25968000Fax : 022 – 25784327Email : [email protected] : www.uhdeindia.com




Kvaerner Pulping Pte. Ltd. v Providing engineering, design, fabrication152 Beach Road #24-02/04 and project management services forGateway East Singapore 189721 • FiberlinesTel. : +65 6392 8500 • Recovery boilers • Power boilersFax : +65 6392 8511Email : [email protected] : www.akerkvaerner.com/fiberline

Chellam Project Consultancy and • Comprehensive consultancy services toTechnical Services Pvt. Ltd. pulp & paper industry46, Krishna Complex, 4th FloorChevalier Sivaji Ganesan RoadT Nagar Chennai – 600 017Tel. : 044 – 2430698/4491Email : [email protected]

International Companies • Project consultancy in paper plants &Jaako Poyry OYP O Box 4, power plantsJaakonkatu 3FIN – 01621 VANTAA Management servicesFinlandTel. : +358 – 9 – 89471/89472678Fax : +358 – 9 – 8781818Email : [email protected] : Mr Ari Runsten, Sr. Process Engr.Pulping Process Dept.

AMEC Simons Forest Industry Consulting • Project consultancy in paper plants111 Dunsmuir St, Suite 400Vancouver, BCCanada, V6R 1R3Tel. : 1- 604 – 6644402Fax : 1- 604 – 6645381E-Mail: [email protected] : Mr Phil Crawford, VP & GM

Forest Industry Consulting • Project consultancy in paper plantsMetso PaperSE – 85194Sundsvall SwedenTel. : +46 – 60 – 1650 00 / 1651 77Fax : +46 – 60 – 165500Mobile : +46 – 70 – 653 3801Email : [email protected] : Mr Yngve LundahlRegional Sales Manager - Fiberline


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EKONO Inc. • Project consultancy in paper plants11061 NE 2nd Suite 107, BellevueWA 98004Tel. : (425) 455 5969Fax : (425) 455 3091E-mail : [email protected]

Associated Professional Engineering • Engineering servicesConsultants, Inc. (APEC) • Professional services865 West Central Avenue • Consulting servicesSpringboro Ohio 45066 – 1115 • Feasibility studiesTel. : 937 - 746 - 4600 • Scope developmentsFax : 937 - 746 – 5569 • Capital cost estimatesEmail : [email protected] • Construction progress monitoringContact : Mr. Richard Ostberg, President • Start-up assistance

• Extensive work in Pulp Mills, De-inking,Fiber Preparation Systems, Paper Machine,Utilities and Coating

Tavistock International • Mill managementLe Rondrais, 56350 Allaire France • Start-up assistanceTel. : +33 (0)2 99 71 8069 • Integrated solutionsFax : +33 (0)2 99 71 8069 • Non-wood speciality know-howEmail : [email protected] • Feasibility studies

Voith Paper Holding GmbH & Co. KGCorporate Marketing St.Pöltener Str. 43D-89522Heidenheim GermanyTel. : +49 73 21 37-64 05Fax : +49 73 21 37-70 08Email : [email protected] : www.voith.com


310Energy Conservation in Fertilizer

Fertilizers




Energy saving potential 2000 million (USD 40 million)

Investment potential onenergy saving projects 6000 million (USD 120 million)


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1.0 IntroductionAgriculture accounts for a third of India’s national income. The agricultural sector providesdirect employment to over 70% of the country’s population.

The issues of productivity and growth of agriculture are important indicators of the economicgrowth of any country. Fertilizers play a key role in improving crop yield and hence are integralto modern farming.

Growth in chemical fertilizer production and consumption therefore presents the single largestcontributor to agricultural progress, its technological transformation and commercialization.

2.0 About FertilizerThe main primary nutrients that deplete with successive cropping are nitrogen (N), phosphorus(P) and potassium (K). Fertilizers supplement the natural deficiency as well as the depletionof nutrients.

Nitrogen is primarily provided by nitrogenous fertilizers, such as, urea (46%N) or ammoniafertilizers, e.g. ammonium sulfate (20.6%N). Further shares of nitrogen are contained incomplex fertilizers that combine all three-plant nutrients (NPK).

Phosphate comes in the form of straight phosphatic fertilizers, such as, single super phosphate(16%P2O5) or as part of a complex fertilizer. Potassic fertilizer is available as straight potassicfertilizer, such as muriate of potash (60%K2O) or sulfate of potash (50%K2O) or as a complexNPK fertilizer component.

3.0 Types of fertilizersThe key fertilizers used in India are:

Urea supplies around 83% of the total nitrogen requirements. It is manufactured from ammoniain an energy intensive process. Natural gas is the preferred feedstock as it results in lowvariable cost compared to naphtha. At present, only 50% of the total domestic capacity is gas-based, about 30% is based on naphtha and rest on fuel, oil and coal.

Single super phosphate supplies 19% of the total phosphatic nutrients. It is manufactured bytreating rock phosphate with sulphuric acid and calcium. Both rock phosphate and sulphur areimported.

Di-ammonium phosphate meets 50% of phosphatic and 8% of nitrogenous nutrients. Rockphosphate is the main feedstock. Phosphoric acid is manufactured by treating rock phosphatewith sulphuric acid. It is then reacted with ammonia to manufacture DAP.

The integrated manufacturers have their own ammonia, phosphoric acid and sulphuric acidplants, while sulphur and rock phosphate are imported.

Potassium fertilizers are not manufactured in India due to the non-availability of the basicfeedstock. Muriate of potash (MOP) is imported from countries like Canada, Jordan andGermany.

Urea being the most affordable fertilizer, dominates the nitrogenous fertilizers, constitutingmore than 80% of consumption. DAP is the dominant phosphatic fertilizer accounting for 58%



of consumption, followed by SSP with a 20% share. During the year 2001-2002, the NPK ratiodeteriorated to 8.5:3.1:1 from 7.9:2.9:1 in 2000-2001.

4.0 Growth of Fertilizer IndustryAgricultural growth is mainly dependent on advances in farming technologies and increaseduse of chemical fertilizers.

4.1 World ScenarioThe capacity and production (in thousand tones of nutrients) of Nitrogen, Phosphate andpotash nutrients in the world are as follows:

Nitrogen Phosphate Potash

Capacity Production Capacity Production Production

125721 84616 40259 31704 25541

The world ammonia productions, increased by about 5% in 2002, while the world urea productionincreased by about 4%.

The average per capita consumption of fertilizer is about 22.1 kg and 91.1 kg/ha.

4.2 Indian Scenario

4.2.1 Installed capacityThe first fertilizer-manufacturing unit was set up in 1906 at Ranipet near Chennai with aproduction capacity of 6000 MT of Single Super Phosphate per annum. The 80’s witnesseda significant addition to the fertilizer production capacity.

India is presently the second largest Nitrogeneous fertilizer manufacturer and thirdlargest Phosphatic Fertilizer manufacturer in the world, accounting for almost 10.9%and 3.8% of the world production, respectively.

The present installed capacity of fertilizer production in India is about 120 lakh MT ofnitrogen and 51.37 lakh MT of phosphate nutrients.

In future, demand is expected to grow at a compound annual growth rate (CAGR) of4%.

4.2.2 Capacity UtilizationExternal factors, such as, weather and monsoon conditions, as well as policy changes regardingfertilizer production, use and agricultural output enhancement exert significant influence oncapacity utilization in the industry.

Against this background, there has been an overall improvement in the levels of capacityutilization over the years. During 1999-2000, the capacity utilization was 100.7% in the caseof nitrogeneous and 94.0% in the case of phosphatic fertilizer plants.


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The capacity utilization of the fertilizer industry is expected to improve as more modern plantsbased on proven technology and equipment go on stream.

The existing plants in the private, public and co-operative sectors are improving their capacityutilization, through revamping & modernisation and incorporation of dual fuel/ feedstock facilities,wherever feasible.

4.2.3 Per Capita ConsumptionThe per capita consumption of fertilizer in India, which was a meager 1 kg in the early 50’s,has increased substantially to about 16.3 kg in 2000-2001.

The per capita fertilizer consumption in different countries is highlighted in the table below:

Country Fertilizer FertilizerConsumption Consumption(per capita) (kg/ha)

India 16.3 98.4

China 26.6 254.2

Japan 11.4 301.0

Egypt 18.4 385.8

Bangladesh 9.4 156.3

Pakistan 20.5 135.1

France 69.7 211.7

Russian Fedn. 9.8 11.2

UK 28.5 285.8

USA 64.7 103.4

World 22.2 91.1

Source FAI

5.0 Profile of Manufacturing UnitsAt present, there are 64 large size fertilizer units in the country, manufacturing a wide rangeof nitrogenous and phosphatic/ complex fertilizers.

Of these, 39 units produce urea, 18 units produce DAP and 7 units produce ammoniumsulphate as a by-product. Besides, there are about 79 small and medium scale units producingsingle superphosphate.

The fertilizer industries are categorised under public sector, cooperative sector and privatesector. The public sector units account for about 47% of the total installed capacity in fertilizerindustry in India. The private sector accounts for about 36% and the co-operative sector forthe remaining 17%.



While most of the nitrogenous fertilizer production capacity can be found in the public sector,phosphatic fertilizer capacity is mainly installed in the private sector.

The table below highlights the sector wise installed capacity of fertilizer plants in India.

Sector Installed Capacity (‘000’MT)

Quantity N P

Public 12390.6 4319.8 827.0

Cooperative 6200.0 2348.4 519.2

Private 17589.6 4402.9 2301.7

Total 36180.2 11071.0 3647.9

5.1 Distribution of Manufacturing UnitsThe plants are located all over India. Also, the consumption of chemical fertilizers in thecountry is unevenly distributed, being much higher in regions with assured irrigation.

The region-wise break-up of number of industries and capacity is highlighted below:

Nitrogeneous Fertilizers Phosphatic Fertilizers

Region Numbers % share to Numbers % share tooverall capacity overall capacity

East 10 4.00 6 29.86

West 15 45.72 43 41.97

South 12 1740 11 25.12

North 9 32.88 13 3.05

Total 46 100.0 73 100.0

5.2 Major players in IndiaThe major fertilizer nitrogeneous and phosphatic fertilizer industries in India, are given below:

5.2.1 Nitrogeneous Fertilizer Units• BVFCL, Namrup III ( Assam)

• CFL Vizag ( AP)

• Chambal Fert Garde, Kota ( Raj)

• Cyanides & Chemicals Surat ( Gujarat)

• Deepak Fert; Osers & Petro Chemicals Corpn. Taloja ( Maha)

• Duncans Industries ( Fomerly ICI India and later Chand Chhap Fert)

• EID Parry ( India) Ennore ( TN)

• FACT


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a) Alwaye (Kerela)b) Ambalamedu Cochin I (Kerala)c) Ambalamedu Cochin II (Kerala)

• FCI Sindri (Jharkhand)

• Godavari Fertilisers & Chemicals, Kakinada ( AP)

• GNFC, Bharuch ( Gujarat)

• GSFCa) Vadodara (Gujarat)b) Vadpdara (Gujarat) Polymer Unitc) Sikkar I (Gujarat)

• HLCL Haldia ( West Bengal)

• IFFCOa) Kalol (Gujarat)b) Kandla ( Gujarat)c) Pulpur ( UP)d) Aonla(UP)

• Indo Gulf Corpn. (Unit: Fertilisers) Pvta) Jagadishpur (UP)b) Dahej( Gujarat)c) KRISBHO, Hazira (Gujarat) 2 plantsd) MFL Manali ( TN)e) MCFL, Mangalore ( Karnataka)f) Nagarjuna Fetilizers & Chemicals, Kakinada ( AP)

NFLa) Bhatinda ( Punjab)b) Nangal I & II ( Punjab)c) Panipat ( Haryana)d) Vijaipur ( MP)e) NLC, Neyveli ( TN)

Oswal Chemicals& Fertilisersa) shajahanpur(UP)b) Pradeep (Orissa)

Punjab National Fertilisers & Chemicals, Naya Nangal ( Punjab)

RCFL:a) Thal Vaishet ( Maha) 2 plantsb) Trobay ItoIV (Maha)

Trombay V ( Maha)

Rashtriya Ispat Nigam, Visakhapatnam( AP)

SAILa) Bhilai ( Chattisgargh)



b) Bokaro ( Jharkhand)c) Durgapur( WB)d) IISCO, Burnpur –Kulti( WB)e) Rourkela ( Orissa)f) Rourkela ( Fert. Plant Orisa)g) SFC, Kota ( Rajasthan)

SPIC, Tuticorin( TN)Tata Chemicals Babrala( UP)Tuticoring alkali Chemicals & Fertilisers, Tuticorin(TN)ZIL, Zurai Nagar (Goa)Under ImplementationBVFCL, Namrup II ( Assam) Revamp (Pun)BVFCL, Namrup III ( Assam) Revamp ( Pun)Gujarat State Fertilisers & Chemicals pvt Sikka II ( Gujarat)Under ConsiderationIFFCO, Nellore ( Andhra Pradesh)KRIBHCO, a) Hazira, Phase II Guj) b) Gorakhpur ( UP)RCFL,Thal Vaishet ( Maharashtra )III StageICS SenegalICS, Senegal ( Expn)Indo Jordan Chemicals CoIndo Maroc Phosphore S ASPIC Fert Chem LtdOman India Fert. Co

5.2.2 Phosphatic Fertilizer UnitsAndhra Sugars, Tanuku, W Godavari ( AP)Arawali Phosphate, Umra, Udaipu (Raj)Arihant Fertilisers & chemicals, Neemuch ( MP)Arihand Phosphate & Fertilizers, Nimbaheda, Chittorgarh ( Raj)Asha Phosphate, Jaggakhedi, Mandsaur ( MP)Asian Fertilizers, Gorakhpur ( UP)Basant Agro Tech ( India) Akola ( Mah)BEC Fertilisers ( Unit of Bhilai Engg. Corpn. Ltd)

a) Bilaspur, (Chhattisgarh)b) Pulgaon, Wardha, (Maj)

Bharat Fertilisers Industries ( Maharashtra) Kharivali, Thane ( Mah)Bohra Industries Umra, udaipur (Raj)Chemtech Fertilizers, Kazipalli, Medak ( AP)Coimbatore Pioneer Fertilizers, Coimbatore ( TN)Dharamsi Morarji Chemicals Co., Ambernath ( Mah)Dharamsi Morarji Co., Kumhari ( Chhattisgarh)Dharamsi Morarji Chemicals Co Amreli (Guj)


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Dharmsi Morarji Chemicals Co., Khemli ( Raj)EID Parry (India) Ranipet ( TN)Gayatri Spinners, Hamirgarh ( Raj)HSB Agro Industries, Shahpur, Dist Hoshipur (PB)Hind Lever Chemicals Ltd Haldia( WB)Jairam Phosphates, Gudichiroli ( Mah)Jayshree Chemicals & Fertiliser Khardah ( WB)Jayshree Chemicals & Fertilizers Unit III Pataudi ( Haryana)Jubilant Organosya Gajraula ( UP)Kashi Urvarak, Jagadishpur Sultanpur ( UP)Khaitan Chemicals & Fertilizers Nimrani, Khargone ( MP)Khaitan Fertilizers, RampurKothari Industrial Corporation Ennore (TN)Krishna Industrial Corporation, Nidadavole (AP)Liberty Phosphate

a) Madri Udaipur ( Raj)b) Vadodara (Guj)

Madhya Bharat Agro products, Sagar ( MP)Madhya Pradesh Orgochem, neemuch, Nayagaon ( MP)Mahadeo Fertilizers fatehpur ( UP)Maharastra Agro industrial development panvel ( mah)Mangalam phosphates, hamirgarh, bhilwara ( Raj)Mardia Chemicals Surendra Nagar ( Gujarat)Mexican Phosphates Nimrani, Khargone ( MP0Mukteswar Fertilizers, Narayankhedi, Ujjain (MP)Narmada Agro Chemicalst, Junagadh( Guj)Nirma Limited, Moralya (Guj)Natraj Organics Muzaffarnagar( UP)Oriental Carbon & Chemicals, Dharunhera( Har)Phosphate Co, Rishra ( WB)Pragati Fertilizers Vizag( AP)Prem Shakhi Fertilizers, lakadwas, Udaipur ( Raj)Prathyusha Chems and Fertilisers, Visakhapatnam (AP)Priyanka Fertilizers & Chemicals, Anakapalli, Visakhapatnam ( AP)Rajalaxmi Agrotech, Jalna ( Mahrastra)Raashi Fertilizers Lakhmpur, Nasik ( Mah)Rama krishi Rasayan, Lkoni Kalbhor ( Mah)Rama Phosphates, Indore ( MP)Rama Phosphates Udaipur (Raj)Ravi Pesticides Bijnaur (UP)Rewathi Minerals and Chemicals, Hirapur, Sagar ( MP)Sadana Phosphates & Chem. Udaipur (Raj)Shiva Fert. Nanded ( Mah)Shree Acids & Chemicals Gajraula ( UP) Shreej Phosphate, Kallipura, Jhabua ( MP)Shri Bhavani Mishra Fertilizers Nanded ( Mah)



Shri Ganpati Fetilizers, Muzaffarpur ( Bihar)Sona Phosphates Sarigam, Valsad ( Guj)Shurvi Colour Chem ( Raj)Swastik Fetilizers, jhansi ( UP)Sri Durga Bansal, Faizabad ( UP)Subhodaya Chems, Gauri Patnam ( AP)Teesta Agro Ind ( Fromely Suderban Fert. And Chem) Jalpaiguri ( WB)TEDCO Granites, Bhilwar (Raj)Tungabhadra Ferts. Chems Koppal Hospet (Karnataka)

6.0 Raw Material Profile

6.1 Nitrogeneous fertilizersDomestic raw materials are available only for nitrogenous fertilizers. For the production ofurea and other ammonia-based fertilizers, methane is the major input.

Methane is obtained from natural gas/ associated gas, naphtha, fuel oil, low sulfur heavystock (LSHS) and coal.

Of late, production has switched over to use of natural gas, associated gas and naphtha asfeedstock. Out of these, associated gas is most hydrogen rich and easiest to process, dueto its lighter weight and fair abundance within the country.

However, demand for gas is quite competitive since it serves as a major input to electricitygeneration and provides the preferred fuel input to many other industrial processes.

6.2 Phosphatic fertilizersFor production of phosphatic fertilizers, most of the raw materials have to be imported. Indiahas no source of elemental sulfur, phosphoric acid and rock phosphate.

Some low-grade rock phosphate is domestically mined and made available to rather small-scale single super phosphate fertilizer producers.

Sulfur is produced as a by-product by some of the petroleum and steel industries.

7.0 Process descriptionThe basic raw material for the production of nitrogenous fertilizers is ammonia, for straightphosphatic fertilizers, phosphate and for potassic fertilizers, potash. Out of the three fertilizertypes, production of ammonia is most energy and resources intensive.

7.1 Ammonia productionThe most important step in producing ammonia (NH3) is the production of hydrogen, whichis followed by the reaction between hydrogen and nitrogen. A number of processes areavailable to produce hydrogen, differing primarily in type of feedstock used.


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The hydrogen production route predominantly used worldwide is steam reforming of naturalgas. In this process, natural gas (CH4) is mixed with water (steam) and air to producehydrogen (H2), carbon monoxide (CO) and carbon dioxide (CO2).

Waste heat is used for preheating and steam production, and part of the methane is burnt togenerate the energy required to drive the reaction. CO is further converted to CO2 and H2using the water gas shift reaction. After CO and CO2 is removed from the gas mixtureammonia (NH3) is obtained by synthesis reaction.

Another route to produce ammonia is through partial oxidation. This process requires moreenergy (up to 40-50% more) and is more expensive than steam reforming. The advantage ofpartial oxidation is high feedstock flexibility: it can be used for any gaseous, liquid or solidhydrocarbon.

In practice partial oxidation can be economically viable if used for conversion of relativelycheap raw materials like oil residues or coal.

In the partial oxidation process, air is distilled to produce oxygen for the oxidation step. Amixture containing among others H2, CO, CO2 and CH4 is formed.

After desulfurization CO is converted to CO2 and H2O. CO2 is removed, and the gas mixtureis washed with liquid nitrogen (obtained from the distillation of air). The nitrogen removes COfrom the gas mixture and simultaneously provides the nitrogen required for the ammoniasynthesis reaction.

7.2 Nitogeneous fertilizersA variety of nitrogenous fertilizers can be produced on the base of ammonia. Ammonia canbe used in a reaction with carbon dioxide to produce urea.

Ammonia nitrate can be produced through the combination of ammonia and nitric acid addingfurther energy in form of steam and electricity.

Other fertilizer types produced on the base of ammonia include calcium ammonium nitrate(ammonium nitrate mixed with ground dolomite) and NP/NPK compound fertilizers.

7.3 Phosphatic fertilizersPhosphatic fertilizers are produced on the basis of phosphoric and sulfuric acids. Phosphoricacid is produced, by the leaching of phosphate rock, with sulfuric acid. Sulfuric acid very oftenremains as a waste product of the chemical industry.

7.4 Potash fertilizersPotash fertilizers are produced from sylvinite salt. Sylvinite is diluted in a circulation fluid inthe flotation process. The potash fertilizer is separated, by skimming the solution.

8.0 Energy IntensityThe fertilizer industry is one of the major consumers of hydrocarbons. The fertilizer sectoraccounts for 8.0% of total fuels consumed in the manufacturing sector.



Energy costs account for nearly 60% of the overall manufacturing cost.

The absolute energy consumption by this sector has been estimated at 112 millionGiga calories.

The specific energy consumption per ton of urea varies between 5.79 Giga calories forthe most efficiently operating plant to 13 Giga calories for the most inefficient plant.

Energy intensity in India’s fertilizer plants has decreased over time. This decrease isdue to advances in process technology and catalysts, better stream sizes of ureaplants and increased capacity utilization.

8.1 Types of fuel usedEnergy is consumed in the form of natural gas, associated gas, naphtha, fuel oil, low sulfurheavy stock and coal for process. LDO, LSHS, HFO and HSD are also used in dieselgenerators.

Large fertilizer plants generate part of their own power through cogeneration mode in TG sets,while smaller plants depend exclusively on purchased power or power from DG sets.

With the ever-increasing fuel prices and power tariffs, energy conservation is strongly pursuedas one of the attractive options for improving the profitability in the Indian pulp and paperindustry.

8.1.1 Nitrogeneous fertilizersProduction of ammonia has greatest impact on energy use in fertilizer production. It accountsfor 80% of the energy consumption for nitrogenous fertilizer.

The feedstock mix used for ammonia production has changed over the last decade. Thechoice of the feedstock is dependent on the availability of feedstock and the plant location.

The shares of feedstocks in ammonia production are as follows:

Feedstock 1980-1990 1990-2000

Natural Gas 54.2% 52%

Naptha 26.1% 19%

Fuel oil 18.2% -

Coke oven gas - 19%

Coal 1.5% 10%

The shift towards the increased use of natural/associated gas and naphtha is beneficial in thatthese feedstocks are more efficient and less polluting than heavy fuels like fuel oil and coal.

Furthermore, capacity utilization in gas based plants is generally higher than in other plants.Therefore, gas and naphtha are the preferred feedstocks for nitrogenous fertilizer production.


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8.1.2 Phosphatic fertilizersThe production of phosphatic fertilizer requires much less energy than nitrogenous fertilizer.Depending on the fertilizer product, energy consumption varied from negative input for sulfuricacid to around 1.64 GJ/tonne of fertilizer for phosphoric acid.

For sulfuric acid the energy input is negative since more steam (in energy equivalents) isgenerated in waste heat boilers than is needed as an input.

8.3 Specific energy consumptionThe specific energy consumption comparison of Indian fertilizer industry is as follows:

Parameter Units Indian Norms

Ammonia (incl. Off site energy)For Naptha based G Cal/ MT 11.40For Natural gas based G Cal/ MT 9.33

UreaFor Naptha based G Cal/ MT 8.32For Natural gas based G Cal/ MT 6.84

9.0 Energy Saving PotentialThe various energy conservation studies conducted by the CII – Energy Management Cell andfeedback received from the various industries through questionnaire survey and plant visits,indicate an energy savings potential of 10% of the total energy use.

This is equivalent to an annual savings potential of about Rs.2000 million.

The estimated investment required to realize this savings potential is Rs.6000 million, with apayback time of three years, depending on scale of operations and technology.

The fertilizer industry has an attractive cogeneration potential of atleast 100 MW, in additionto the existing cogeneration plants.

9.1 Major factors that affect energy consumption in fertilizer unitsThe major factors that affect energy consumption in the Indian fertilizer industry are asfollows:

• Age of plant

• Technology used

• Capacity of plant

• Level of capacity utilisation

- Weather and monsoon conditions

- Use and agricultural output



- Policy changes regarding fertilizer production

• Availability, storage and transportation

- Raw materials

• Finished products

• Availability, choice and cost of feedstock/ fuels

• Location of plant

• Reduction in raw material consumption

• Reduction in utility consumption

• Environmental impact abatement systems

• Level of safety and reliability controls

• Number and multiplicity of machinery

• Boiler type & pressure levels

• Level of cogeneration power generation

• Levels of instrumentation

• Extent of utilisation of variable speed drives, such as, variable frequency drives (VFD),variable fluid couplings (VFC), DC drives, dyno-drives etc.

These are the various major factors, which affect the specific energy consumption in fertilizerplants.

10.0 Energy saving schemesAn exhaustive list of all possible energy saving projects in the fertilizer industry is given below.The projects have been categorised under short-term, medium term and capital-intensiveprojects.

The projects which have very low or marginal investments and have an energy saving potentialof upto 5% has been categorised as short-term. The projects which require some capital -investment having a simple payback period of less than 24 months and having an energysaving potential of upto 10% has been categorised as medium-term.


There are several projects, which have very high energy saving potential (typically 15% ormore), besides other incidental benefits. These projects have very high replication potentialand contribute significantly to improving the competitiveness of the fertilizer industry. However,these projects require very high capital-investment and hence has been categorised separately.


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10.1 List of all possible energy conservation projects in a fertilizer plant

10.1.1House-Keeping Measures – Energy Savings Potential of 5%A. Process areas1. Avoid idle running of equipment, like conveyors and bag filters, by installing simple interlocks.

2. Providing timer control for agitators for sequential operation

3. Ensure optimum loading of all equipment

4. Avoid fresh water use for condensers, wherever possible, by maximizing use of recycledwater

5. Optimise fresh water consumption in process areas

6. Avoiding pump operation by utilisation of gravity head

7. Optimising excess capacity/ head in pumps by change of impeller or trimming of impellersize

8. Optimising excess capacity/ head in fans/ blowers by RPM reduction or change of impeller

9. Optimise capacity of vacuum pumps by RPM reduction

B. Steam, Condensate Systems and Cogeneration1. Monitor excess air levels in boilers and hot air generators

2. Arrest air infiltration in boiler flue gas path, particularly economiser and air preheatersection

3. Plug steam leakages, however small they may be

4. Always avoid steam pressure reduction through PRVs. Instead, pass the steam throughturbine so as to improve cogeneration



7. Monitor boiler blow down; use Eloguard for optimising boiler blow down

8. Monitor the blow-down quantity of water in cooling towers and the quality of water

C. Electrical Areas1. Install delta to star convertors for lightly loaded motors











D. Miscellaneous1. Avoid/ minimise compressed air leakages by vigorous maintenance

2. Optimise the pressure setting of the compressor, closely matching the requirement



5. Install level indictor controllers to maintain level in tanks

6. Install hour meters on all material handling equipment

10.1.2 Medium term Measures – Energy Savings Potential upto 10%A. Process areas1. Install new correct size high efficiency pumps for process pumps, scrubber circulation

pumps, recycled water, DM water and Soft water pumping

2. Install booster pumps for high head cooling water users (if they are only minor users) andoptimise overall head of cooling water pumps

3. Install VSD for process pumps, DM water pumps, soft water pumps, raw water pumpsand condensate transfer pumps

4. Install VSD for raw water, recycle water, effluent discharge and sulphur pumps

5. Optimising the capacity of vacuum pumps by RPM reduction or bleed-in control

6. Optimise the suction line size of water ring vacuum pumps

7. Install pre-separators for water ring vacuum pumps

8. Install new high efficiency fans & blowers in boiler

9. Install new high efficiency blowers for scrubbers in complex plant

10. Install VSD for scrubber blowers in complex plant

11. Mechanical unloading system in raw material handling area

B. Co-Generation, Steam & Condensate Systems1. Install automatic combustion control system/ oxygen trim control system in steam boilers

and soda recovery boilers

2. Install economiser/air preheater for boilers

3. Install boiler air preheater based on steam to enhance cogeneration


5. Install automatic blow down system for boilers

6. Install heat recovery from boiler blow down

7. Banking of boilers instead of cold start-up

8. Installation of flash vessels for heat recovery from hot condensate vapours

9. Condensate recovery and rinse water usage in complex plant

10. Convert medium pressure steam users to LP steam users to increase co-generation


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13. Replace dyno-drives with VSD for coal feeder

14. Install chlorine dosing and HCl dosing for circulating water.

15. De-superheating station for low pressure steam users

16. Solar water heating for boiler feed water preheating

17. Installation of automatic debris filter at TG cooling water inlet

C. Electrical Areas1. Install maximum demand controller to optimise maximum demand


3. Installation of thyristorised rectifiers


5. Install energy efficient motors as a replacement policy

6. Thyristor room AC units provided wit timer control

7. Replace HRC fuses with HN type fuses

8. Replace 40 Watts fluorescent lamps with 36 Watts fluorescent lamps


10. Install SV lamps at wood and coal yard areas instead of MV lamps



13. Installation of neutral compensator in lighting circuit

14. Optimise voltage in lighting circuit by installing servo stabilisers

15. Minimising overall distribution losses, by proper cable sizing and addition of capacitorbanks

16. Replace V-belts with synthetic flat belts

D. Air Compressors1. Segregate high pressure and low pressure users

2. Replace heater - purge type air dryer with heat of compression (HOC) dryer for capacitiesabove 500 cfm


E. DG System1. Use cheaper fuel for high capacity DG sets

2. Increase loading on DG sets (maximum 90%)

3. Increase engine jacket temperature (max. 85°C) or as per engine specification

4. Take turbocharger air inlet from outside engine room

5. Installation of steam coil preheaters for DG set fuel in place of electrical heaters



F. Miscellaneous1. Install VFD for AHU fans with feed back control based on return air temperature

2. Install two port control valves for chilled water supply to AHU’s and install VFD for chilledwater pump

3. Install Variable Frequency Drive for ammonia transfer pump in atmosphere ammoniastorage system

4. Floating type aerator in place of fixed aerators

5. High efficiency diffuser aerators instead of conventional aerators

6. Treatment of effluent through activated sludge lagoon resulting in stopping of aerators

7. Use of ETP filter cakes in boilers

8. Solar water heating for canteen and guest house

9. Convert V-belt to flat belt drives

10.1.3 Long term Measures – Energy Savings Potential of 10-15%1. Maintaining 42 kg/cm2 pressure at reformers outlet with the latest manurite 36M material

for reformer tubes and operating with low S/C ratio

2. Utilization of superior catalysts in reformer

3. Installation of pre-reformer

4. Utilization of latest and active HTS and LTS catalysts for shift conversion

5. Utilization of efficient CO2 removal process

6. Installation of radial flow converters with active catalysts in the synthesis conversion

7. Installation of purge gas recovery systems and Ammonia recovery systems

8. Installation of DCS control systems and process optimiser

9. Installation of modified total recycled process for maximum heat recovery at Urea plant

10. Installation of Urea hydrolyser stripper for reducing Ammonia losses in Urea plant

11. Installation of multi-stage high efficiency turbine in sulphuric acid plant

12. Installation of plate heat exchanger for cooling of sulphuric acid coming from drying tower

13. Installation of mechanical conveying system (Bucket-elevator or pipe conveyor) in placeof pneumatic conveying system for rock phosphate transportation

14. Install conical port high efficiency vacuum pumps in place of flat port vacuum pumps

15. Segregate high-vacuum & low-vacuum sections of the paper machine and connect todedicated systems

16. Segregation of high-head and low head users in cooling towers and process areas

17. Replacement of steam ejectors with vacuum pumps to enhance cogeneration

18. Install DCS controls for process automation in sulphuric acid, phosphoric acid and complexplants

19. Install belt conveyor for conveying ground rock phosphate instead of pneumatic conveyors.In case of space constraint, install pipe conveyors


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20. Installation of new correct size high efficiency pumps for sea water or raw water intake

21. Improvement of turbo-generator performance

22. Upgradation of utility boiler

23. Installation of waste heat recovery system in the process areas

24. Installation of hydraulic turbine

25. Install vapour absorption system to utilise LP steam and enhance cogeneration

26. Install vapour absorption system based on DG jacket water, if DG is run on a continuousbasis

27. Install steam-generating system from DG exhaust, if DG is run on a continuous basis

28. Installation of DCS monitoring and targetting system for better load management

29. Installation of harmonic filters

30. Replace multiple small size DG sets with bigger DG sets

31. Conversion to low NOx system for one 4 MW DG sets

32. Install Evaporative Condensers For The Atmospheric Ammonia Storage System



Case Study No.1

Installation of High Efficiency Turbine for Air Blower inSulphuric Acid Plant

BackgroundThe sulphuric acid plant generates substantial quantity of heat, which is converted to steamin the waste heat boiler. The sulphuric acid plant also needs energy for operating equipment,such as, fans and pumps. One of the major energy consumers is the air blower, whichsupplies air at high pressure for burning sulphur in the furnace. The blower is either turbinedriven or motor driven.

Conventionally, the fans were turbine driven and the turbines were of single stage. Thesesingle stage turbines have a low efficiency of 35 to 40 %.

The latest trend is to replace these single stage turbines with high efficiency multi-stageturbines and reduce the steam consumption.

This project has greater benefits in a plant where there is venting of low pressure steam, asany efficiency increase of the turbine results in reduction of high-pressure steam generation.

Previous statusIn the sulphuric acid plant (1200 TPD capacity) of a huge fertilizer complex, the sulphurfurnace blower was driven by a single stage turbine operating between 35 kg/cm2 and 3.5 kg/cm2. The turbine had a specific steam consumption of 16.9 tons per MW.

The turbine was consuming about 27 TPH of steam during normal operation. There was alsoa mis-match of LP steam generation and requirement, resulting in an average venting of LPsteam (pressure of 3.5 kg/cm2) of about 4 TPH.

The plant also had taken up some modernising schemes to upgrade the capacity of thesulphuric acid plant. This meant that there will be additional load on the turbine and hencemore venting of LP steam.

Energy saving projectThe single stage turbine was replaced with a new multi-stage steam turbine of higher efficiency.The improvement in efficiency was about 15 % resulting in reduction of steam consumptionby about 3 TPH, even when operating at higher load.

Implementation methodology & time frameThe implementation of this project was taken up parallel, during the operation of the plant forthe stand-by fan. During a stoppage of the plant, the fan fitted with the new turbine was putinto service.

The implementation took about 1 month to complete. No problem was encountered duringimplementation and subsequent operation of plant.


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Benefits of the projectThe implementation of this project resulted in the saving of about 3 TPH of steam (35 kg/cm2).

Financial analysisThe implementation of this project resulted in an annual saving (@ Rs.400/ MT of steam) ofRs 9.60 million. The investment made was about Rs 15.00 million, which had a simplepayback period of 19 months.

Replication potentialThe project has replication potential in all phosphatic fertilizer plants in the country, where, theblower drive has a single stage turbine and plant has commercial cogeneration.

On a conservative basis, the project can be implemented in atleast 5 fertilizer units in thecountry.


• Investment - Rs.15.0 millions



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Case Study No.2

Installation of Variable Frequency Drive (VFD) for Sulphur Pump

BackgroundThe phosphatic fertiliser plants use sulphuric acid for reacting with rock phosphate to producephosphoric acid. The sulphuric acid is generated from elemental sulphur. The elementalsulphur is melted and the molten sulphur is pumped to the furnace for oxidation.

The sulphur pump is generally rated for maximum capacity along with a safety margin. Thecontrol normally followed is a re-circulation control, i.e., part of the molten sulphur from theoutlet of the pump is sent back to the melting pit.

The re-circulation method of control is highly energy inefficient as energy is wasted forpumping extra liquid. The latest energy efficiency method is to install variable frequency drivesand control by varying the speed.

Previous statusIn the sulphuric acid plant (1200 TPD capacity) of a huge fertiliser complex, the sulphur pumpwas being driven by a steam turbine with inlet steam at 35 kg/cm2.

The pump was of 10.2 m3/h capacity and 265 m head and was being controlled by re-circulation. Also, the turbine driving the pump was a small one consuming a maximum ofabout 0.7 TPH of steam. Since the quantity of steam was less, the exhaust was let out intothe atmosphere.

This was an energy in-efficient system, as the pump was being operated with re-circulationand the exhaust was also let into the atmosphere.

Energy saving projectThe steam turbine was replaced with a motor of 22 kW with a variable frequency drive. Therewere two pumps and one was operated continuously.

The replacement was done for one of the pumps and other turbine driven pump was kept asa stand-by. Consequent to the installation of the variable frequency drive, the pump wascontrolled by varying the speed to meet the varying process requirement.

Implementation methodology & time frameThe implementation of this project was taken upparallel during the operation of the plant for thestand-by pump. During a stoppage of the plant, thepump fitted with the VFD was put into service.

The implementation took about 1 month to complete.No problem was encountered during implementationand subsequent operation of plant.



Benefits of the projectThe implementation of this project resulted in the saving of about 0.4 TPH of steam. The motorinstalled along with VSD was consuming about 15 kW.

Financial analysisThe implementation of this project resulted in a net annual saving (@ Rs.350/ MT of steam)of Rs 0.75 million. The investment made was about Rs 0.50 million, which had a simplepayback period of 8 months.

Replication potentialThe installation of variable frequency drives for various critical applications is well proven. Thisproject has very good replication potential in several phosphatic fertilizer units, particularly thesmaller plants in the country.



• ISimple payback - 8 months


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Case Study No.3

Installation of Right Size Hot Sump Pump

BackgroundIn the phosphatic fertiliser plants, the phosphoric acid is produced from rock phosphate byreacting with sulphuric acid. Subsequently, the weak phosphoric acid is concentrated in theconcentrators from a concentration of 28 % to 48 – 50 %.

These concentrators are maintained under vacuum with the help of steam ejectors. Thissection consumes electrical energy for the cooling water pumps and the hot sump pumps.

These pumps need to be of the right size; otherwise, the pumps have to be operated withvalve throttling to meet the process requirement.

The installation of the right size pumps is therefore essential for operation of the plant at lowerenergy consumption.

Previous statusIn a fertiliser complex involved in production of complex fertilisers with ammonia plant andphosphoric acid plant, two hot sump pumps of

1500 m3/h capacity and 25 m head are used for pumping hot water from the sump to the topof cooling tower.

The motor driving the pump had a rating of 160 kW. The water requirement was around 1700m3/h. Hence, one of the pumps was operating with the discharge valve throttled.


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Energy saving projectThe detailed study of the water requirementindicated that the maximum requirement of hotwater to be pumped is around 1700 m3/h only.Hence, one of the hot sump pump was replacedwith a smaller pump of capacity 250 m3/h and 30m head and driven by a motor of 45 kW.

The system is schematically shown in thediagram.

Consequent to the implementation of this projectthe pumps were operated with discharge valve fully open.

Before After

2 pumps of 1500 m3/h capacity 1 pump of 1500 m3/h capacity

One pump with valve throttling 1 pump of 250 m3/h capacity

Implementation methodology & time frameThe implementation of this project was taken up during the operation of the plant. Theimplementation took about 4 months to complete.

A pump, which was available in the plant as a spare, was used for this. No problem wasencountered during the implementation and subsequent operation of the plant.

Benefits of the projectThe implementation of this project resulted in the reduction in the power consumed for hotwater pumping. The power consumption reduced by 32 kW, resulting in a saving of 2.5 millionunits per year.

Financial analysisThis amounted to an annual monetary saving (@ Rs.3.1/unit) of Rs 0.78 million. As the pumpavailable in the plant was used for replacement, no significant investment was involved forimplementing this project.

The investment, which would have been made, had the pump been not available is Rs.0.50million, which will have a simple payback period of 8 months.




Replication potentialThe installation of correct size – capacity/ head pumpsfind numerous applications in the fertilizer industry. Thisconcept can be extended to all the various types ofpumps in a fertilizer industry, namely, raw water pumps,soft water pumps, DM water pumps, scrubber circulationpumps, effluent water pumps, recycle water pumps etc.

Hence, this project has very high replication potential, with innumerable applications.


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Case Study No.4

Optimisation of Vacuum Pump Operation

BackgroundThe vacuum pumps are used in different sections of the fertiliser plant for creating vacuum.The choice of the right size of vacuum pump and maintaining of the system without leaks areessential for achieving energy efficiency.

In the phosphatic fertiliser units, the Aluminium fluoride is produced as a

by-product. In the production of AlF3 , the final slurry comprising of silica and small quantitiesof AlF3 is filtered in a long belt filter before discharging the dry cake (which is free of acid andAlF3). The filtration requires a vacuum of

150 to 200 mmHg, which is produced by a vacuum pump.

Previous status

In a phosphatic fertiliser unit which is part of a bigger fertiliser complex involved in productionof complex fertilisers, a long belt filter was being used for final filtration of the slurry of silicaand AlF3.

Two vacuum pumps of 500 m3/h capacity and 0.3 kg/cm2 vacuum were being used forcreating vacuum. One of the vacuum pumps was being operated with valve throttling.

Energy saving projectThe detailed study of the system revealed the following:

• There were leaks in the vacuum line joints close to the belt filter.

• The capacity of the vacuum pump was reduced due to uneven wearing of the pump.



During a maintenance stoppage of the plant, the leakges were arrested and a trial was takento operate the filter with one vacuum pump. The trial was satisfactory and the operation of onevacuum pump per filter was made into a standard operating procedure.

Implementation methodology & time frameThe implementation of this project was taken up during the planned shut down of the plant. Theimplementation took about 1 week to complete. No problem was encountered during theimplementation and subsequent operation of the plant.

Benefits of the projectThe implementation of this project resulted in the reduction in the power consumed for vacuumgeneration. The power saving was about 15 kW, which annually amounted to 1,20,000 units.

Financial analysisThis amounted to an annual monetary saving (@ Rs.3.1/unit) of Rs 0.37 million. As theimplementation of this project involved only some maintenance and change of operatingprocedure there was no significant investment.



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Case Study No.5

Installation of a Pipe Reactor in Complex Plant

BackgroundThe complex fertiliser is produced by reacting the different components such as phosphoricacid, sulphuric acid, ammonia etc. in specific proportions in a reactor. Subsequently, theproduct from the reactor is granulated, dried, coated if required and sent for despatch.

Though these units are not highly energy intensive like the nitrogenous plants, there isnevertheless a good potential to save energy by suitable modifications and technologyupgradation.

Previous statusIn a phosphatic fertiliser complex, producing Ammonium sulphate and Mono-ammoniumphosphate, the final section of the plant had the following configuration:

• The phosphoric acid, sulphuric acid and ammonia are reacted in a tank reactor to producea melt of 85 % solids.

• This melt was then pumped to a granulator for converting to the form of granules. The meltconcentration had to be maintained below 85 % solids, so that the melt is pumpable. Tomaintain this concentration water was being added to the system.

• The granules were then dried in a furnace oil fired rotary drier for removing the moisture.

• The average furnace oil consumption was 20 litres/ton of product.

The system is shown in the diagram.

Energy Saving ProjectThe plant replaced the existing tank reactor with a pipe reactor. The new system afterimplementation is indicated in the diagram.


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Implementation methodology & time frameThe implementation of this project was taken up during the annual maintenance of the plant.The implementation took about 4 months to complete. No problem was encountered duringthe implementation and subsequent operation of the plant.

Benefits of the projectThe implementation of this project resulted in operation of the reactor at higher concentration.The outlet of the reactor was directly inserted into the granulator. Hence the concentration ofthe melt was maintained at about 95 %, as against < 85 % earlier.

The increase in concentration of the melt reduced the drying requirement in the dryer. Thefurnace oil consumption came down from 20 litres/ton of product to 5 litres/ton of product.

Financial analysisThe implementation of this project resulted in a net annual saving (@ Rs.7.0/litre and aproduction of 2.0 lakh tons) of Rs 21.00 million. The investment made was aboutRs.80.00 million, which had a simple payback period of 45 months.

Replication potentialThe replication potential is very high, particularly in the smaller size complex fertilizermanufacturing plants.





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Case Study No.6

Installation of Right Size High Efficiency Sea Water Pumps

BackgroundThe fertiliser plant consumes substantial power for cooling water pumping to different parts ofthe plant. The installation of the right size and high efficiency pumps therefore is essential foroperation of the plant at lower energy consumption.

Previous statusIn a fertiliser complex involved in production of complex fertilisers with ammonia plant andsulphuric acid plant was using seawater for meeting a part of its cooling requirements.

The plant had three sea water pumps, out ofwhich two pumps were being operated forpumping sea water. This was being used in theAmmonia plant & Sulphuric acid plant for bothindirect cooling in various heat exchangers anddirect uses such as scrubbing and washing.

The pumps were of 15000 USGPM capacity and4.5 kg/cm2 head driven by a

800 HP, HT (3.3 kV) motor. One of the pumpswas being operated with discharge valve throttled.

Energy saving projectThe detailed study of the water requirement and the pressure profile of the whole plant indicatedthe following:

• The maximum water quantity requirement was around 20000 USGPM

• The maximum head requirement was only 2.5 kg/cm2

Hence, the plant replaced one of the pumps with 23000 USGPM capacity, 30 m head highefficiency pump. The old motor was retained for driving the pump.

Implementation methodology & time frameThe implementation of this project was taken up during the operation of the plant. Theimplementation took about 4 months to complete. No problem was encountered during theimplementation and subsequent operation of the plant.

Benefits of the projectThe implementation of this project resulted in the following benefits:

• Reduction in the power consumed for sea water pumping



• Only the new pump was operated. The other two pumps were kept as stand-by.

The above benefits resulted in the reduction of energy consumption by 11 lakh units perannum.

Financial analysisThis amounted to an annual monetary saving (@ Rs.3.3/unit) of Rs 3.63 million. The investmentmade was around Rs 4.00 million. The simple payback period for this project was 14 months.

Replication potentialThe project has excellent replication potential in the raw water pumps of all fertilizer plants.





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Case Study No.7

Installation of Vapour Absorption System

BackgroundThe non-process areas in a fertiliser plant also consume substantial electrical energy. Thevarious consumers include building & control room air-conditioning and lighting. The air-conditioning requirement has been conventionally met through various vapour compressionmachines.

The latest trend has been to install vapour absorption systems in plants where cheap LPsteam is available. These systems are quite reliable and less maintenance prone.

The fertiliser plant offers an excellent opportunity for installation of vapour absorption systems,as huge quantities of cheap low-pressure steam is available.

Previous statusIn a big fertiliser complex producing Urea and some phosphatic fertilisers, conventional vapourcompression systems with Ammonia as refrigerant and reciprocating compressors, wereused for meeting the air-conditioning requirement of the plant buildings and control rooms.

Three reciprocating compressors each of 100 HP were being operated to meet the requirement.The average load was about 200 to 250 TR at an average power consumption of 1 kW/TR.

Energy saving projectA vapour absorption system of 300 TR capacity was installed to meet the plant air-conditioningrequirement.

The vapour absorption system was based on steam at 3.5 kg/cm2 and had a specific steamconsumption of 7 kg/TR.

Implementation methodology & time frameThe implementation of this project was taken upparallely during the operation of the plant. Thevapour absorption system was installed and washooked up replacing the vapour compressionsystem.

The implementation took about 12 months tocomplete. No problem was encountered duringimplementation and subsequent operation ofplant.


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Benefits of the projectThe implementation of this project resulted in the following benefits.

• Reduction in power consumption by 7.0 lakh units per year

• Saving of Ammonia make-up costs – Rs. 4.0 lakh per year

• Reduction in maintenance costs – Rs. 1.20 lakh per year

Additionally the implementation also aided in continuous, trouble-free and reliable operation ofthe air-conditioning unit.

Financial analysisThe implementation of this project resulted in an annual monetary saving (@ Rs.3.10/kWh) ofRs 2.70 million. The investment made was about Rs 9.00 million. The simple payback periodis 36 months.





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Case Study No.8

Replacement of Old PRDS Valves with Superior Design Valves

BackgroundThe nitrogenous fertiliser plant is a major consumer of thermal energy for meeting the variousheating requirements and mechanical energy for driving the different equipment such ascompressors, pumps and fans. To meet both power and steam demand, co-generation systemis installed.

The bigger equipment are driven generally by steam turbines and the smaller ones by electricalmotors. The steam extracted from the turbine is used for meeting the process steamrequirement.

To the extent possible, the flow of steam flow through the PRDS (pressure reducing and de-superheating station) i.e., reduction of pressure without generating power, is avoided.

However, to take care of the ‘Power-steam’ mis-match, exigencies and start-up conditions, thePRDS is installed. The effective operation and maintenance of the PRDS is therefore essentialfor over-all efficiency.

Previous statusThis case study pertains to a ammonia fertiliser complex producing 900 tons per day of Urea.

The PRDS system in the ammonia plant is described below.

• The entire demand of the ammonia plant at 40 ata, is met by the 40 ata extraction of thesynthesis gas compressor turbine. Two PRDS systems are installed to meet the 40 atasteam demand during start-up and tripping of the synthesis gas compressor.

• The system is installed so that the PRDS comes in line, immediately when the synthesiscompressor trips.

• However, these PRDS valves need to be maintained with a minimum flow of 150 kg/h, sothat the valve opens immediately when required.

This continuous minimum flow caused high erosion of the valve internals leading to muchhigher flow of steam through the valve, ultimately resulting in continuous venting of 40 atasteam.

Energy saving projectThe plant installed a new PRDS system with drag type valves of superior design. These valvesneeded little continuous flow of only 20 kg/h, for quick opening. The erosion of the valve at thisflow was almost nil.



Implementation methodology & time frameThe implementation of this project was taken up when the plant was in operation. The installationof the new system and successful commissioning took about one year. No problem wasencountered during the implementation and subsequent operation of the plant.

Benefits of the projectThe implementation of this project resulted in reduction of 40 ata steam loss. The loss reducedfrom 10000 kg/h to 20 kg/h. The total energy saved per year is about 63,360 GCal.

Financial analysisThe implementation of this project resulted in a net annual saving (@ Rs.350 / GCal) ofRs. 22.00 million. The investment made was about Rs. 12.20 million, which got paid backin 8 months.





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Case Study No.9

Replacing Reformer Tubes with Tubes of HPNb MaterialStabilised with Micro-Alloys

BackgroundThe reformer is very important process equipment, used in the production of Ammonia. Thisammonia is consequently utilised, for the production of nitrogenous fertilisers.

The reformer is a major consumer of energy andthe efficiency of the reformer section has a majorbearing on the over-all energy consumption of afertiliser plant. Hence, the process of reformingand the equipment used for reforming, needspriority attention in a fertiliser plant.

Nitrogenous fertilisers use Ammonia as the basicmaterial for providing the nitrogen component.Ammonia is synthesised by chemically combiningHydrogen and Nitrogen under pressure, in thepresence of a catalyst. The Hydrogen requirement

is met by, catalytically reacting a mixture of steam and hydro-carbons, at an elevatedtemperature, to form a mixture of Hydrogen and oxides of Carbon.

CnHm + nH2O ——>

<——- nCO + (m/2 + n) H2

CO + H2O ——>

<——- CO2 + H2

The first reaction is called the Reforming reaction. This is a highly endothermic reaction, andhence needs energy input in the form of fuel firing, which is normally natural gas / naphtha.

One of the important factors which affects the performance of the reformer is the material ofconstruction of the reformer tubes.

Conventionally the HK40 or IN519 or equivalent material were being used for the reformer.Presently, modified HPNb materials stabilised with micro-alloys are available and are beingincreasingly considered for the reformer tubes. These materials have better strength andstability at higher temperature and increased creep strength.

These aspects aid in:

• Possibility of operation of the reformer at higher temperature & pressure

• Reduced reformer wall thickness

• Increased quantity of catalyst packing in the same space – this aspect has been utilisedadvantageously, for increasing the capacity and reducing the energy consumption of existingReformers.


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This has been taken up successfully in many fertiliser plants with substantial advantages.

Previous statusIn a 357 TPD Ammonia plant involved in production of Urea and other Phosphatic fertilisers,the reformer tubes were made of conventional material with 25 % Chromium & 20 % Nickel.

Energy saving projectThe Reformer tubes were replaced with ‘modified HPNb materials stabilised with micro-alloys’with higher Chromium & Nickel and stabilised with Niobium (25 % Chromium, 35 % Nickel, 1.5% Niobium and traces of Zirconium).

Implementation methodology & time frameThe implementation of this project was taken up as part of the Revamping exercise and tookabout 9 week to complete. The implementation and consequently the operation did not poseany problem.

Benefits of the ProjectThe replacement of the reformer tubes with modified superior material resulted in the followingbenefits:

• Reduction in thickness of tube from 20 mm to 10 mm

• Increase in internal diameter of tubes from 100 mm to 120 mm – Aided in packing additionalcatalyst to the extent of 35 %

• Increase in capacity of the plant by 15 %

• Reduction in Reformer tube skin temperature

The above benefits together resulted in reducing the energy consumption for production ofAmmonia by 0.15 GCal / MT of Ammonia.

Financial AnalysisThis amounted to an annual monetary saving (@ 1,00,000 MT production of Ammonia & Rs1000 / Gcal) of Rs. 15.00 million. The energy saving alone has been considered. The investmentmade was around Rs. 50.00 million. The simple payback period for this project was40 months.





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Case Study No.10

Modernisation of the Ammonia Converter Basket

BackgroundThe Hydrogen generated by reforming of hydro-carbons is reacted with Nitrogen in the

atmospheric air in the presence of a catalyst athigher pressure to synthesise Ammonia. Thesynthesis of Ammonia occurs in the Ammoniaconverters.

The older Ammonia converters were all of axialtype which required higher pressure and resultedin lower conversions. These have been replacedin some of the plants with radial type / axial-radial system with considerable benefits.

Previous statusIn a 357 TPD Ammonia plant, the Ammonia converter basket had a conventional axial typebasket, as shown in the figure. This needed an operating synthesis loop pressure of 300 bar.The catalyst used was Topsoe supplied of 10 mm size with a pressure drop of 5 bar.

The conversion per pass was around 16 %. In 1992, the bottom exchanger developed a leak,leading to further reduction of ammonia conversion and increased loop pressure. The totalproduction loss was around 30 %.

Energy saving projectThe converter basket was modified to a axial-radial type system. The modified system isindicated in the diagram.




The implementation of this project was taken up as part of the Revamping exercise and hencea separate stoppage of the plant was avoided. The implementation and consequently theoperation did not pose any problem.

Benefits of the projectThe replacement of the old axial type converter basket with the modern axial-radial systemresulted in the following benefits:

• Loop pressure reduced to 250 bar – reducing compression energy

• Lower pressure drop in converter beds – 3 bar as against 5 bar before

• Higher Ammonia production ( about 10 TPD )

The above benefits resulted in the reduction of energy consumption by 0.35 Gcal / MT ofAmmonia.

Financial analysisThis amounted to an annual monetary saving (@ 1,00,000 MT production of Ammonia & Rs1000 / Gcal) of Rs. 20.00 million. The energy saving alone has been considered. The investmentmade was around Rs 50.00 million. The simple payback period for this project was30 months.





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Case study No.11

Installation of Waste Heat Boiler (WHB) at the Inlet of LTSConverter in Ammonia Plant

BackgroundThe reformer section converts the Hydrocarbons to a mixture of Carbon monoxide and Hydrogen.The Carbon monoxide is converted to Carbon-di-oxide in the presence of a catalyst.

The conversion takes place in two stages i.e., one at a higher temperature and the other ata lower temperature. The lower the temperature of conversion the higher is the heat recovery.It is also advantageous from the process point of view, to operate the converters at a lowertemperature.

Previous statusIn an Ammonia plant, the Low Temperature ShiftConverter (LTSC) was designed to operate at ainlet temperature of 238°C.

Energy saving projectAs it is advantageous to operate at a lowertemperature of around 210°C from the processand energy point of view, a Waste Heat RecoveryBoiler was installed to reduce the temperature ofthe gases entering the LTSC to about 210°C.



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The implementation of this project was taken up during a major stoppage of the plant. Theimplementation took about 4 week to complete. The implementation and consequently theoperation of both the WHRB & the LTSC did not pose any problem.

Benefits of the projectThe installation of the WHRB resulted in the following benefits:

• Reduction of LTSC inlet temperature to about 210°C and generation of 2 TPH of steam at14 kg/cm2

• Prolonged life of LTSC catalyst

• Increased process efficiency – Resulting in higher Ammonia production by 0.9 % ( about3 TPD)

The above benefits resulted in the reduction of energy consumption by 0.082 GCal / MT ofAmmonia.

Financial AnalysisThis amounted to an annual monetary saving (@ 1,00,000 MT production of Ammonia & Rs1000 / GCal) of Rs 8.20 million. The energy saving alone has been considered. The investmentmade was around Rs 4.50 million. The simple payback period for this project was 7 months.

Replication PotentialThe fertiliser plant is a consumer of heat and power. The utilisation and integration of the plantin terms of heating and cooling can lead to substantial energy saving. The projects asmentioned above and variations of the above project have substantial replication potential inmany fertiliser plants.





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Case Study No.12

Installation of Make-up Gas Chiller at Suction of SynthesisGas Compressor at Ammonia Plant

BackgroundThe compressor is the heart of nitrogenous fertiliser plant and is used for various purposessuch as compressing the synthesis gas, air, re-cycle gas and ammonia. The compressorcapacity is also one of the important parameters controlling the capacity of the plant.

Hence, the design of the compressor and its effective utilisation is essential for achievinghigher production and lower energy consumption.

The compressor is a constant volume equipment and hence the capacity of the compressorcan be increased by increasing the density of the gas at the suction of the compressor. Asthe gas density is inversely proportional to the temperature, there is a good possibility ofincreasing the capacity of the compressor by cooling the inlet gas.

Previous statusThis case study pertains to a ammonia fertiliser complex producing 900 tons per day of Urea.The plant was operating at about 920 TPD of ammonia production. The synthesis gas wasentering the compressor at about 39°C.

Energy saving project

The plant installed a vapour absorption refrigeration systemwith LP steam for cooling the synthesis gas.

Implementation methodology & time frameThe implementation of this project was taken up when theplant was in operation. The hooking up of the new systemwith the existing was done during the planned shut of theplant.



The installation of the new system and successful commissioning took about

18 months. No problem was encountered during the implementation and subsequent operationof the plant.

Benefits of the projectThe implementation of this project resulted in the following benefits.

Parameter Units Before AfterImplementation Implementation

Ammonia Production TPD 920 944

Syn. gas temperature °C 39 13

Syn. gas compressor speed RPM 13,142 13,071

The implementation of this project resulted in a saving of 28,035 GCal per year, which amountedto 0.09 GCal / ton of ammonia.

Financial analysisThe implementation of this project resulted in a net annual saving (@ Rs. 350/GCal) ofRs. 9.80 million. The investment made was about Rs. 22.00 million, which got paid back in27 months.





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Case study No.13

Replacement of Air Inter-coolers in the Ammonia Plant

BackgroundThe Ammonia is synthesised by reacting Hydrogen generated by reforming of hydrocarbonsand Nitrogen in the atmospheric air in the presence of a catalyst at higher pressure to synthesiseAmmonia.

The atmospheric air is supplied to the reactor by a battery of air compressors. Thesecompressors are very important for the operation of the plant and hence are rightly referredto as the heart of a fertiliser plant. The efficiency of these compressors therefore play a veryimportant role in efficiency of the whole plant.

Previous statusIn a 1,00,000 ton per annum capacity Ammonia plant, the air requirements of the Ammoniaconverter were being met by two numbers of oil lubricated 4 stage reciprocating compressors.

The compressors were provided with inter-coolers with finned tubes and were laid in a horizontalfashion. The oil in the air from cylinders used to plug the gap between the fins and reduce theheat transfer. The exit air from the inter-cooler used to be at 55 – 58°C as against the designof 42°C. The capacity of the subsequent stages was getting reduced leading to loss of Ammoniaproduction.

Energy saving projectThe inter-coolers for the compressor was replaced with finless tubes and laid in a verticalfashion.

Implementation methodology & time frameThe implementation of this project was taken up parallelywhile the plant was operating. The replacement was donefor one compressor first and the second compressorwas taken up subsequently. The implementation and thesubsequent operation did not pose any problem.

Benefits of the ProjectThe replacement of horizontal fin type cooler with verticalfinless coolers resulted in reduction of exit air temperatureto around 45°C. There was a reduction of power to theextent of 45 kW.


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Financial AnalysisThis amounted to an annual monetary saving of Rs 0.85 million. The power saving alone hasbeen considered. The investment made was around Rs 2.00 million. The simple paybackperiod for this project was 28 months.





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Case study No.14

Routing of Ammonia Vapours from Urea Plant to ComplexPlantBackground

The fertiliser plant has many consumers of thermal and electrical energy distributed over theentire complex. The energy consumption is for heating, cooling, compression, vaporising,condensation etc,.

The system has to be balanced as a whole to ensure operation at the maximum efficiency.

Previous status

In an Urea & Phophatic fertiliser complex, the off-gases from the primary and secondarydecomposers contain NH3 and CO2. These gases are separated in re-cycle section whereCO2 is absorbed in MEA solution and NH3 is re-circulated.

There are two absorbers, one at 19 kg/cm2 and the other at 0.4 kg/cm2. The Ammonia vapoursfrom primary absorber is cooled in water cooled condensers while Ammonia vapours fromsecondary absorber is compressed to 19 kg/cm2 in two reciprocating compressors and thencondensed.

At the same time in the complex plant, the liquid Ammonia (about 6 TPH) at 0°C was drawnfrom the storage spheres was vapourised at 6 kg/cm2 and used for neutralisation of thephosphoric acid. This process of vapourising needed LP steam at 3.5 kg/cm2.

Energy saving projectIn the above system, Ammonia is compressed from vapour to liquid form by compressionwhile in the other part of the plant, Ammonia is vapourised by heating. Both these operationdemand energy in the form of electricity for compression and steam for vapourisation.

The system was modified as below:



• Ammonia was compressed to only 6 kg/cm2 in the Urea plant.

• The hot vapours were exported from the Urea to the complex plant.

The required controls and piping for the proposed arrangement were made for the transfer ofhot Ammonia vapours. The modified system is schematically shown in the diagram.

Implementation methodology & time frameThe implementation of this project was taken up while the plant was in operation. The hookingup with the existing system was done with a stoppage of about 10 days. The implementationof this project faced no problems.

Benefits of the ProjectThe implementation of this project resulted in the following benefits:

• Reduction of electrical energy consumption for compression of Ammonia in the Urea plant.

• LP steam saving in the Complex plant

The above benefits resulted in the reduction of energy consumption by 6 lakh units per yearand 2000 MT of LSHS.

Financial analysisThis amounted to an annual monetary saving ofRs 4.00 million. The investment made was aroundRs 0.50 million. The simple payback period for thisproject was 2 months.





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Case study No.15

Replacement of Pellet Type Catalyst with Ring Shaped Catalystin Sulphuric Acid Plant

BackgroundThe Sulphuric acid plant is an integral part of the complex fertiliser unit involved in productionof phosphatic fertilisers. The sulphuric acid is produced by combustion of elemental sulphurto its oxides and subsequently absorping in acid.

The conversion of the sulphur-di-oxide to sulphur-tri-oxide is one of the important reactions inthis plant.

This reaction is exothermic and is carried out in the presence of a catalyst. The geometry ofthe catalyst affects the performance of the plant and the conversion. Presently, catalyst ofsuperior geometry are available. These have the advantage of longer life and reduced pressuredrop.

Previous statusIn a sulphuric acid plant which was a part of the larger fertiliser complex plant, pellet shapedV2O5 catalyst was being used.

The plant was frequently facing problems of dust accumulation and increase in pressure drop.Additionally the plant had to be shut down once every six months for screening and re-chargingthe catalyst.

Energy saving projectThe pellet shaped catalyst was replaced with ring shaped catalyst of the same materialcomposition.

Implementation methodology & time frameThe implementation of this project was taken up during the yearly stoppage. The implementationtook about 2 week to complete. The implementation and consequently the operation did notpose any problem.

Benefits of the projectThe replacement of the pellet type catalyst with ring type catalyst resulted in the followingbenefits:

• Reduction in the pressure drop build up of the converter

• Reduction in the load of the main air blower

• Shut down (for screening and recharging catalyst) frequency reduced from two per year toonce per year


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The above benefits resulted in the reduction of energy consumption by 900 MT of LSHS andadditional production of 10,000 MT of sulphuric acid per year.

Financial analysisThis amounted to an annual monetary saving(energy saving and additional acid production)of Rs 7.80 million. The investment made wasaround Rs 40.00 million. The simple aybackperiod for this project was 60 months.





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Case study No.16

Installation of a Waste Heat Recovery Boiler for GeneratingSet Exhaust

BackgroundThe fertiliser plant is a huge consumer of electricity and steam. A part of the electrical energyis supplied by the co-generation system comprising of the boilers and the back pressureturbines. The balance power is met partly through condensing turbines, oil fired generatingsets and grid.

The increase in the cost of grid power has made many fertiliser plants to install condensingturbines and oil fired generating sets. In the case of oil fired generating sets, about 30 to 35% of the energy supplied goes out through the stack in the form of high temperature flue gas.

In many of the plants, waste heat boilers are installed to generate LP steam from generatingset exhaust, which can be connected to the LP steam header.

The implementation of this project results in greater benefits; in plants where some quantityof LP steam is generated by passing HP/MP steam through pressure reducing valves. In suchplants, augmentation of LP steam through waste heat recovery system can lead to a savingof HP steam and hence the fuel.

Previous statusIn a big fertiliser complex producing Urea and some phosphatic fertilisers, the power requirementof the plant was met through steam turbines, grid and oil fired generating sets. The cost ofdifferent sources of power is as below:

Grid Rs.3.00/unit

Oil fired generating sets Rs.1.72/unit

As the cost of power generation with LSHS fired generator was lower, the plant was operatingtwo 4 MW capacity generating sets continuously. The generating set exhaust was going outto the atmosphere at a temperature of 390°C.

This offered a good potential to install a waste heat recovery system. In the plant also, thepower steam balance was such, that nearly 4 TPH of LP steam was being generated byreducing the pressure of HP steam (35 kg/cm2 pressure) through a pressure reducing valve.Hence, any generation of LP steam from the generating set exhaust can aid in an equivalentreduction of HP steam generation and reduce the fuel fired in the boiler.



Energy saving projectA waste heat recovery system was installed for generating LP steam from the generating set

exhaust.

Implementation methodology & timeframeThe implementation of this project was takenup parallely during the operation of thegenerating set. A waste heat recovery systemwas installed for each of the sets. A provisionwas also made for by-passing the waste heatrecovery system.

The implementation took about 12 months tocomplete. No problem was encountered during

implementation and subsequent operation of plant.

Benefits of the projectThe implementation of this project resulted in the saving of about 4 TPH of HP steam, whichneed not be generated.

Financial analysisThe implementation of this project resulted in an annual monetary saving (@ Rs.300/ MT ofHP steam for 4000 hours per year) of Rs 4.50 million. The investment made was aboutRs 12.00 million. The simple payback period was 32 months.




Replication potentialThe project has excellent replication potential in allfertilizer plants, which operate large size DG sets ona continuous basis


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Case study No.17

Coating of Pump Impeller and Casing with Composite ResinsBackgroundThe pumps are major consumers of electrical energy in a fertiliser plant. Hence, the design,operation and maintenance of pumps are essential for operating the plant at higher levels ofenergy efficiency.

In any pumping system, the hydraulic passages of casings & impeller vane shape get damageddue to wear, tear and corrosion. The clearances of wear rings also increases over a period.This damage results in deterioration of hydraulic performance and reduces the efficiency of thepumps, resulting in increased power consumption and frequent breakdowns.

The latest trend is to use composite resin coating on the pump impeller & casing, to restorethe geometric shapes, surface finish & clearances. This aids in restoring the original efficiencyand sustains over a longer period. The following organic based systems are being used forrefurbishing the impeller and casings:

• Bisphenol glass flake polyester resins• Vinyl ester glass flake resins• High build epoxy systems

The utilisation of these systems along with the standard engineering practises can

• Limit the extent of mechanical damage• Resist chemically aggressive service environment• Act as a barrier to prevent permeation of corrosion ions to the substrate (metal)

Previous statusIn a sulphuric acid plant of 600 TPD capacity, there were 4 cooling water pumps of 2700 m3

/h capacity and 50 m head driven by a 500 kW motor. The pumps were operating at anefficiency of 64.5 %, consuming about 430 kW.

Energy saving projectThe casing of the pump was coated with epoxy resin coating.

Implementation methodology & time frameThe implementation of this project was taken up during the planned shut down of the plant. Theover all implementation took about 10 days to complete. No problem was encountered duringthe implementation and subsequent operation of the plant.

Benefits of the projectThe implementation of this project resulted in the reduction in the power consumed for pumpingof cooling water for Sulphuric acid plant. Consequent to the coating the efficiency of the pumphad improved and there was a reduction of about 16 kW in the power consumed by eachpump. The total saving was about 0.13 million units.

Financial analysisThis amounted to an annual monetary saving (@ Rs.3.1/unit) of Rs 0.40 million. The investmentmade was about Rs. 0.13 million and the simple payback period was 4 months.


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Case study No.18

Installation of a Second Turbo Alternator in Sulphuric AcidPlant

BackgroundThe sulphuric acid unit is one of the important sections of the phosphatic fertiliser plant.Sulphuric acid is produced by burning elemental sulphur to produce sulphur- di-oxide, convertedto sulphur-tri-oxide and subsequently absorbed in a solution of 98 % acid. This is highlyexothermic resulting in generation of substantial quantity of heat, which is converted to steamin the waste heat boiler.

In the older & smaller units, the steam is generated at 11 kg/cm2, reduced to a lower pressureand used in the sulphuric acid plant and other areas. The sulphuric acid plant however needsenergy for operating equipment such as fans and pumps.

One of the major energy consumers is the air blower, which supplies air at high pressure forburning sulphur in the furnace. In the subsequently installed plants, the steam is produced athigher pressures, 24 kg/cm2 and expanded in a turbine to a lower pressure. This turbine isused for generally driving the air blower.

The latest trend is to generate steam at much higher pressures and use it for increased powergeneration. In this manner, the plant is able to increase the internal co-generation power.

The cost of co-generation power is much lower than the grid power cost, resulting in substantialcost reduction for the plant.

Previous statusThis case study pertains to a sulphuric acid plant in a phosphatic fertiliser complex producingAmmonium sulphate and Mono-ammonium phosphate. The plant had two sulphuric acid unitsof capacity 300 TPD and 400 TPD respectively.

The old plant of 300 TPD capacity had a waste heat recovery boiler of 24 kg/cm2 and thesteam was expanded to about 1.5 kg/cm2 in a turbine which was being used for driving theair blower.

The second plant, which was installed subsequently, had a waste heat boiler of 40 kg/cm2

pressure. This steam was also being used for driving the air blower only, with the help of asteam turbine operating with a backpressure of 1.5 kg/cm2.

Since the pressure was higher, only 70 % of the total steam generated (about 21 TPH at 400TPD acid production), was being used by the turbine and the remaining steam was beingpassed through a pressure-reducing valve.


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Energy saving projectThe plant did a detailed study of the steam system and implemented the following modifications.

• The LP steam coming out of the turbine was being used for de-salination of sea water inmultiple effect evaporators. The maximum pressure requirement in this section was only0.5 kg/cm2.

Hence, the plant started operating the turbines with a back pressure of only 0.5 kg/cm2, afterconfirming with the turbine supplier. This reduced the steam requirement for driving the blowerto about 50 % of the steam generation.

• Installed a 1.0 MW turbine alternator, so that the steam previously passing through pressure-reducing valve could be used for generating additional power.

Implementation methodology & time frameThe implementation of this project was taken up parallely during the operation of the plant.During a stoppage of the plant, the new turbine alternator was put into service.

The implementation and stabilisation of the second alternator took about 6 months to complete.No problem was encountered during the implementation and subsequent operation of theplant.

Benefits of the projectThe implementation of this project resulted in additional average power generation of about 500kW. Since the plant was buying power from the grid @ Rs.3.50/ unit, this project resulted insubstantial cost saving.

Financial analysisThe implementation of this project resulted in a net annual saving (@ Rs.3.50/ unit) ofRs 14.00 million. The investment made was about Rs.10.00 million, which got paid back in9 months.





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Case study No.19

Installation of Hydraulic Turbine in the CO2 Removal Section

BackgroundThe Ammonia in a nitrogenous fertiliser plant is manufactured by synthesising Hydrogen andNitrogen in the presence of a catalyst. The Hydrogen is generated by reacting hydrocarbonswith steam in the presence of a catalyst, to produce a mixture of Carbon-di-oxide and Hydrogen.

The gas is stripped of Carbon-di-oxide in a solution of aqueous mono ethanol amine (MEA).This MEA absorbed in the CO2 absorber which is at a pressure of 24 kg/cm2, enters the CO2

stripper operating at a lower pressure of around 0.4 kg/cm2. This pressure reduction is normallyeffected through a pressure reducing valve.

There is a good potential to install a hydraulic pressure recovery turbine in such a system torecover power to drive, say a pump. Some plants have installed this system and have benefitedsubstantially.

Previous statusIn a particular nitrogenous fertiliser plant of about 1,00,000 tons per year capacity, the MEAprocess was being used for CO2 removal. The absorption of the CO2 in the absorber is carriedout at high pressure and the rich MEA at the outlet of the absorber is at a pressure of 24 kg/cm2.

This rich MEA exchanges heat with the hot lean MEA coming from the stripper, its pressurereduced in a pressure reducing valve after which it enters the stripper. The rich MEA afterstripping of CO2 becomes lean and can be used for absorption of CO2 again.

This lean hot MEA after heating up the rich MEA coming out of the absorber is pumped througha steam turbine driven pump to the absorber. This turbine has a BHP of 800 hp and operatesbetween pressures of 32.6 kg/cm2 and 5.5 kg/cm2.

Energy saving projectA Hydraulic Power Recovery Turbine (HPRT) wasinstalled to recover the pressure energy being lostacross the valve.

The detailed calculations revealed that nearly 175hp generation was possible by installing the turbine.The nearest drive operating in CO2 removal sectionwas the lean MEA pump, which was being drivenby a steam turbine with a BHP of 800 HP.



Hence, the hydraulic turbine was installed in the same shaft as that of the steam turbine andwas being used for supplementing part of the power required to drive the lean MEA pump.

Implementation of the project, time frameThe following modifications were done during the implementation of this project.

• Piping was modified to route rich MEA through hydraulic turbine to the stripper.

• A second level control valve at the inlet of the hydraulic turbine was installed. The controlloop was modified so that the second level control valve operates on a split range basis.This operates in parallel with the first level (i.e., original valve) valve, which is sized forminimum pressure drop.

• The control system was made so that, the new second level control valve, controls the levelin absorber during normal operation. The original valve operates only when hydraulicturbine is not in operation.

• Additional controls and instruments were installed so as to take care of various situationslike start up, shut down and other contingencies.

• A one-way clutch was also installed so that coupling and de-coupling take place automaticallybetween hydraulic turbine and pump.

The installation of the turbine and the successful commissioning took about 8 months tocomplete. The hydraulic turbine has since then been operating successfully resulting insubstantial benefits.

Benefits of the projectThe implementation of this project resulted in reduction of the load on the steam turbine drivingthe lean MEA pump.


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The steam saving on the steam turbine amounted to 2.5 TPH of high pressure steam, whichannually amounted to about 600 tons of LSHS. The reduction in specific energy consumptionamounted to about 0.06 GCal / MT of ammonia.

Financial AnalysisThe annual saving achieved by the company on installing hydraulic turbine wasRs. 3.80 million. The investment made was about Rs. 1.10 million with a simple paybackperiod of 4 months.





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Case study No.20

Installation of Plate heat exchangers for drying tower cooler insulphuric acid plant

BackgroundSO3 gas from “Converter” is absorbed in the Intermediate and Final Absorption Towers (IAT &FAT) with sulphuric acid from the respective absorption tanks. The absorption of SO3 being anexothermic reaction, the heat from the reaction has to be removed using a cooling medium.

The sulphuric acid from the drying tower tank is circulated to the drying tower or acid storagetanks, through heat exchangers, which are of the serpentine type and made of cast irontrombone. These heat exchangers use either seawater (depending on location of plant) orcooling tower water for cooling.

These types of coolers are characterised by higher-pressure drops, lower approach temperatureand high maintenance costs (due to frequent scaling/ choking).

The plate heat exchangers are excellent substitution for serpentine coolers, as they arecharacterised by lower pressure drops, approaches of upto 1°C and ease of maintenance.

Previous statusIn one of the phosphatic fertilizer units, the sulphuric acid from drying tower was cooled inconventional cast iron trombone serpentine coolers, using seawater as the cooling medium.

The distribution of seawater was always problematic on the lengthy coolers, due to frequentscaling/ choking. The outlet acid temperature used to be higher by about 5°C than the design,leading to reduced throughput.

There were also frequent problems of leaks in the coolers, necessitating stopping the plant forattending on them. The downtime on account of this used to be about 5 days per year.

Energy saving projectThe serpentine coolers were replaced with 3 new sets of Plate Type Heat Exchangers (PTHE).These PTHE’s are supplied with seawater, for cooling, using dedicated vertical submersiblepumps.

Implementation of the project, time frameThe plate type heat exchangers and connecting lines from the sulphuric acid pump (at bottomof the drying tower) discharge header to the heat exchangers were kept ready and hookedon during the planned maintenance shutdown.

There were no problems faced during the implementation of this project and this has beenoperating successfully, resulting in substantial benefits.



Benefits of the projectThe following benefits were achieved on installing the plate type of heat exchangers:

• Approach temperatures of upto 2°C, leading to better cooling

• Lower pressure drop, resulting in lower head requirement of cooling water pump

• Practically nil downtime, due to ease of cleaning and maintenance, on account of themodular design

Financial AnalysisThe annual saving achieved by the company on installing hydraulic turbine wasRs. 12.00 million. The investment made was about Rs. 25.00 million with a simple paybackperiod of 25 months.

Replication potentialThe installation of plate type heat exchangers for cooling applications has excellent replicationpotential in almost all the fertilizer plants.





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Case study No.21

Installation of mechanical conveying system in place ofpneumatic conveying system for rock phosphate conveyingin phosphoric acid plant

BackgroundThe basic raw materials required for phosphoric acid manufacture are sulphuric acid and rockphosphate.

Raw rock phosphate, obtained from various sources, is ground in ball mills to a size of 60%retention on –200 mesh screen. This ground rock is discharged into storage silos using apneumatic conveying system.

From the storage silos, the ground rock is extracted and conveyed to the phosphoric acidplant also using a pneumatic conveying system.

Pneumatic conveying uses compressed or blower air as the material conveying media and ishence, highly energy intensive. It is atleast 4 to 5 times power intensive than mechanicalconveying systems.

The latest trend among all industries is to replace pneumatic conveying systems to mechanicalconveying systems. There are mechanical systems, which are designed to convey fine powderymaterial, over steep gradients and long horizontal distances, without spillage.

The replacement of pneumatic conveying systems with mechanical conveying systems is wellproven, in cement industries.

Previous statusIn one of the complex fertilizer plants in the country, the ground rock from mill outlet wasconveyed to the storage silos using pneumatic conveying system, utilizing compressed air.The power consumed by the compressors was 225 kW.

Similarly, the ground rock from the silos is conveyed to the phosphoric acid plant usingcompressed air. The material is conveyed over a horizontal distance of 150 m and height of25 m. The power consumption of system was about 320 kW.

Energy saving projectThe pneumatic conveying systems in the plant were replaced with mechanical conveyingsystems.

In the rock grinding section, an air slide and bucket elevator combination was used to conveymaterial from the mill outlet to the storage silos. For ground rock conveying to the phosphoricacid plant, an air slide and pipe conveyor combination was installed.


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Implementation of the project, time frameThe entire project was completed over a period of 15 months. This did not require the stoppageof the plant.

There were no major problems encountered during the implementation of this project, exceptfor routing of the conveyor, due to space constraint.

Benefits of the projectThe major benefits of the modified mechanical conveying system are:

• Tremendous power savings

- 110 kW at rock grinding section

- 280 kW at phosphoric acid plant

• No material spillage

• Relatively low maintenance

Financial AnalysisThe total annual savings achieved on conversion of pneumatic conveying system to mechanicalconveying systems is Rs. 7.00 million. The investment required for the system was Rs.23.00million, which had a simple payback period of 40 months.

Replication potentialThe installation of mechanical conveying systems has good replication potential in severallarge and majority of the smaller size fertilizer plants.





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Case study No.22

Replacement of steam ejectors with vacuum pumps

BackgroundIn the concentration section of phosphoric acid plant, the evaporators are operated undervacuum for concentrating phosphoric acid from 28% to 46%.

The vacuum maintained in the evaporators is about 580-600 mm Hg and is achieved usingsteam ejectors. These steam ejectors use medium pressure or low pressure steam.

Vacuums of upto 680-700 mm Hg can be easily achieved with a water ring vacuum pump. Theinstallation of a water ring vacuum pump or steam ejector is decided based on cost of steamand power.

The utilization of MP or LP steam in steam ejectors will offset an equivalent amount of powergeneration in the turbine, if the plant has commercial cogeneration.

In such cases, there is a good potential to replace the steam ejectors with water ring vacuumpumps, save MP/ LP steam and enhance power generation in turbines.

Previous statusIn one of the complex fertilizer manufacturing units, there were five evaporators for concentrationof phosphoric acid. The evaporators were operated under vacuum using 2-stage steam ejectors.

These ejectors consume about 1.5 TPH each of 27 kg/cm2 pressure steam.

Energy saving projectAll the five steam ejectors in evaporator section were replaced with water ring vacuum pumps.

Implementation of the project and time frameThe replacement of steam ejectors with water ring vacuum pumps, were taken up one-by-one.There was no stoppage required for the implementation of the project, as there was alwaysone standby evaporator available.

The entire project was completed over a period of 15 months. There were no major problemsencountered during the implementation of this project.

Benefits of the projectThe steam saved by replacement was equivalent to about 7.5 TPH of 27 kg/cm2 pressure.This can generate additional power equivalent to about 50 units/ ton of steam, therebyoffsetting equivalent power drawn from the grid.



Financial AnalysisThe total annual savings achieved on replacing steam ejectors with water ring vacuum pumpsis Rs. 10.00 million. The investment required for the vacuum pumps was Rs. 7.50 million,which had a simple payback period of 9 months.

Replication potentialThe replacement of steam ejectors with water ring vacuum pumps has excellent replicationpotential in the large fertilizer units in the country. This project becomes particularly attractive,when the plant has commercial gogeneration.





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9.0 List of Contractors/ Suppliers


Alfa Laval India Ltd. • EvaporatorsMumbai - Pune RoadDapodiPune - 411 012Tel. : (020) - 24116100 / 27107100Email : [email protected] : www.alfalaval.co.inContact : Mr Neeru Pant

FFE Minerals India Limited • Material handling systemsFFE Towers, 27 G N Chetty Road • Classification, filtration and thickeningT Nagar technologiesv Crushing and grindingChennai – 600 017 • Calcination, roasting, sintering, dryingTel. : 044 – 28220801/ 02, 28252840/ 44Fax : 044 – 28220803Email : [email protected]

Johnson India • Steam engineering and consultancy3, Abirami Nagar, G.N. Mills PostCoimbatore – 641 029Tel. : 0422 - 2442692Fax : 0422 - 2456177email: [email protected]

Hindustan Dorr-Oliver Limited • Liquid-solid separationDorr-Oliver House • Environmental pollution controlChakala, Andheri East • Water treatmentMumbai – 400 099Tel.: 022 – 2832 5541, 2832 6416/ 17/18Fax : 022 – 2836 5659Email : [email protected] : www.hind-dorroliver.com

Nash International Company • Water ring vacuum pumpsNo. 1 Gul Link Singapore 629371Rep. of SingaporeTel. : (65) 861 6801Fax : (65) 861 5091Email : [email protected] : www.nasheng.com


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PPI Pumps Pvt. Ltd. • Water ring vacuum pumps4/2, Phase 1, GIDC Estate,Vatva, Ahmedabad – 382445Tel. : 079 – 25832273/4, 25835698Fax : 079 – 25830578Email : [email protected] : www.prashant-ppi.com

Sulzer Pumps India Limited • All types of centrifugal pumpsNo.9, MIDCThane-Belapur Road, • Wear resistant pumpsDigha, Navi Mumbai – 400 708 • Acid resistant pumpsTel. : 022 – 55904321Fax : 022 – 55904302Web : www.sulzerpumps.com

The Eimco-KCP Limited • Solids-liquid separation equipmentRamakrishna Buildings like rotary vacuum filters, thickeners,239, Anna Salai clarifiers, classifiers etcChennai – 600 006 • Water & waste water treatment plantsTel. : 044 - 28555171Fax : 044 – 28555863Email: [email protected] : www.ekcp.com

10.0 List of Consultants


Indian Companies

Development Consultants Limited • Detailed project reports24-B, Park Street, Kolkata - 700016 • Basic and detailed engineeringTel. : 033 - 22267601, 22497603 • Procurement, inspection & expeditingFax : 033 - 22492340/3338 • Project construction and managementEmail : [email protected] • Structural engineering

• Technical management



Engineers India Limited • Preliminary planningEngineers India Bhavan1, Bhikaji Cama Place • Detailed project reportsNew Delhi – 110 066 • Basic and detailed engineeringTel. : 011 - 26186732, 26102121 • Procurement, inspection & expeditingFax :011 – 26194760, 26178210 • Project managementEmail : [email protected] : www.engineersindia.comContact : Mr D K Gupta,General Manager – Mktg.

FACT Engineering & Design Organisation • Project designA Division of FACT Ltd. • Engineering(A Government of India Enterprise) • Comprehensive turnkey projectUdyogamandal implementationKochi - 683 501 • Plant operation and maintenance servicesTel. : +91-484-545451 to 545458 • Feasibility reportsFax : +91-484-545215Email : [email protected]

Jacobs EngineeringJacobs House, Ramkrishna Mandir RoadKondivita, Andheri (East)Mumbai - 400 059Tel. : 022 – 2824 4873Fax : 022 – 2820 8295Web : www.jacobs.com

Monsanto India LimitedAhura Centre, 5th Floor96, Mahakali Caves RoadMumbai - 400 093Tel. : 022 - 2824 6450, 2690 2100Fax : 022 - 2690 2111, 2690 2121

Projects & Development India Limited • Preliminary planning and surveyingPDIL Bhawan, A-14, Sector-I • Detailed project reportsPost Box No.125 Noida - 201301 • Basic and detailed engineeringDist. Gautam Budh Nagar Uttar Pradesh • Procurement, inspection & expeditingTel. : 011- 252 9842/ 843/ 851/ 853 / 854 • Project construction and managementFax : 011- 252 9801, 254 1493, 2646 6199 • Structural engineeringEmail : [email protected] • Technical management

• Cathodic Protection of UndergroundPipelines


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TCE Consulting Engineers Limited • Preliminary planningTata Press Building • Detailed project reports414, Veer Savarkar Marg • Basic and detailed engineeringMumbai – 400 025 • Procurement, inspection & expeditingTel. : 022 - 24374374, 24302419 • Project managementFax : 022 – 24374402 • Construction supervisionEmail : [email protected] • Assistance in start-up testing andWeb : www.tce.co.in commissioningContact : Mr M G YagneshwaraGroup Commercial Manager

UHDE India Limited • Preliminary planningUHDE House, LBS Marg • Detailed project reportsVikhroli (W), Mumbai – 400 083 • Basic and detailed engineeringTel. : 022 - 25783701, 25968000Fax : 022 – 25784327Email : [email protected] : www.uhdeindia.com

International Companies • Upgrades and buildsCasale • Fertilizer plantsvia Sorengo, 76900 Lugano - Methanol plantsSwitzerland - AmmoniaTel. : ++41 91 9607200 - UreaFax : ++41 91 9607291/2 - Methanol derivativesEmail : [email protected] • Speciality ChemicalsWeb : www.casale.ch

Davy Process Technology Limited20 Eastbourne TerraceLondon W2 6LETel. : +44 (0)207 957 4120Fax : +44 (0)207 957 3922E-mail : [email protected] : www.davyprotech.com

Grande Paroisse S.A.12, place de l’Iris 92062Paris La Défense 2 CedexFranceWeb : www.grande-paroisse.fr



Haldor Topsoe A/SPO Box 213 Nymøllevej 55DK-2800Lyngby, DenmarkTel. : +45 45 27 20 00Fax : +45 45 27 29 99Email : [email protected] : www.haldortopsoe.comContact : Mr Peter Søgaard-AndersenDirector – Mktg. & Sales- Technology DivisionTel. : +45 45 27 20 97Email : [email protected]

INCRO S.ASerrano, 27 - 28001 Madrid SpainTel. : (34) 91 435 08 20Fax : (34) 91 435 79 21Email : [email protected]

Jacobs Engineering Group Inc.1111 South Arroyo ParkwayP.O. Box 7084, PasadenaCA 91109-7084United State of AmericaTel. : + 1 626 578 3500Fax : + 1 626 578 6916Email : [email protected]

Kellogg Brown & Root (KBR)KBR Tower, PO Box 4557601 Jefferson Street,Houston, TX 77002United States of AmericaTel. : (+1) 713 - 753 20 00Fax : (+1) 713 - 753 53 53Emai : [email protected]

Linde AG Coporate CenterAbraham-Lincoln-Strasse 2165189Wiesbaden GermanyTel. : +49 611 770 0Fax : +49 611 770 269E-Mail : [email protected]


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Monsanto Enviro-Chem Systems, Inc.14522 South Outer Forty RoadSt. Louis, MO 63017United States of AmericaTel. : +314 275 5700Fax : +314 275 5701Email : [email protected]

Snamprogetti Sud FrazioneTriparni 89900 Vibo ValentiaItalyTel. : +39 0963 9611Fax : +39 0963 961356Contact: G. Carcano

Toyo Engineering CorporationTel. : (81)47-454-1113Fax : (81)47-454-1160Email : [email protected]

University Technologies Intl. Inc.Suite 130, 3553 - 31st Street NW,Calgary, AlbertaCanada, T2L 2K7Tel. : +403-270-7027Fax : +403-270-2384Email : [email protected]


400Energy Conservation in Foundry Industry

Foundry

Growth percentage 3-5%

Energy Intensity 25% of total manufacturing cost

Energy Costs Rs.45000 million (US $ 900 million)

Energy saving potential Rs.4500 million (US $ 90 million)

Investment potential on energysaving projects Rs. 5000 million (US $ 100 million)


401

1.0 IntroductionThe Indian Foundry Industry plays a significant role in improving country’s economy. India iscurrently among the 10 largest producers of ferrous and non-ferrous castings. India exportsannually above Rs.700/- Crores worth of castings to countries like USA, U.K., Canada, Germanyetc.

There are about 10,000 foundries in India inclusive of organised and unorganised sectors. Outof 10,000 foundries about 90% are small-scale units. These foundry units are mostly in clusterswith a cluster size ranging from less than 100 to about 500 units. These plants have aninstalled capacity of 4.5 million tonnes/ annum.

Majority of foundries in India produce grey iron castings. Annual production of Indian foundryindustry is about 3 million tonnes, consisting of 2.30 Million tonnes of grey iron castings, 0.4million tonnes of steel castings and 0.3 million tonnes of malleable and SG iron castings.

Among the foundry units, more than 6000 are cupola based foundry units operating in small-scale sector. The other units have rotary and induction furnaces.

The Indian foundry industry has been very responsive to energy efficiency. The latest plantsinstalled since early 90’s incorporate many energy saving measures by design. The olderplants also, continuously upgrading their technology and reducing their specific energyconsumption.

Various studies undertaken and the data collected indicate the annual energy saving potentialin Indian foundry industry is about 10-12% of the total energy bill. This includes short term andmedium term projects, which have payback period of less than 2 years. If the long term energysaving projects are considered the energy saving potential in Indian foundry industry is as highas 15 – 20% of the total energy consumption.

2.0 Energy Intensity in Indian Foundry industryIndian foundry industry is very energy intensive. The energy input to the furnaces and the costof energy play an important role in determining the cost of production of castings.

Major energy consumption in medium and large scale foundry industry is the electrical energyconsumption for induction and Arc furnaces. Fuel oil is used for heat treatment furnaces. Insmall foundry industry, coke is used for metal melting in the Cupola furnaces.

The energy costs contributes about 25% of the manufacturing cost in Indian foundry industry.The total energy cost in Indian foundry industry is about Rs 4500 Crores.



3.0 ENERGY CONSUMPTION PATTERN

3.1 Electrical energy consumptionMelting and holding furnaces are the major electrical energy consumers. The other electricalenergy users include sand plant, major utilities such as compressors, auxiliary cooling watersystems and lighting.

Typical electrical energy consumption pattern in a foundry industry is depicted in a power treegiven below.

3.2 Thermal energy consumptionIn Cupola furnaces, coal/coke is used as fuel for metal melting. Typical coke consumption incupola furnace is about 135 kg/MT of molten metal.

Fuel oil is used for metal melting in rotary furnaces. Specific consumption of fuel oil is about135 lit/MT of molten metal.

Heat treatment furnaces and ladle preheating furnaces are the other major users in foundryindustry.

Power Input 100%

Melting 86%

Lighting 1.4%

Furnace 83%

Auxiliary 3%

Moulding 3.6%

Sand Plant 1.6%

Mixer 2%

Melting 73%

Holding 10%

Cooling Pumps 2.5%

Crane & Hoists 0.5%

Utilities 4.4%

Others 4.6%


403

4.0 ENERGY SAVING POTENTIAL IN INDIAN FOUNDRY INDUSTRYThere are about 10,000 foundry units in India. The total annual energy bill of foundry industryis about Rs 4500 Crores. The energy saving potential considering the short term and mediumterm energy saving projects is 10-12 % of the total energy consumption.

Number of Annual Energy Saving Potential Investmentfoundry units Bill Rs Crores required

Rs Crores % of Energy bill Rs Crores

10,000 4500 450 10-12% 500

The energy saving potential considering the long-term energy saving projects, which havepayback period of about 3-4 years, is in the range of 15-20%. The energy saving potentialamounts to Rs 650 – 700 Crores.

5.0 FOUNDRY UNIT - PROCESS DESCRIPTIONThe manufacturing process of foundry industry is almost similar in all the units. The utilitiesand auxiliary equipment varies depending upon the requirement. The manufacturing processin foundry industry includes metal melting, sand preparation, pattern making, mould preparationand casting.

5.1 Melting SectionThe raw material is melted in melting furnace. The melting furnace can be an indicationfurnace or rotary or arc furnace or cupola furnace. Molten metal from the melting furnace istapped in Ladles and then transferred to the holding furnaces.

Typically the holding furnaces are induction furnaces. The holding furnace is used to maintainthe required molten metal temperature and also acts a buffer for storing molten metal forcasting process. The molten metal is tapped from the holding furnace whenever it is requiredfor casting process.

5.2 Sand PlantGreen sand preparation is done in the sand plant. Return sand from the moulding section isalso utilised again after the reclamation process.

Sand Mullers are used for green sand preparation. In the sand mullers, green sand, additivesand water are mixed in appropriate proportion. Then the prepared sand is stored in bunkersfor making moulds.

5.3 Pattern makingPatterns are the exact facsimile of the final product produces. Generally these master patternsare made of aluminium or wood. Using the patterns the sand moulds are prepared.



5.4 Mould PreparationIn small-scale industries still the moulds are hand made. Modern plants are utilising pneumaticor hydraulically operated automatic moulding machines for preparing the moulds.

After the moulding process if required the cores are placed at the appropriate position in themoulds. Then the moulds are kept ready for pouring the molten metal.

5.5 CastingThe molten metal tapped from the holding furnace is poured into the moulds. The moltenmetal is allowed to cool in the moulds for the required period of time and the castings areproduced.

The moulds are then broken in the shake out for removing the sand and the used sand is sentback to the sand plant for reclamation and reuse. The castings produced are sent to fettlingsection for further operations such as shot blasting, heat treatment etc. depending upon thecustomer requirements.

PROCESS FLOW DIAGRAM OF A FOUNDRY INDUSTRY

Molten Metal

Sand Plant Mould Preparation

Raw Material

Induction Furnace & Arc Furnace

Casting

Mould Cooling

Shake out Sand Reclamation

Castings


405

6.0 EQUIPMENT IN FOUNDRY INDUSTRY

6.1 Cupola furnaceThe cupola is a shaft furnace for continuous melting of cast ironwith new pig iron, return scrap iron and steel scrap. Coke is usedas fuel in cupola furnace. Cupola has not only an economicadvantage of low equipment cost but also has refining and selfpurifying capability. This makes it possible to get good quality ofmolten metal, even from inferior quality of raw material.

Cupola is divided into various zones such as preheating zone,melting zone, and superheating zone from the functional point ofview. Metal charged through the charging door is first preheatedin the preheating zone by the exhaust gas going out of the furnace.In the preheating zone the temperature is in the range of 500-1000oC.

Then the metal is melted in the melting zone and superheated in the superheating zone. Themolten metal is tapped from the tapping hole through the trough. The temperature in themelting zone is in the range of 1200-1500oC and 1600- 1800oC in the superheating zone.

The melting zone and the superheating zone are classified into the deoxidation zone and theoxidation zone depending upon the combustion reaction. In cupola melting, the positions of thedeoxidation and oxidation zones are important, since they have great influence on the propertiesof molten metal.

If the oxidation zone is expanded to the top of furnace, the solid metal is put in a strongoxidation atmosphere. This leads to increased oxidation of molten metal and hence increasedmetal loss.

Coke consumption in a single, cold blast cupola for molten metal temperature in the range of1380 – 1410oC is about 150-200 kg/MT of molten metal. Many technological modifications havebeen effected in cold blast cupola designs to increase operating efficiency and reduce specificfuel consumption.

6.2 Divided Blast CupolaIn the divided blast cupola is blast is equally divided between two Tuyers in the cupola. Thedivided blast cupola permits one to choose the best cupola process as required for theparticular production.

The advantages of divided blast cupola over cold blast cupola are as follows:

• 20% reduction in charge coke

• 40oC rise in tapping temperature

• No blocking or freezing of tuyeres

• 10% less loss in percentage of silicon

• 10% less loss in percentage of manganese



• Higher carbon pickup

• 20% increase in melting rate

• Reduction in exit gas temperature ( only 250oC as against 450oC in conventional cupola)and hence reduced flue gas loss.

• Can take 100% bigger lumps of remelting scrap

• Conversion from single blast to divided blast is very low

6.3 Hot blast cupolaThe temperature of exhaust gas of Cupola furnace is as high as 800oC. The high temperatureflue gas can be utilised for preheating the combustion air supply.

The combustion air supply can be preheated to a temperature of 300 or higher. This leads toincrease in combustion temperature and heat efficiency of the Cupola furnace.

Moreover in the upper part of the combustion zone, CO2 gas due to coke is deoxidised by hightemperature. This creates a reductive atmosphere and decreases the oxidation loss of metal.

Two methods, which widely used to preheat the blast air, are

1. The recuperative type which uses the heat of gases

2. The externally fired type which does not use any products of combustion in the cupola asfuel, but instead utilises an independent heater fired by coal, gas or oil

The advantages of hot blast cupolas are:

• Increased melt rate

• Reduced coke consumption

• Increased melt temperature

• Increased usage of steel scrap

• Ensures little loss of Si and Mn in molten metal in a reductive atmosphere, saving ferroalloys cost

• Energy savings of 25-30%

6.3.1 Oxygen enrichment in Cupola furnaceOxygen enrichment is an established practice for increasing the operating efficiency of Cupolafurnace. This also raises the tapping temperature and increases the melting speed.

Though a method using an Oxygen enrichment membrane has also been developed recently,generally pure Oxygen produced by evaporating liquid oxygen is added through inserting ductin the air blast tube. Oxygen is diluted with blast air and enriched uniformly to 22 to 25%blasted through tuyeres.


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6.4 Induction furnaceIn induction furnace a magnetic field is generated by the current passed through induction coil.Material to be melted is placed in the magnetic field. An electromotive force is induced by theaction of ectromagnetic Induction and the induced current flows to heat up and melt thematerial placed in the magnetic field.

Induction furnace is classified into two types based on the operating frequency.

• Medium frequency induction furnace – 500 to 600 Hz

• Main frequency induction furnace - 50 Hz

The main features of the induction furnace are as follows:

• High efficiency due to direct heating of material by electromagnetic induction

• Improved temperature control.

• Uniform metal composition by agitation effect

• Heating is done without air. Hence no metal loss due to oxidation effect

6.4.1 Energy consumption pattern in induction furnaceTypical power consumption in induction melting furnace of capacity 12 – 15 tonnes is in therange of 625 – 650 kWh/tonne of metal(cast iron) melted. In case of smaller furnaces thespecific power consumption increases.

The specific power consumption of induction furnaces of capacity 1 – 3 tonnes is in the rangeof 700 – 725 kWh/tonne of metal melted.

In induction furnace the efficiency is expressed as total energy input detective electrical andheat transfer losses.

The electrical losses consist of losses in transformer, frequency converter, capacitor bankscable and coil losses. Heat losses in induction furnace consist of heat escaping from furnacewall to coil side (carried away by cooling water0, radiation loss from melt surface and heat lossdue to slag removal.

Efficiency of medium frequency furnace is higher compared to efficiency of main frequencyfurnaces. The operating efficiency of medium frequency furnace is in the range of 55-60%,whereas the operating efficiency of main frequency furnace is in the range of 45 –50%.

In main frequency furnaces larger is the heat loss, whereas in case of medium frequencyfurnaces. This is due to the fact that main frequency furnace has lower power density, longermelting time and hence higher heat loss. Medium frequency furnace has higher electrical lossdue to frequency conversion and lower heat loss due to lower melting time.



7.0 ENERGY SAVING MEASURES IN MELTING PROCESSIn foundry industry substantial reduction in energy consumption can be achieved by improvingthe operational practices. Improvement of operational practices include the following:

• Improving melting process

• Reducing heat losses and heat input

This can be implemented irrespective of the type of melting furnace used for metal melting.These measures do not call for any major investment. But these need to be closely monitoredfor achieving reduction in energy consumption and sustaining the same.

7.1 Improving melting processEnergy consumption in melting furnace can be reduced by improving the charging practices,quality of charge, reducing the time taken for transferring the molten metal etc.

7.1.1 Removal of rust, sand and oil from chargeRust, sand and oil in the charging material form slag during the melting process. Majority oftime the slag formation is due to sand in returns such as runners & risers and rust in scraps.Before the metal tapping from the melting furnace the slag is removed.

Due to slag formation both heat loss and material loss takes place. Typically in a meltingfurnace, the heat loss due to slag formation is in the range of 1-2%.

The heat loss and material loss can be minimised by reducing the slag formation. This canbe achieved by shot blasting the charge and removing the sand, rust etc. In addition, attentionshall be paid to the material storage to prevent rusting.

7.1.2 Reducing the analysis timeMolten metal analysis is an important process through which, the quality of the castings isestablished from material composition point of view.

Melting and holding time of molten metal can be reduced by reducing the time taken for metalanalysis. To realize this, it is necessary to put the melting furnace and analysis test place asnear as possible and attention should be paid for rapid and exact communication of theanalysis result.

The latest trend is utilizing spectrometer for molten metal analysis. This reduces the analysistime substantially. Molten metal analysis can be done within 5-10 minutes.

Reducing the time taken for metal analysis directly reduces holding time of the molten metalin furnace and hence the power consumption. Energy saving of 10-15 units per tonne ofmolten metal can be achieved in furnaces, where holding is more than 30 mins.


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7.1.3 Reducing holding time of molten metal in furnaceThe time taken for the mould preparation should be matched with the metal tapping time.Molten metal should not weight for the moulds. This can be achieved by advanced planningand close monitoring.

Matching of time taken for mould preparation and metal tapping from the furnace will lead toreduction in holding time of molten metal in the furnace and hence reduction in powerconsumption.

7.1.4 Reduction of residual molten metalThe weight of casting has to be calculated and the weight of material melted should bematched with the weight of castings to be produced. This reduces the quantity of residualmolten metal and the associated energy consumption in the furnace.

7.1.5 Reducing time of slag removalThe slag formation takes place due to oxidation of molten metal and the unwanted material inthe feed such as rust, sand etc. The slag is removed periodically before tapping the moltenmetal for the casting process.

Generally in a medium size foundry industry the slag removal is done manually. Each slagremoval takes minimum about 5 to 10 minutes.

The latest trend is going for back tilting mechanism for the induction furnace. The slag removalcan be done quickly. This leads to reduction in cycle time of the metal melting process andreduction in energy consumption. Furnaces above 5 tons /batch capacity should be providedwith back tilting facility for de-slagging.

Quick slag removal using back tilting mechanism in the induction furnace results in atleast 1-2% reduction in energy consumption.

7.1.6 Reduce the time of composition adjustmentChecking of composition of molten metal and again changing the composition during themelting process leads to increased cycle time. The increased melting cycle time leads toincreased to energy consumption.

The right composition can be arrived at first check by correctly weighing and feeding the rawmaterial into the furnace. This can be achieved by installing load cells in the charge hopper.

Weighing and feeding of raw materials ensures right composition at first check.

7.1.7 Optimizing size of foundry cokeThe size of foundry coke has a direct bearing on the coke consumption per ton of iron meltedas well as the melting rate. The use of come below 75 mm(3") in size reduces the metaltemperature for a given amount of coke charge. The decrease in coke size also increasesthe blast pressure required to deliver a given volume of air.



When the coke size decreases below 75 mm(3") the amount of coke in the charge must beincreased to ensure the required tapping temperature.

The following figures indicated, effect of coke size on metal temperature when using 62mm(2.5") coke, 88 mm (3.5") coke in both 725 mm’ (29") and 1200 mm (48") cupolas

Additional coke amounting to about 2.5% of the metal charge would be required when using2.5" (62mm) coke when compared to 3.5" (88mm) coke. This additional coke would reducethe melting rate by about 20%

Coke saving in cupola furnaces can also be effected by:

• Undertaking repair and burn back of the linings to maintain the melting diameter to thatcompatible with the melting rate required.

• Regularly checking the weighing equipment to ensure accurate weight

• Keeping the cupola full of charge upto the charging door, thereby the descending metalliccharge obtain maximum preheating from the ascending hot gases. This calls for adequateheight of stack above the bed till the charging door.

• Recovering the un burnt coke by water quenching the contents of the drop and using thesame for split charge after sorting

By adopting the suggestions mentioned above, it could be possible to effect a coke saving ofone lakh tonnes per annum at the national level worth Rs.500 million assuming about 90% ofgrey iron production comes through cupolas and coke to metal ratio of 1:8.5. The energysaving measures would also reduce air pollution as SO2 level in stack emissions come down.

7.2 Reducing heat losses and heat input

7.2.1 Lower metal tapping temperatureThe energy consumption increases with increase in tapping temperature. The heat loss fromthe furnace is also increases with increase in operating temperature. Hence, the temperatureof molten metal should be closely monitored to avoid over shoot in temperature and increasedenergy consumption.

In gray iron melting, energy consumption increases by 20 kWh/ tonne for 100oC over shoot intemperature.

To keep the tapping temperature lower, the parameters such as pouring temperature requirement,the ladle traveling distance and drop in metal temperature during metal transfer etc should beconsidered.

7.2.2 Provide furnace coversIn induction furnaces the molten metal is maintained at a temperature of about 1400-1450oCdepending upon the requirement. The furnace is kept open and the molten metal is directlyexposed to atmosphere. This leads to radiation loss.

In an induction furnace the radiation loss is estimated as about 3 to 5%. This radiation losscould be minimised by providing closed hood for the furnace and a cover.


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8.0 LIST OF ENERGY SAVING PROPOSALS IN FOUNDRY INDUSTRY

8.1 Short-term energy saving proposals1. Reduce the tapping temperature of the molten metal from the furnace to match with the

requirement

2. Insulate and provide insulated lid for the ladle to minimise heat loss during metal transfer

3. Provide insulated lid for the holding furnace to avoid heat loss due to radiation

4. Install oil fired ladle preheating to minimise heat loss from the molten metal during metaltransfer

5. Suitably size the ladle to match with the molten metal requirement for the casting process

6. Reduce the tap to tap time in the furnace

7. Utilise the entire quantity of molten metal in the furnace by optimal scheduling of pouring

8. Optimise the operating pressure of the compressor to match with the requirement

8.2 Medium term energy saving proposals1. Improve combustion efficiency of cupola furnace

2. Optimise the size of the coke fed into cupola furnace

3. Practice oxygen enrichment in cupola furnace

4. Optimise combustion air supply to the oil fired heat treatment furnaces

5. Install blower air for sand cooling and avoid compressed air supply

6. Install temperature indicator control for induction furnace cooling tower fans

7. Install KWH indicator cum integrator for induction furnace

8. Segregate thick and thin section molten metal requirement and operate furnace at differenttemperatures

9. Match the moulding time and melting time to minimise the holding time of the moltenmetal

10. Monitor temperature of molten metal continuously using online infrared thermometer andavoid overshoot in temperature

11. Bundle and improve the bulk density of the input material

12. Provide closed hood for the furnace and minimise the loss due to radiation and convection

13. Control of sintering cycle through automatic sintering cycle time

14. Optimise cooling water supply to the induction furnace

15. Apply ceramic coating on the inner walls of heat treatment furnace for improving heattransfer



8.3 Long term energy saving proposals1. Install spectrometer for molten metal analysis and minimise testing time

2. Install automatic vibratory feeder for faster and continuous feeding of material

3. Charge hopper and furnace on load cells to achieve right composition at the first check.

4. Convert cold blast cupola furnace to divided blast cupola furnace

5. Replace electrical heating with thermic fluid heating for core baking oven

6. Install air pre heater for preheating the combustion air supply to the heat treatment furnaces

7. Install medium frequency induction furnace in place of main frequency furnace

8. Install dual track medium frequency furnace

9. Replace electrical Arc furnace with medium frequency furnace

10. Replace existing oil fired aluminium melting furnaces with gas fired furnaces

11. Segregate high pressure and low pressure compressed air users in the foundry industry

12. Install variable frequency drive for the screw compressor

13. Replace pneumatic operated tools with electrical tools


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Case study - 1

INSTALL KWH INDICATOR CUM INTEGRATOR FOR INDUCTIONFURNACE

BackgroundMedium frequency induction furnace is used for metal melting. The specific energy consumptionpattern for each batch is monitored. There is a huge variation in the specific energy consumption.

The variation in specific energy consumption is due to operational practices such as overshoot in metal temperature, holding of molten metal in the melting furnace due to break downin the moulding line, metal waiting for tapping and furnace waiting for raw material etc. Thelowest specific energy consumption is achieved in few batches due to adoption of the bestoperational practices incidentally in those batches.

The latest trend is installing KWh Integrator for the furnaces. The power consumption requiredfor the melting has to be established based on the lowest specific energy consumption achievedin the past. The established power consumption should be set as a target for each melt.

The KWh integrator measures the power consumption as the melting progresses and indicatesthe units available to complete the batch as per the target. The KWh Integrator gives the signalto the operators to tap the molten metal within the target power consumption.

The advantages of installing Kwh indicator cum integrator for the furnace are as follows:

• The furnace operators get an opportunity to take necessary steps online to complete themetal tapping within set target power consumption

• The lowest specific power consumption in the furnace for metal melting could be sustained

Previous statusMedium frequency furnace is used for cast iron melting. The variation in per ton of metalmelted is between 50 to 80 units.

The lowest specific power consumption achieved is 650 units/ton of molten metal.

Energy saving projectKWH indicator cum integrator was installed for the medium frequency furnace.

The power consumption per ton of molten metal is established based on past records. Targetfor power consumption per ton of molten metal is set as 650 units/ton.

Implementation methodology



The KWH indicator and integrator could be installed with very minimal downtime of the furnace.The indicator should be provided in the prominent location, visible to all the operators.

BenefitsThe variation in power consumption of the furnace is minimised. Atleast 20 kWH /batchreduction in power consumption was achieved.

Financial analysisThis amounted to an annual monetary saving (@ Rs 3.50/unit) of Rs 0.6 million. The investmentmade was Rs 0.20 million. The simple payback period for this project was 4 Months.

Replicating Potential in Indian foundry industryThere are about 10,000 foundry units are in operation in India. About 10% of the foundry unitsare utilising induction furnace for metal melting.

Atleast 50% of units, utilising induction furnace for metal melting can incorporate the KWHindicator cum integrator for monitoring.

The energy saving potential using KWH indicator is about Rs 25 Crores in Indian foundryindustry.

The investment opportunity for KWH indicator is about Rs 50 Crorers.


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Case study – 2

INSTALL MEDIUM FREQUENCY INDUCTION FURNACE OF MAIN FREQUENCY FURNACE

BackgroundInduction furnace can be basically classified into two types depending upon the operatingfrequency.

• Medium frequency furnace – over 500 Hz

• Main frequency furnace – 50 Hz

Heat efficiency of medium frequency furnace is higher than that of main frequency furnace.

The medium frequency furnace can be operated with three times higher power density thanthe main frequency furnace. This speeds up the melting rate, reduces the cycle and theassociated heat losses. This leads to increased operating efficiency of the furnace.

Main frequency furnace has higher heat loss, where as medium frequency furnace has higherelectrical loss. This is explicable from the fact that low frequency furnace has lower powerdensity at melting and larger heat loss due to long melting time.

While medium frequency furnace has higher power density. Heat loss is less due to shortmelting time and primary electrical loss is higher due to frequency conversion.

The other advantages of medium frequency furnace over main frequency furnaces are

• Absence of molten heel and hence increased productivity

• Reduced start up time

• Less melting time and hence reduced losses

Previous statusIn a large size foundry industry a main frequency furnace of capacity 10 tons/batch was inoperation. The specific power consumption of main frequency furnace was 690 units/ton ofmolten metal.

Energy saving projectThe main frequency furnace was replaced with medium frequency furnace of the same capacity.The specific power consumption of metal melting has been reduced to 615 units/ton of moltenmetal.


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Benefits of the projectThe implementation of the project resulted in reduction of specific power consumption of about95 units/ton. This saving annually amounted to about 9.0 Lakh units.

Financial analysisThe total benefits amounted to a monetary annual savings of Rs 3.15 million. The investmentmade was around Rs 20.00 million. The simple payback period for this project was76 Months. Cost benefit analysis

• Annual Savings - Rs. 3.15 millions




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Case study - 3

INSTALL SPECTRO METER FOR ANALYSING THE MOLTENMETAL

BackgroundMolten metal analysis is an important process through which, the quality of the castings isestablished from material composition point of view.

Typically in a medium scale and large scale foundry industry the molten metal sampling isdone and then tested in the laboratory. The metal sampling and testing takes about 30 min.This adds to the holding time of the molten metal in the furnace.

Melting and holding time of molten metal can be reduced by reducing the time taken for metalanalysis. This can be achieved by installing a spectrometer for analyzing the quality of moltenmetal.

The spectrometer analysis takes only about 5-10 mins. This leads to significant reduction inholding time of the molten metal in the furnace and hence reduction in energy consumption.

Present statusIn one of the medium size foundry industry laboratory test method is followed for testing themolten metal. Time taken for the molten metal testing is about 15-20 min.

Energy saving projectThe spectrometer was installed for molten metal analysis. This has minimised the time takenfor the analysis by 60-70%.

BenefitsThis has resulted in overall reduction in metal holding time and hence reduction in energyconsumption of about 10 units per ton of molten metal.

Financial analysisThe benefits amounted to a monetary annual savings of Rs 0.42 million. The investmentmade was around Rs 0.80 million. The simple payback period for this project was 23 Months.





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Case study – 4

INSTALL ONLINE SHOT BLASTING MACHINE FOR CLEANINGTHE RETURNS

BackgroundThe returns such as runners and risers from the moulding section is again utilised for melting.Typically in a small scale foundry industry the quantity of runners and risers accounts for about30-40% of the quantity of total feed into the furnace.

The returns contain green sand, which leads to increased slag formation. Also if the feed isrusted, the rust leads to slag formation. Before tapping the molten metal for the castingprocess, the slag formed on the top of the furnace is removed.

The slag formation results in increased metal loss and also energy loss. The energy consumptiondue to slag (1.2 units/kg of slag) is two times the power consumption of the metal melting. Themetal loss in the furnace is about 4-5% and the energy loss is about 2-3% of the energy inputto the furnace for melting.

The slag formation in the induction furnace can be minimised by cleaning the feed to thefurnace. This can be achieved by shot blasting the feed materials, specifically the returnsbefore fed into the furnace.

Previous statusThe returns from the molding section are directly used for the melting applications. The metalloss is about 6%.

The heat loss is about 125 units / batch of metal melted. This contributes 2.5-3% of the totalenergy input to the furnace.

Energy saving projectShot blasting machine was installed for cleaning the returns and fed into the furnace formelting process.

BenefitsThe slag formation was minimized and hence metalloss was reduced from 6% to 2.5-3%. The powerconsumption is reduced by 8-10 units/batch.

Financial analysisThis amounted to an annual monetary saving (@Rs 3.50/unit) of Rs 0.52 million. The investmentmade was around Rs 2.00 million. The simplepayback period for this project was 46 Months.





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Case study -5

REPLACE ARC FURNACE WITH MEDIUM FREQUENCYINDUCTION FURNACE

BackgroundIn the arc furnace the electric arc is produced between the electrodes. The heat generated dueto electric arc is utilised for melting the metal.

In arc furnace the melting heat efficiency in the process from ordinary temperature to meltdown is high. But the heat efficiency in superheating process after melt down is lower than halfof induction furnace.

The very low heat efficiency during superheating leads to increased specific power consumptionin the Arc furnace.

The typical specific power consumption between the Arc furnace and the induction furnace isgiven below.

Arc furnace - 710 - 720 units/tonMain frequency induction furnace - 680 - 690 units/tonMedium frequency induction furnace - 590 - 600 units /ton

Hence there is a good potential to save energy by installing medium frequency furnace.

Additional benefits• Cost savings due to elimination of electrodes

• Reduction in power consumption of exhaust system

• In some of the states an additional tariff to the extend of 25% is charged for the use of Arcfurnace for the melting process. This additional tariff can be totally eliminated.

Present statusIn one of the large-scale foundry industry Arc furnace of capacity 14 tons is used for cast ironmelting process.

The specific energy consumption of the Arc furnace was in the range of 710-715 units/ton ofmolten metal.

Energy saving projectThe arc furnace is replaced with two numbers of medium frequency furnaces of capacity 8tons/batch each.



The specific power consumption of medium frequency furnace is 610 units/ton of moltenmetal.

BenefitsThe implementation of the project resulted in reduction in energy consumption of about 110units/ton of molten metal.

Financial analysisImplementation of the proposal resulted in monetary benefit of Rs 6.5 million. Investmentmade was Rs 50.00 million. The payback period was 92 Months.





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Case study - 6

MONITOR TEMPERTURE OF MOLTEN METAL CONTINUOUSLYSUING ONLINE INFRARED THERMOMETER

BackgroundMolten metal temperature is an important parameter for the casting process. Lower moltenmetal temperature will lead to defective castings. The tendency of the operators of the furnaceis to maintain higher molten metal temperature than the requirement considering all thetemperature drops during metal transfer.

The temperature of molten metal in the furnace is monitored periodically using contact typethermocouple. This is done to ensure that the temperature of the molten metal is more thanthe requirement.

This temperature measurement at intervals using contact type thermocouple leads to overshootin temperature. The overshoot in molten metal temperature leads to increased powerconsumption in the furnace.

The latest trend is to install online infrared pyrometer. The pyrometer continuously monitors themolten metal temperature and can be prominently displayed. This facilitates tapping of moltenmetal within the required temperature and minimise overshoot in temperature.

Previous statusTemperature requirement for molten metal is 1460oC. The molten temperature overshootsbeyond 1480oC.

Energy saving projectOnline infrared pyrometer was installed for continuously monitoring the molten metal temperature.

The overshoot in temperature of molten metal was avoided.

BenefitsEliminates overshoot in molten metal temperature. Reduction in energy consumption of about5 units/ton of molten metal is achieved.

Financial analysisThe total benefits resulted to an annual saving of Rs 0.20 million. The investment made wasRs 0.20 million. The simple payback period for this project was 12 Months.


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Case study – 7

INSTALL WASTE HEAT RECOVERY SYSTEM FOR THE STRESSRELIEVING FURNACES TO RECOVER HEAT FROM THEEXHAUST FLUE GAS

Back groundIn the Stress relieving furnace the castings are heated to a temperature of about 550oC andthen cooled in atmospheric air. Light Diesel Oil is used as fuel in these furnaces.

The exhaust flue gas from the Stress relieving furnace is directly sent to atmosphere. TheExhaust flue gas temperature is in the range of 615-625oC. The percentage of heat lossthrough exhaust flue gas is in the range of 58-60 %.

There is a good potential to save energy by recovering heat from the exhaust flue gas. Thiscan be achieved by installing an air preheater and preheating the combustion air supply to thestress relieving furnace

In the air preheater the combustion air supply can be preheated to a temperature of about180oC. After air preheater the flue gas can be sent to atmosphere.

Energy saving projectAir preheater was installed for preheating the combustion air supply. The combustion air waspreheated to a temperature of about 180oC.

BenefitsPreheating of combustion air has resulted in about 4% reduction in fuel consumption.

Financial analysisThe total benefits amounted to a monetary annual savings of Rs 0.32 million. The investmentmade was around Rs 0.30 million. The simple payback period for this project was 12 Months.





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Case study -8

SEGREGATE HIGH PRESSURE AND LOW PRESSURECOMPRESSED AIR USERS

BackgroundIn foundry industry the compressed air pressure requirement varies depending upon the users.For pneumatic actuators and cylinders the compressed air pressure requirement is about 5-5.5 kg/cm2.

For other applications such as cleaning the compressed air pressure is not the criteria. Thevolume of air flow is the criteria and not the operating pressure. The maximum compressedair requirement is 2.5-3 kg/cm2.

In compressed air systems, the power consumption of a compressor is directly proportionalto the operating pressure of the compressor. The compressor power consumption increaseswith increase in pressure and vice versa. Hence there is a good potential for energy savingby segregating the high pressure and low-pressure compressed air (cleaning air) users andsupplying compressed air at lower operating pressure.

Present statusIn one of the foundry industry compressed air pressure is maintained at 6.5 kg/cm2 in the mainheader. Majority of the compressed air is utilised for the pneumatic operations in the coremaking m/c’s, pneumatic lifts, pneumatic grinders and cleaning operations etc.

The total number of cleaning points in core making sections is 32 and that in the AluminiumDie Casting (ADC) section is 54. The quantity of compressed air utilised for cleaning operationis estimated as 750 cfm in the core-making area and about 850 cfm in the Aluminium DieCasting section.

Energy saving projectThe high pressure & low-pressure (for cleaning application) compressed air users weresegregated by laying a separate compressed air line.

Compressor of capacity 1500 cfm was dedicated for the cleaning applications and operatedat a pressure of 3.0 kg/cm2.

BenefitsImplementation of the project resulted in atleast 30% reduction in compressor powerconsumption.


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Case study -9

INSTALL VARIABLE FREQUENCY DRIVE FOR SCREWCOMPRESSOR

BackgroundIn compressed air system once the required pressure is achieved the compressor is gettingunloaded. The loading unloading pattern indicate the quantity of compressed air requirementin the plant. The higher unload time of the compressor indicates excess capacity available inthe compressor

During the unload time, the compressor does not deliver useful work, but operates only toovercome its internal losses. The compressors should be so selected to operate with aminimum unload time.

There is a good potential to save energy by minimising the unload time of the compressor.This can be achieved by varying the speed of the compressor to match with the compressedair requirement. speed variation can be carried out by installing a Variable Frequency Drive.

A Variable Frequency Drive (VFD) with the feed back as the receiver pressure, would constantlysense even the slightest increase / decrease in the receiver pressure. Accordingly it wouldvary the speed of the compressor.

This installation of the VFD would completely avoid the unload time and would hence result intremendous savings in power consumption.

Present status A screw compressor of capacity 480 cfm is in operation for the compressed air requirement.The load / unload pattern of the 480 cfm screw compressor is as below:

Description Power consumption (kW) Time (%)

Load 81.5 43

Unload 49.7 57

The load and unload timings of the compressor is recorded in the hour meter fitted to thecompressor. Over the past 1600 hours of operation of the compressor, the compressor isloaded only for 43% of time.

Energy saving projectThe screw compressor was installed with variable frequency drive.



BenefitsThe implementation of the proposal resulted in the following benefits:

The unload power consumption of the compressor was totally eliminated.

The operating pressure is precisely maintained to match with the requirement. This has resultedin reduction in operating pressure of 0.5 kg/cm2 and hence corresponding reduction in loadpower consumption.






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Case study -10

REPLACE PNEUMATIC TOOLS WITH ELECTRICAL TOOLS

Back groundIn foundry industry pneumatic tools are one of the major compressed air consumers. Pneumatictools are used for core dressing in the core shops and in the fettling shop for the grindingoperations.

Also pneumatic hoists are used for lifting the products. The compressed air pressure requirementfor operating the pneumatic tools is in the range of 5-5.5 kg/cm2. Use of compressed air foroperating the tools is energy intensive and costlier.

Electrical energy is used to generate high pressure air in the compressor, which has theoperating efficiency in the range of 35-40% i.e only maximum 40% of the energy input isavailable in the form of compressed air.

If electrical energy is directly used for driving the tools, the inefficiency of the compressor canbe eliminated. Which will result in atleast 50% reduction in energy consumption.

Hence there is a good potential to save energy by replacing the pneumatic operated tools withelectrical tools.

Present statusIn one of the medium scale foundry industry about 20 pneumatic tools are used for coredressing and grinding operations in the fettling sections.

The quantity of compressed air utilised for operating the pneumatic tools is about 250 cfm

Energy saving projectAll the pneumatic operated tools such as grinding machines and the pneumatic hoists arereplaced with electrical tools and hoists.

One compressor of capacity 250 cfm, which was in operation for the compressed air supplywas stopped.

BenefitsImplementation of the proposal has resulted in 50% reduction in energy consumption of thetools.

This has also resulted in avoiding maintenance of one compressor running for the pneumatictools.


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Financial analysisImplementation of the proposal has resulted in annual saving of Rs 0.75 million. The investmentmade was Rs 2.30 million for converting the pneumatic tools to electrical tools. The paybackperiod was 37 Months.





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Case study -11

INSTALL OIL FIRED CORE DRYING OVENS FOR DRYING THECORESBackground

In medium scale and large scale foundry industry electrical energy is used for drying the coresin the core drying ovens. the cores will be dried in batches by placing inside the electricalheated ovens for a period of time.

Typically the operating temperature of the core drying oven is in the range of 175 –200oC.

Electrical energy is high grade energy. Cost of heating using electrical energy is very highcompared to cost of heating using low grade thermal energy.

The cost comparison between the electrical heating and thermal heating is given below.

• Cost of electrical heating @ Rs 3.50/unit - Rs 4283/MMkCal

• Cost of thermal heating (LDO fired) - Rs 1830/MmkCal

Cost of electrical heating is two times more than cost of thermal heating.

Hence there is a good potential to save cost by utilising thermal heating for the core dryingapplications.

In the oil fired system, the fuel is fired using a burner and mixed with air. The hot gas iscirculated in a chamber through the cores are sent for the drying process. This system is acontinuous process unlike the electrical heated ovens. This leads to increased production also.

Present statusIn one of the medium scale foundry industry electrical heated oven is used for the core dryingapplications.

The operating temperature of the core drying oven is 200oC. The power consumption of thecore drying oven is 120 kW and the heaters are “switched ON” for atleast 50% of the operatingtime.

Energy saving projectThe electrical heated oven was replaced with oil fired oven for the drying application.

This has resulted in 50% reduction in operating cost of the core drying oven


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Case study -12

REPLACE EXISTING OIL FIRED ALUMINIUM MELTINGFURNACES WITH GAS FIRED FURNACES

BackgroundTypically for aluminium melting either electrical or oil fired furnaces are used. In oil firedfurnaces flue gas passes around the crucible in which metal to be melted is placed. The heattransfer from the flue gas to the metal takes place through the crucible.

The melting furnaces the oil fired burners are fitted with a dedicated combustion air supplyblower. The exhaust flue gas from the melting furnace is in the range of 750 to 800oC. Theflue gas is directly sent to atmosphere. This results in increased flue gas loss.

In oil fired system, the quantity of excess air sent for the combustion process is in the rangeof about 25-30% of the stoichiometric air requirement. The increased excess air supply leadsto increased flue gas loss.

The recent trend is installing gas fired system for Aluminium melting application. For gas firedsystem the excess air requirement is only 3-5% of Stoichiometric air requirement, which isvery low compared to excess air requirement for the oil fired system. This results in lower loss.

In the gas fired system gas firing can be effectively controlled based on temperature. Thetemperature of flue gas between the outside shell and crucible or molten metal temperaturecan be given as a feed back to the gas firing control system. This eliminates over shoot intemperature of molten metal.

In the gas-fired system, the quantity of combustion air requirement is less compared tocombustion air requirement for the oil fired system. Hence, the power consumption in thecombustion air supply fan is also significantly reduced.

There is a good potential to save energy replacing the existing oil fired system with gas-firedsystem for all the melting furnaces in the aluminium foundry.

Present statusIn one of the medium scale aluminium foundry oil fired furnaces are used for Aluminiummelting. Light Diesel oil and furnace oil are used as fuel for the melting furnaces. The detailsof the melting furnaces available in the Aluminium foundry are as follows:

S No Furnace type No of furnaces Capacity Kgs Burner capacity lit/hr

1 Big Skelenar 1 500 62

2 Small Skelenar 4 250 30

3 Big tilting 3 300 32

4 Small tilting 5 150 20


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Energy saving projectThe oil fired systems were replaced with gas fired system for all the melting furnaces in thealuminium foundry.

BenefitsThe implementation of the proposal has resulted in about 20% fuel cost saving.

Financial analysisThe benefits amounted to a monetary annual savings of Rs 2.01 million. The investmentmade was around Rs 2.50 million. The simple payback period for this project was 15 Months.


• Investment - Rs. 2.50 million



445

List of Contractors / Suppliers Name of the Company and Address Area of expertise INDUCTOTHERM INDIA LTD Bopal, Ahmedabad - 380 058 Gujarat (India) Tel:91-79-3731961 (8 Lines) Fax: 91-79-3731266, 91-79-3731268 Email: [email protected] URL: www.inductothermindia.com

Induction Furnaces, Controls for the furnaces

M/S ENCON INTERNATIONAL (P) LTD. Mr. R.P. Sood 14/6, Mathura Road, Faridabad - 121 003 (Haryana) Tel: +91-129-2275307 Fax: +91-129-2276448 E mail: [email protected]

Induction furnaces

PILLAR INDUCTION (I) LIMITED EXPORTERS OF FURNACES. A-13, 2nd Avenue Anna Nagar, Chennai - 600102, India Tel(44)6261703/26261704/2621705 Fax: +(91)-(44)-26260189

Induction furnaces

WESMAN GROUP OF COMPANIES "Wesman Center", 8, Mayfair Road, Kolkata - 700 019, Tel:(91)-(33)-22405320 Fax: +(91)-(33)-22478050

Burners

ADVANCE HEATING SYSTEMS d1/23 (back side) Mayapuri ind. area, phase-ii, New Delhi -110064 Tel: 91-11-5139315 Email:[email protected]

Industrial furnaces, ovens, oil fired systems, heat treatment furnaces

ASSOCIATED INDUSTRIAL FURNACES f-9, sector-xi, Noida -201301 Tel:91-11-84529169 Fax: + 91-11-84555703 E-mail: [email protected] Website

Shuttle & Tunnel kilns, pit type annealing furnaces, continuous ovens and driers



ENGINEERS ASSOCIATE 10-d, Garpar road, Calcutta -700009 Tel: 91-33-3510690 E-mail: [email protected]

Muffle furnaces, oven, drier, thermo couple

HEATCON SENSORS (P) LTD. mes road, bangalore -560013 Tel:+ 91-80-8384564 Fax: + 91-80-8382914 E-mail: [email protected] Website http://www.heatc onsensors.com

Temperature controllers, thermocouples etc

INDUSTRIAL FURNACE & CONTROLS Vempu road, Bangalore -560021 Tel:+ 91-80-3329840 Fax: + 91-80-3329840 E-mail: [email protected] Website http://www.indfurnace.com

Electrical and oil fired furnaces, temperature controllers, thermocouples

MACRO FURNACES PVT. LTD. 16/2, mathura road, faridabad -121002 Tel:+ 91-129-5260004 Fax: + 91-129-5260146 E-mail: [email protected]

Electrical and gas fired industrial furnaces

PYROTHERM ENGINEERS PVT. LTD. 245/2b, 2b-vanagaram road, athipet, Chennai -600058 Tel:+ 91-44-6358038 Fax: + 91-44-6358038

Aluminium melting furnaces, ovens

THERMOTHERM ENGINEERS 455, 12th cross, 4th phase, peenya indl. area, bangalore -560058 Tel:+ 91-80-8362507 Fax: + 91-80-8362919 E-mail:[email protected]

Industrial furnaces, heat treatment furnaces and ovens

PADAM ELECTRONICS Plot No 1/103, West Kanti Nagar, St No 3, New Delhi - 110 051, India Tel:+(91)-(11)-22001791/22003581 Fax: +(91)-(11)-22003581 Website: http://www.indiamart.com/padam -electronics

Muffle furnaces, electrical furnaces, diesel fired furnaces and heat treatment furnaces

NORTH-WEST INDUSTRIES Opp. Indo Bulger, Meerut Road, Sihani Chungi, Ghaziabad - 201 001, India

annealing furnaces.


447

Tel:+(91)-(120)-2736650/9810367173 Website: http://www.indiamart.com/northwest

ALIDIA POWERTRONICS PRIVATE LIMITED Address: Shed 1, Computer Complex, DSIDC Scheme 1, Okhla Industrial Area Phase II, New Delhi - 110 020, India Tel:+(91)-(11)-4963017/4963028/4963163 Fax: +(91)-(11)-26386602 Website: http://www.indiamart.com/alidia

Medium frequency induction melting and heating furnaces, portable high frequency Induction heating equipment.

METROPOLITAN EQUIPMENTS & CONSULTANTS PVT. LTD. Plot No. A - 486, Wagle Industrial Estate, Road 24, Thane - 400 604, India Tel:+(91)-(22)-5823294/5800799/5814654 Fax: +(91)-(22)-5800801 Website: http://www.indiamart.com/metropolitan

Roller hearth tunnel furnaces, material handling systems etc

ENCON INTERNATIONAL (P) LTD. Address: 14/6, Mathura Road, Faridabad - 121 003, India Tel:+(91)-(129)-2275307/2275607 Fax: +(91)-(129)-2276448 Website: http://www.indiamart.com/enconindia

All types of furnaces

Precision Controls Manufacturer & exporters of furnaces. 20, SIDCO Industrial Estate, Ambattur, Chennai - 600098, India Tel: +(91)-(44)-26250370 Fax: +(91)-(44)-26257835

All types of furnaces

REFRACTORIES & FURNACES COMPANY P.O.Box:80, Kezhakkenada, Chengannur - 689 121, India Tel: +(91)-(479]-454310 Fax: +(91) -(479]-452481

Furnaces and refractories


448Energy Conservation in Textile Sector & Technology in Textile Industry

Textile

Energy Intensity 10.4% of total energy consumption

Energy saving potential 506 MW

Investment potential onenergy saving projects Rs 40000 million


449

IntroductionThe textile industry is one of the oldest in the country, more than 105 years old. The textileindustry has undergone rapid changes over the years. There are more than 2324 unitsoperating in the power-processing sector. Many new units are being set up and older unitsbeing mordanised.

Indian textile industry is worth around Rs 800 billion (US$ 22.05 billion) accounting forapproximately 20% of India’s total industrial output.

The textile industry is an important segment of the country’s economy, which contributes 3%to country’s GDP and earns about 27% of the gross export earnings, totaling to 12.1 BN USD,USD 50 billion has been set by 2010. Indian textile sector also employs 15 million people,about 21% of the work force.

The cotton cloth production in the year 2001 – 02 was 40256 million sq. mtrs. Which showsrise in production by 2.7%. The growth potential of textile sector is estimated to be 5.65%.

The Indian textile industry consumes nearly 10.4% of the total power produced in India.

In a large composite textile mill, the cost of energy as percentage of the manufacturing costvaries between 12 – 15%, which includes electrical and thermal energy. The energy cost isnext to the raw material cost and comparable to labour cost. Hence, energy conservation ina textile mill plays significant importance and is a priority area for maximising profits. Thescope for energy conservation in the textile sector is normally around 15%.



Process Flow Diagram for High Value Cotton Fabric

Raw Material

Blow Room

Carding

Combing

Draw Frame

Ring Frame

Winding Yarn Dyeing

Warping

Sizing

Weaving

Singeing

Bleaching

Mercerizing

Finishing

Yarn Preparation


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Process Flow Diagram for Denim Fabric

Raw Material

Blow Room

Card

Drawframe

Autocore

Dyeing & Sizing

Weaving

Finishing

Folding

Packing

Dispatch

Processing



Textile ManufacturingThe manufacturing process in a composite textile mill involves three broad categories:

1. Spinning

2. Weaving

3. Processing

1.1 Spinning

a) Blow roomHard pressed bales of raw cotton obtained from the market are first put through blowroom where, by a combination of rapid beating and suction, the cotton lumps are brokendown in size and part of the impurities such as sand leaf, stalk etc, which are heavy, areremoved. The opened cotton is delivered in the form of roll called a lap or in loose tufts.

b) CardingDuring the carding process the laps are acted upon by a series of wire points set closetogether and individual fibre separation is achieved. Residual trash in the opened cottonis almost entirely removed in this process.

c) CombingThis is an additional process introduced between carding and drawing to parallelise thefibres, remove short fibres and impurities so that yarn quality obtained is substantiallyimproved.

d) DrawingIn this operation the drawn fibres are made thinner and wound on to a bobbin afterintroducing a small amount of twist.

e) Ring spinningIn this operation attenuation of the assembly of fibres takes place so as to obtain therequired count and the required twist is imparted to obtain the desired strength. Theresulting material is wound on a spindle.

f) WindingThe spinning packages obtained in ring frames contain a small quantity of yarn, whichare converted to bigger packages in winding.

g) ReelingCertain markets required the yarn to be supplied in the form of hanks containing certainlengths of yarn, which is on a reeling machine.

2.1 Weaving

a) WarpingThe yarn from spinning frames is cleaned and obtained on a long length of cones. Thesecones are placed on warping creel and the ends are drawn forward and wound on to awarper beam placed on warping machine headstock.


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b) SizingA number of warper beams as required are placed at the back of the sizing machine andthe layers of yarn are drawn forward and impregnated in a solution containing adhesive,gum & lubricant and dried so as to withstand the rigors of weaving.

c) WeavingThe sized warped beams are mounted at the back of the loom and by suitably drawingthe ends through warp stop motion heads and the reed, they are made to interlace withthe weft, to produce the fabric. The woven fabric is collected in front of the loom.

3.1 Processing

a) SingeingSinging is a process in which the protruding fibres and loose threads on both faces ofthe fabric are removed. This is achieved by passing the fabric close to gas flames orelectrically heated hot plate.

b) DesizingThe fabric is given an enzyme treatment so that the impurities such as starch, gum etc.,are degraded into water-soluble products, which are then easily removed by washing.This carried out in jiggers.

c) BleachingBleaching is a process where the natural colour of Grey fabric is removed and renderedwhite by treating it with sodium hydrochlorite or hydrogen peroxide. The treatment timevaries depending on the fabric.

d) MercerisingThe purpose of mercerising is to impart luster and strength to the fabric. The processconsists of treating the fabric with concentrated caustic soda solution. Stretching preventsthe shrinkage of the material. Caustic is washed off while in the stretched stage.

e) DyeingDuring dyeing, a single shade is applied to the material, which can be a batch or continuousprocess. There are different methods of dyeing – dyeing of yarn in cones, cheese, sheetdyeing, rope dyeing, jet dyeing, jigger dyeing etc.

f) PrintingPrinting is done on screen printing machine to impart designs to the bleached or dyedfabric.

g) CuringCuring is a treatment on curing machines to improve crease recovery properties of cottonfabrics or to fix pigment colour on fabric. Curing is done on polymersing machine.

h) Heat settingHeat setting is normally carried out in a stenter to impart dimensional stability to syntheticfabric. The temperature and time for heat setting depends on the fabric count.

i) FinishingFinishing process is done to improve the attractiveness of the fabric. Some of the majorfinishing processes are anti shrink finishing, crease – resistance finishing, Shrinkagefinishing etc. Finishing is carried out on stenter or finishing machine.



Case study - IInstall High Efficiency Atomisers in Lieu of Nozzles inHumidification PlantsBackground

Humidification plays an important role in any composite textile unit. In composite textile units,humidification is a major load.

In textile plants humidity is a critical parameter for the conditioning / stickiness of yarn. Humidityvaries with the type of yarn and type of application. Humidity varies from 50 – 75% based onapplications e.g. spinning, weaving and types of fabric.

Generally, all humidification plants are installed with conventional type nozzles. This requiressmall nozzles in large numbers to meet the humidity requirement. This causes loss of forcedue to friction for spraying water through small orifice. This also requires high head and highflow of water.

Now a days better designed atomizer with high efficiency is available. One nozzle can replacewith 50 conventional type nozzles.

Advantages• No cleaning / Maintenance• Water flow : 1/3 flow of normal flow required• Head : 1.45 times normal head required• Lower flow due to better aomisation• Substantial energy savings• Density of atomised water could be adjusted according to the requirement

RecommendationsIt is recommend to install atomisers in lieu of conventional type nozzles, where spray pumpsare running continuously.

AHU No Actual Power (KW) No of Nozzles No of Atomisers required

2 7.02 280 6

4 7.04 280 6

5 5.22 288 6

6 4.52 288 6

7 4.76 162 4

8 4.98 288 6

10 4.48 504 10

11 7.86 504 10


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BenefitsInstallation of atomiser in humidification plants will result in annual savings of Rs. 0.43 million.This calls for an investment of Rs. 0.35 million for changing the atomisers. This has a simplepayback period of 10 months.

Nozzle

Air Flow Fan

Water

Spray

Wate

Humi D i f i ed A i r





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Case study - II

Install Energy Efficient Pnuemafil Fans in Ring FramesBack groundThe main function of the pnuemafil fans in Ring frame machine is to remove fluff from cotton/ fiber threads and preparing cones of yarn, which in further used for preparation of yarnbeams.

Normally 5 – 7.5 kW motor is installed for Pnuemafil fan of Ring Frame machine, andconventional pnuemafil fan consumes 4.1 – 4.5 kW.

Now a day energy efficient fan with suction tube is available which are specially designed andcan reduce power consumption atleast by 20%

Comparison• For G 5/1 Ring Frames

Sl no Special features Conventional Energy Efficient FansPneumafil fans

1 Weight 14 kgs 6.5 kgs 6.2 kgs

2 Fan Diameter 490 mm 460 mm 420 mm

3 kWh consumed 5.00 3.97 2.41

• Comparative study on Impeller and Suction tube

Spindle no. Conventional fan Energy efficient fan Energy efficient fan490 mm dia. fan with 490 mm dia. with 460 mm dia.with suction tube and suction tube and suction tube

(OE) 505 *115 *150 *110

(Middle) 751 *50 *100 *70

(GE) 1008 *30 *85 *60

*Above suction results are in mm water column.

RecommendationIt is recommend to install energy efficient pnuemafil fans for existing ring frame machines. Byinstalling energy efficient fans in atleast 2/3 machines, trial should be taken and after seeingthe performance, all the Ring Frames should be converted with energy efficient fans.




BenefitsThe total annual savings will be Rs. 0.78 million. Theinvestment required is Rs. 0.40 million, which will getpaid back in 6 months.


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Case study - III

Install VFD For Humidification Fans and Reduce Speed DuringFavourable ConditionBackground

Humidification, in the textile plants plays a very important role, as humidity plays an importantpart in conditioning of the yarns and in turn in manufacturing of end product – fabric.Humidification system comprises of fans and pumps for water spraying. It is one of the majorconsumers of power in textile units.

It is customary to provide two fans adjacent to each other to meet the humidification requirementand also to avoid complete shut down of humidification system in case of failure of one fan.

During unfavorable climatic condition all the pumps and fans will be running and during favorableclimatic condition, like – Monsoon & winter – when humidity in out side air is good (@90 – 98% - Monsoon) and temperature is also less, some of the pumps and fans will be stopped.

During favorable condition, normally one fan is stopped and one fan is kept “ON”. This causesrecirculation of part of fresh air and this is energy inefficient method.

The operation is mentioned below:

Area Required condition Fresh Air Intake Power (KW)

Weaving

80 sulzer 28-30oC June – September 12.385 % Rh (24 Hrs)

16 sulzer 28-30oC June – September 10.685 % Rh (24 Hrs)

Spinning

Rope Race Carding 37-38oC March – September 15.050 - 54% Rh (7 Months)

Crosrol Carding 37-38oC 15.050 - 54% Rh

LR Section Plant -II 38oC 10.654% Rh

Ring Can I & II (LUVA) 38oC 10.354% Rh

LTG Plant No 4 38 – 40 oC 12.558% Rh



Good energy saving potential exists by installation of VFD for supply air fans with closed loopcontrol system and reducing the speed of the fan.

Recommendation• Install VFD for supply air fans with closed loop control system.

• Providing feed back of Temperature and % Rh, close loop system can be made.

• Reduce the speed of the fans

• Then put the fans in operation

Good energy saving potential exists by installation of VFD for supply air fans with closed loopcontrol system and reducing the speed of the fan.

BenefitsReducing the speed of the fan by installation of VFD will result in annual savings in the tuneof 25 – 30%.





461



Reducing the speed of the fan by installation of VFD will result in annual savings ofRs. 0.36 million. This calls for an investment of Rs. 0.70 million for changing the pulley. Thishas a simple payback period of 23 month.

Case study - IV

Convert V-belt Drives to Synthetic Flat Belt Drives For TheTFO Machines

BackgroundTFO (Two Folds One) machine is used for strengthening yarn by twisting. Generally, V-beltdrive is used for all TFO machines.

Belt is used for transmission purpose. “V” belt causes wedge – in and wedge – out losses.

Flat belt is crown at the center.

Replacement with synthetic flat belts will reduce

• Wedge-In and Wedge-Out losses

• Reduce the mass of the belt

Proven results show that there is a saving potential of 4% by converting V-belt drives to flatbelt drives. Flat belt drives are highly suitable for steady loads.

Motor of TFO machine is normally in the range of 20 – 25 kW and average power consumptionis @10 - 13 kW. Therefore very good potential can be tapped by converting “V” belt drivesto Flat belt drives.

RecommendationIt is recommend to convert V-belt drive to flat belt drive in the TFO machines.

This conversion should be done in phased manner, starting from installation on one or twomachines.

During implementation, it should be ensured that the area is free from oil or water spillage.There should also be proper alignment between the drive and the driven equipment.

BenefitsThe annual savings potential will be @ 4% / machine.





463



The annual savings potential is Rs 0.73 million shall be achieved. This will require an investmentof Rs 1.45 million for new flat belts and pulleys and shall be paid back in 24 Months.

Case study - V

Install VFD For Autocoro Suction Motor

BackgroundIn the spinning department, autocoro machine is used for manufacturing yarn. Autocore machinedraws cotton rope and prepares finer count yarn (7s / 16s / 2 X 50s / 2 X 40s etc…) whichis further used as raw material for processing in process department.

Autocoro machine is used to get required count of the yarn and in the process it removes fluffand other impurities from the yarn. Normally, based on type of count, constant suction pressureis maintained in the suction box of autocoro machine. Suction motor is used to maintainsuction pressure for removal of fluff and other impurities from yarn.

Suction pressure is varying with the count of the yarn. Maximum suction of 85 mbar issufficient for the process. But due to accumulation of fluff in suction box and choking ofsuction net suction pressure is varied or maintained high.

Power consumption of suction motor is @ 20 kW because of high suction pressure.

RecommendationIt is recommended to install variable speed drive with suction pressure as feed back signal,for suction motor and set the pressure at 85 mbar.

Variable speed drive will always try to match the suction requirement of suction pressure andwill operate at lower speed.

BenefitsBy installing variable speed drive atleast 15 – 20% energy can be saved.

The annual energy saving potential is Rs 1.28 million. This requires an investment ofRs 2.00 million, for installing variable frequency drive for all the pumps, which gets paid backin 19 months.





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Case study - VI

Install Variable Frequency Drive for Water Circulating Pumpsof Jet Dyeing MachineBackground• The Jet dyeing machines are used for washing and dyeing the fabrics. For washing the

fabrics hot water is circulated inside the jet-dyeing machine. A dedicated centrifugal pumpfor individual jet dyeing machine remains in continuous operation for circulating the hotwater inside the machine.

• During the washing process the pressure requirement for water circulation varies over aperiod of time. The initial pressure requirement for water circulation is in the range of 1-1.5kg/cm2. For maintaining the required pressure a control valve provided at the outlet of thecentrifugal pump is manually throttled based on the pressure gauge indication provided atthe down side of the control valve. This condition prevails for atleast 30-35% of the batchtime.

• During the washing process, as heating of water takes place in the jet dyeing machines thepressure gradually increases. After certain period of time the required pressure for watercirculation is in the range of 2.0-2.5 kg/cm2. The pressure requirement and the time takenfor washing varies depending upon the fabrics. During the maximum pressure requirementthe control valve provided at the outlet of the pump is kept fully opened.

• During valve throttling, there is a significant pressure loss and hence energy loss occursacross the control valve. There is a good potential to save energy by avoiding the pressureloss across the control valve. This can be achieved by installing variable frequency drive forthe centrifugal pumps. Instead of throttling the control valve the speed of the centrifugalpump has to be varied using the variable frequency drive to meet the required pressure.

RecommendationIt is recommended to:

• Install variable frequency drive for the centrifugal pump in each jet-dyeing machine.

• Provide a speed control switch at the user end. So that instead of valve throttling the speedof the centrifugal pump can be varied to meet the required pressure.

• Keep the control valve fully opened.

BenefitsOn a conservative basis 35% energy savings can be achieved for 30% of the operating time.




The annual energy saving potential is Rs 0.32 million .This requires an investment of Rs.0.8 million, for installingvariable frequency drive for all the pumps, which gets paidback in 30 months.


467



Case study - VII

Reduce the Speed of Exhaust Fans in Stenters

Background• In Stenters centrifugal fans are kept in continuous operation for removing the exhaust air

after the drying process. The air is collected from various zones and sent to atmosphere.

• It is observed that the dampers provided in ducts from various collection zones are heavilythrottled. The dampers are only 25 – 35% open. Due to damper throttling there is asignificant pressure loss and hence energy loss across the damper.

• Hence, there is a good potential to save energy by avoiding the pressure loss across thedamper control. This can be achieved by reducing the speed of the fan to match therequirement and increasing the damper opening.

RecommendationsIt is recommend to:

Step –1

• Install a variable frequency drive for the fan temporarily and gradually reduce the speedof the fan. Simultaneously gradually increase the damper openings.

• Periodically check the quality of the product. Identify the minimum speed of the fan atwhich the dampers can be kept fully opened without affecting the quality of the product.

Step -2

• After identifying the speed of the fan, permanently reduce the speed of the fan.

• The driver or driven pulleys can be accordingly changed for the bet driven fans. For directdriven fans, convert the directly driven fans to belt driven fans and reduce the speed.

BenefitsOn a conservative basis atleast 40% savings can be achieved.

The annual energy saving potential is Rs 0.10 million. This requires an investment ofRs 0.03 million for changing the pulleys, which gets paid back in 3 Months.

CCost benefit analysis• Annual Savings - Rs. 0.10 millions




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Case study - VIII

Avoid Idle Operation of Motors by Providing Stop Motion Circuitfor Blow Room

BackgroundHard pressed bales of raw cotton obtained from the market are first put through blow roomwhere, by a combination of rapid beating and suction, the cotton lumps are broken down insize and part of the impurities such as sand leaf, stalk etc, which are heavy, are removed.The opened cotton is delivered in the form of roll called a lap or in loose tufts.

Blow room cycle operates continuously for almost 23 hrs a day.

Blow room consists of following:

Stripper roller : 0.55 kW

Take off roller : 0.37 kW

Opening roller : 4.00 kW

Dust fan : 3.00 kW

De – Duster : 4.50 kW

Mono Cylinder beater : 2.20 kW

Ventilator : 4.00 kW

The opened cotton in the form of lap or loose tufts is than transferred to drawframes. Wheneverthe above mixtures are filled upto the pre-determined limit, the subsequent material transportmotor is stopped. But all other motors, such as the beaters and stripper rollers etc., will berunning idly, leading unnecessary energy consumption. Motor idle time varies between 10 to12 hrs.

All these idle running motors could be stopped step by step and could also be re-started atpre-determined time intervals whenever the demand arises. This is possible by introductionof stop motion circuit into the blow room.

RecommendIt is recommended to install stop motion circuit in blow room. As soon as cotton mixture willbe filled to pre-determined limit, it will stop the above mentioned motors.

Assuming idle time of 10 hrs and loading of motors at 50%, atleast 40% energy can be savedby avoiding idle operation of motors.

Sample calculationLR Blow room single line


471

The following motors can be stopped

(Assuming 4500 kg process for 23 hrs running)

Stripper roller : 0.55 kW

Take off roller : 0.37 kW

Opening roller : 4.00 kW

Dust fan : 3.00 kW

De – Duster : 4.50 kW

Mono Cylinder beater : 2.20 kW

Ventilator : 4.00 kW

Total : 18.62kW

Power consumption @ 50% load / hr

18.62 kW X 50% Load = 9.31 kWh

Assuming motor idle time be 10 hrs out of 23 hrs of operation.

Units saved = 9.31 kW X 10 hrs= 93.1 kWh/day= 33516 kWh/Annum

BenefitsThe annual energy saving potential is Rs 0.13 million. This requires an investment ofRs 0.05 million for changing the pulleys, which gets paid back in 5 Months.





473

Case study - IX

Install Transvector Nozzle for the Cleaning Applications

BackgroundGenerally for cleaning application same air pressure is used as air required for plant. Forcleaning application compressed air tapping from main header is taken and same air is usedfor cleaning of machines. The observations on compressed air generation and utilization forcleaning application are as below:

• Three screw air compressors of capacity 1475 cfm is in operation to supply compressedair for the plant requirements. The compressed air is supplied at an average pressure of7.00 kg/cm2.

• In weaving section about 10 -15% of the compressed air is used for cleaning the weavinglooms and removal of fluff fabric. There are about 8 numbers of such air cleaning pointsavailable in the plant.

• For cleaning operations the volume of the airflow is the criterion, not the pressure. Air at apressure of 2.0-2.5 kg/cm2 can effectively clean the products.

• The following observations were made in cleaning of cabinet section:

1. Total 8 cleaning points in operation

2. 1/ 2 “ hose- pipe is used for cleaning

3. Header pressure is 7.0 Ksc

4. Cleaning points are without guns.

• The recent trend is using Transvector nozzles for cleaning applications. The Transvectornozzles can be fitted at the user ends. It works based on venturi principle. When thecompressed air flows through the nozzle, the atmospheric air is sucked in through theholes provided in the periphery of the nozzle.

• The atmospheric air is mixed with compressed air and supplied for cleaning at lowerpressure (2-3 kg/cm2). The atmospheric air replaces 50% of the compressed air.

There is a good potential to save energy by installing Transvector nozzles for cleaning operations.

RecommendationIt is recommend to install Transvector nozzles at the identified cleaning points in the packingsection.

BenefitsOn a conservative basis, atleast 30% energy savings can be achieved by replacing thecompressed air with atmospheric air.

The total annual savings that can be achieved by implementing this project is Rs. 0.08 million.The investment required is estimated at Rs. 0.01 million with a payback period of 2 months.


475

Case study - X

Install Waste Heat Recovery Systems for Stenters

BackgroundThe stenters located in the processing sectionare major consumers of steam in any textileunit. The stenters are being used for drying, stretching and finishing. The fabric enters thestenters after the pre-drying cylinders with moisture of about 60 – 65 %. This moisture needsto be dried and vented out in the stenters. The stenters have normally two exhaust blowerswhich are operating continuously venting hot air & moisture at temperatures around 100 degC. At the processing plant the jigger dyeing section needs hot water at temperatures rangingfrom 40 degC to 80 degC. Presently steam is being used for supplying this heat. There is agood potential to install waste-heat recovery systems for stenter exhaust and utilise thisrecovered heat for dyeing machines.

RecommendationIt is recommend to install waste-heat recovery systems for stenters.

BenefitsThe total annual savings that can be achieved by implementing this project is Rs.0.85 million.The investment required is estimated at Rs.1.50 lakhs with a payback period of 22 months.





477

Case study - XI

Install FO Based DG Set to Meet Power Requirement of thePlant

BackgroundComposite textile units are power intensive and require huge power demand. Normally, powerrequirement of the plant is met through SEB power. Normally, power frequency of the gridvaries between 48 Hz to 50 Hz.

Composite textile unit comprises of Ring frames, Autocoro, TFO machines. These machinesare power sensitive machines i.e. production varies with the change in frequency of incomingpower. Also any interruption in power will cause breakage of yarn. This causes down time ofthe machine for almost 2-3 hrs and loss of production. Production of entire unit depends onthese machines i.e. lesser the production out put from these machines, lesser the productionof finished fabric.

If, it is possible to maintain stability of the power i.e. constant frequency and no interruptionthen there will be increase in production by 1 – 1.5% and less breakage of yarn result into goodquality of product.

This can be achieved by installing FO based DG set to meet power requirement of the plant.

RecommendationIt is recommended to install 4.2 MW FO based DG set to meet power requirement of the plant.

This will result in drastic reduction in cost of power. Cost of power generated through FObased DG set is Rs 2.50 / kWh.

BenefitsThe total annual savings that can be achieved by implementing this project is Rs. 40 million.The investment required is estimated at Rs.120 million with a payback period of 36 months.

While calculating annual savings, rise in output by 1 – 1.5% is not considered.





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Case study - XII

Replace Chain Stroker Boiler to FBC Boiler System

Background• A composite textile industry is having IJT Chain stroker boiler of 30 TPH at 30 kg / cm2.

Efficiency of boiler is about 70%. Boiler is generating high pressure steam at 30 kg/ cm2,350 deg C super heat, passes through back pressure turbine and generating about 2000kW power. Out let of steam turbine at 10.50 kg / cm2 is used in process. Requirement ofprocess is @ 24 – 26 TPH at 8.50 kg/cm2.

• At present imported / indigenous coal is used. Average calorific value of coal is 4500 kcal/ Kg. Landed cost of coal is Rs 2700 / MT. Average consumption of coal is 6.0 MT / hr.

• Power generation through STG is 12 Lakhs kWh / Month.

• There is a possibility of improving efficiency of the boiler from existing 70% to atleast 79%.

• Work out possibilities of using cheaper fuel, which will lead to differential cost saving offuel, without compromising capacity and quality of steam.

Recommendation• Convert existing boiler to multi fuel fluidised bed combustion system, by which efficiency

can be increased from existing 70% to atleast 79%.

• Also this conversion will have facilities of using multi fuel like agro waste, saw dust, lignite,rice husk having calorific value more than 3000 kcal / kg.

• This will give flexibility of using cheaper and available fuel.

• Expected lignite consumption is 5625 MT / month considering average CV of lignite 3200kcal/ kg.

• Cost of lignite at site is Rs 1400 / MT

• Power generation will remain same i.e. 12 Lakhs kWh / Month

BenefitsThe total annual saving that can be achieved by implementation of this project implementationof this is Rs 52.38 million. The investment required is estimated at Rs 12.50 million with apayback period of 4 Months.

Project cost for conversion of existing boiler to FBC

1) Estimated conversion cost : Rs 1,16,10,000/-

2) Approximate cost of ESP : Rs 50,00,000/-

Total cost : Rs 1,25,00,000/-



Cost SavingsCost of coal consumption of : Rs 1,16,10,000/-4300 MT /month at 72% efficiency @ Rs 2700 / MTand CV 4500 Kcal / kg

Equivalent cost of lignite consumption of : Rs 78,75,000/-5625 MT / Month at 72% efficiency@ Rs 1400 / MT and CV 3200 Kcal / kg

Additional savings in lignite consumption with : Rs 6,30,000/-increase in efficiency from 72% to 80%

Net savings in fuel cost / month : Rs 43,65,000/-

Estimated Savings / Annum : Rs 5,23,80,000/-

Payback : 03 months





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Case study - XIII

Replace Old Conventional Motors with Energy Efficient Motors

BackgroundThe conventional standard induction motors have efficiencies of 75 to 88% depending on thesize and the loading of the motors. The Energy Efficient Motors (EEM) are designed with lowoperating losses. The efficiency of Energy Efficient motors is high when compared toconventional AC induction motors, as they are manufactured with high quality and low lossmaterials.

The efficiency of Energy Efficient motors available in the market range from 80 to 95%,depending on the size.

The efficiency of energy efficient motors is high due to the following design improvements:• More copper conductors in stator and large rotor conductor bars, resulting in lower copper

loss• Using a thinner gauge, low loss core steel and materials with minimum flux density reduces

iron losses.• Friction loss is reduced by using improved lubricating system and high quality bearings.

Windage loss is reduced by using energy efficient fans.• Use of optimum slot geometry and minimum overhang of stator conductors reduces stray

load loss.

Efficiency of a motor is proportional to the loading of the motor. Conventional Motors operatein a lower efficiency zone when they are loaded less than 60%. At all loading ranges of themotor, efficiency of EEM is higher than conventional motors.

There is a good potential to replace these inefficient motors with energy efficient motors.Replacing with energy efficient motors would result in at least 8-10% efficiency improvement.

Energy saving projectIn a textile plant, the old conventional motors, which were rewound for more than 5 times werereplaced with energy efficient motors.

Benefits




An annual energy savings potential of Rs. 1.49 million has been achieved by replacing the oldinefficient motors with energy efficient motors. The investment made was aroundRs. 1.10 million, which got paid back in 9 months.


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484Energy Conservation in Engineering Sector

Engineering Sector

Energy Intensity 3.7% of the manufacturing cost

Energy Costs Rs. 25000 Million

Energy saving potential Rs. 5000 million.

Investment potential onenergy saving projects Rs.10000 million


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About the sectorIndia has a well-diversified general engineering goods sector. It consists of automobiles andauto components, power plant/prime mover equipment, industrial processing machinery,domestic goods, pumps, construction machinery, engines and other special purpose machines,pumps, domestic goods, etc

Energy Intensity in the Engineering sectorIn the engineering sector, fuel and power costs vary from 3% to 7% of the total manufacturingcost. The energy bill of the engineering industry in India amounts to Rs 2500 Crore per annum.

Energy Saving PotentialThe energy savings potential in this sector ranges from 6% to 18 % of the total bill for fuel andpower. The energy saving potential in engineering sector is Rs 2500 millions. The totalinvestment potential for energy savings in the sector is Rs 5000 million.

For any investments made in energy saving projects in the general engineering sector, the payback is less than 2 years.

Growth potentialThe sector represents a market of Rs 1250 billion, with annual growth averaging nearly6% during the last five years. The sector is expected to maintain the same levels of growthin the coming years also.

Major Players

The engineering sector in India is a very diverse sector, having a number of major and midsizeplayers - Telco, Ashok Leyland, Bajaj Auto, Hero Honda, TVS group, LML, Kinetic Engineering,Escorts group, TI (Tubes India) Group, Bharat Heavy Electricals Ltd (BHEL), Godrej & BoyceManufacturing, Kirloskar Group, Bharat Forge etc to name a few.

Manufacturing ProcessIn engineering sector, the processes are diverse in nature and vary from industry to industrydepending on the final end product being manufactured.

In the case of automobile industry, the processes vary from sheet metal cutting, moulding, heattreatment, pressing, machining, drilling, milling, grinding, electroplating, induction heating, welding,painting, pneumatic applications etc.

Utilities in the sector, account for almost 70% the whole of the energy being consumed. Themain utilities are Compressor, Pump, Fan, air conditioning, refrigeration etc. Also present aresome common processes like painting, drying, heat treatment, electroplating etc. There is nosingle process in the sector that can be generalised.

The process equipment involved in the engineering sector offer only a minimum potential forenergy savings. This study on energy saving potential in engineering sector therefore mainlyfocuses on utility loads like Compressors, dryers, Pumps, fans, blowers, heat treatmentequipment (furnaces), air-conditioning equipment, lighting etc.



Short, Medium and The Long term Projects

Long term projects

Compressors1. Replace old energy inefficient compressors with new energy efficient compressors

2. Install variable Frequency Drives for Screw compressors catering to varying demands ofcompressed air

3. Segregate high pressure and low-pressure compressed air users

4. Replace the refrigeration /Desiccant type air dryer with Heat of Compression type (HOC)air dryers, in case of reciprocating air compressors

Short-term & Medium-term1. Arrest compressed air leakages by vigorous maintenance

2. Optimise overall operating pressure of compressors based on the system requirement

3. Provide ball valves at the user ends of compressed air cleaning hoses and other similarpoints where the exiting control exists at a distance from the user.

4. Replace compressed air with blower air for agitation in effluent treatment plants,phosphating tanks and in similar applications

5. Install Transvector nozzle for cleaning applications involving compressed air

6. Replace pneumatic tools with electrical tools where ever possible

Pumps

Long-term1. Install VFD for Oil pump in Hydraulic power pacs and reduce idle operation

2. Install Variable Frequency drives (VFD) for pumps catering to varying demand instead ofoperating with recirculation / valve throttling

Short-term & Medium-term1. Optimise the excess capacity / head of the pump by installing next lower size impeller for

pumps and avoid throttling / recirculation

2. Switch “OFF” the main circulation pump in the curing press hydraulic power pacs duringthe idle cycle

3. Install LIC (Level Indicator Controller) for water over head tank pump to avoid recirculationi/ over flow

4. Install correct size pumps for cooling tower based on the system head / flow requirements


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Fans

Long-term1. Replace low efficiency exhaust fans with new fans of higher efficiency.

2. Install variable Frequency driveS (VFD) for hot air circulating fans in preheating furnaces

Furnaces

Long-term1. Provide ceramic fibre insulation for batch operated furnaces

2. Install Radiant tube recuperative burners in place of electrical heaters for applicationsinvolving temperatures less than 1000 deg C.

Short-term & Medium-term1. Optimise the overall loading of furnaces by better planning of jobs

2. Improve the combustion efficiency of furnaces, by optimizing the combustion air supply

3. Install pneumatic operated door for push type furnaces

4. Install Air curtains at exit / entry of drying ovens to reduce heat loss.

5. Replace refractory bricks with ceramic fibre in furnaces

6. Improve the over all Insulation levels and close the openings in furnaces, so as to minimizeheat losses.

7. Use ceramic coating for achieving improved insulation levels

8. Install KWH integrator controller for induction furnaces

Electrical

Long-term11. Replace Motor – Generator sets (Ward – Leonard System) with Static Inverters.

12. Replace High pressure Mercury vapour (HPMV) lamps with High pressure Sodiumvapour (HPSV) lamps

Short-term & Medium-term1. Switch-off primary of idle transformers

2. Replace faulty capacitor banks

3. Relocate capacitors to the machine ends, or from the MSBs to the SSBs (at the substationends), to minimise voltage drop in cables.



4 Improve the over all power factor and Surrender excess demand

5. Install automatic voltage stabilizers for lighting circuits and other precision electronic circuits.

6. Install lighting transformers in all major lighting feeders and operate the lighting circuit at210 V

6. Optimse the Operating voltage and frequency in DG sets

7. Avoid night time lighting at where lighting is not required

8. Replace the conventional fluorescent tubes with slim fluorescent lamps

9. Replace conventional chokes with electronic HF ballast

10. Replace 40 watts fluorescent lamps with 28 watts T-5 lamps where lights are kept “ON”through out.

11. Replace filament indication lamps in control panels and with LED lamps.

12. Install translucent sheets at identified places to avoid day time lighting, where ever feasible

13. Install neutral compensator at unbalanced lighting feeders

14. Replace the delta connection with permanent star in case of motors, which are lightlyloaded permanently.

15. Install Automatic - Star - Delta - Star converter in the lightly loaded motors which handlefluctuating loads

16. Replace old inefficient motors with energy efficient motors

Other Projects1. Recover waste heat from flue gas of furnaces, by installing air pre heater.

Cooling Tower- Chilled water system

Short term & medium term1. Install temperature indicator control (TIC) for cooling tower fans

2. Replace aluminium blades with FRP blades at all cooling tower fans

3. Convert the 2-well system to a single well system in the chilled water system, where everpossible

4. Improve the insulation levels of the chilled water distribution system

5. Optimise the Operation Of Chilled Water Pumps In Vapor Absorption Machine based onthe head/capacity requirements of the system.

Thermopacs


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Short term & medium term1. Improve the combustion efficiency of the thermopac by reducing the excess airflow.

2. Replace inefficient burners in the thermopacs with energy efficient burners.

3. Install variable frequency drives (VFD’s) for Thermic fluid pumps catering to multiple users

Boiler

Short term & medium term1. Improve combustion efficiency of boilers by optimizing the combustion air supply,

2. Install condensate recovery system for the boiler

Dust collection systems

Short term & medium term

1. Clean Scrubber Regularly and optimise the operation of Sand Dust Collection Blower

2. Replace inefficient dust collection systems improve the dust collection system

Refrigeration & Air conditioning

Short term & medium term1. Install Micro processor based Temperature Indicator Controller (TIC) for window air

conditioners

2. Use polyester sun film controls in the areas exposed to direct sunlight and optimise thetemperature settings of the cooling system.

3. Optimise temperature settings of AHU’s and install thermostat controls for chillercompressor

4. Replace air-cooled condensers with water-cooled condensers. In case of higher TRcapacities, go for evaporative condensers.

Vapour Absorption Machine

Short term & medium term1. Optimise Combustion Air Supply To Vapour Absorption Machines (HSD fired)



Electroplating

Short-term & Medium-term

1. Install polymer balls for reducing the heat loss in Phosphating systems

2. Replace the inefficient Auto Plating Scrubber Blower With energy Efficient Blower

3. Replace Electrical heating with Thermal heating (Aquatherm) at Phosphating / Electroplatingsection

Miscellaneous1. Replace Eddy current controls with VFD

2. Convert V Belt to Flat Belt drives in equipments like Compressors and Blowers etc


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Case Study 1

REPLACE OLD INEFFICIENT COMPRESSORS WITH NEW ENERGY EFFICIENTCOMPRESSORS

BackgroundAir compressors are very commonly used in engineeringIndustry. In a typical engineering Industry, the powerconsumption of the air compressors is as high as30 % of the total energy consumed.

The most common type of compressors used in theindustry is the reciprocating compressor. Off late, thereis a growing inclination for companies to go in for screwcompressors, mainly due to their flexibly in operationas well as due to their low noise characteristics.Centrifugal compressors are used for high capacitiesor base loads, greater than 1500 CFm.

A typical comparison between the different types of compressors at 7-kg/cm2 pressure,is given below.

Description Reciprocating Centrifugal Screw

Specific Power 4.9 4.65 5.8

(kW/m3/min)

Specific Power (kW/Cfm) 0.139 0.132 0.164

Whenever there is a significant variation in the power consumption of the compressorfrom the above-mentioned values, it signifies that the compressor may be energyinefficient.

The reason s for higher specific power consumption can be the age of the compressor, wearand tear of the pistons and cylinders, improper maintenance etc.

In such cases, if the compressor is noted to be energy inefficient, it is suggested to go for thereplacement of the compressor with a new one. The choice of the type of compressor dependson the application.

A case study pertaining to the same is discussed below.



Previous status The following observations made with respect to a reciprocating compressor in an engineeringunit

Capacity test was conducted on the compressor. The details about the rated volume of thecompressor against its actual delivered volume with the power consumption were (@ 6 kg/ cm2).

Rated volume Actual volume Power consumption

(Cfm) (Cfm) (KW)

744 565 103

It was observed that the volumetric efficiency of the compressor was about 75% and that thespecific power consumption (SEC) was 0.182 kW/cfm.

As mentioned in the table earlier, the typical norm for power consumption of an air compressoroperating at 7.0-kg/cm2 pressures is 0.14 kW/cfm. Similarly, the typical power consumption ofa compressor operating at 6.0-kg/cm2 pressure, should be 0.12 kW/cfm.

Energy Saving ProjectThere was an option to replace the existing reciprocating compressor with an energy efficientcompressor either of the reciprocating type or of the screw type. Since the compressor wascatering to a steady base load and since the comparative capital investment was lower for areciprocating compressor, the existing compressor was replaced with new energy efficientreciprocating compressor, having a lower SEC of 0.13 kW/cfm.

Project Implementation StrategyThe project was implemented during the preventive maintenance period in the plant. No stoppageof the plant was needed. The plant team did not face any problems during the implementationof the project.

BenefitsThe implementation of this project resulted in reduction of energy consumption of compressors.

Financial AnalysisThe replacement of the old compressor with new energy efficient compressor resulted in anannual savings of Rs.0.95 million. The investment(for new reciprocating type air compressors)amounted to Rs.1.5 million, which had a simplepayback period of 20 Months

Replication potentialThe replacement of old compressors with newenergy efficient compressor is a project with hugereplication potential. On a conservative basis, this project could be replicated in at least inabout 100 installations. The investment potential for this project is Rs 100 millions.





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Case Study 2

INSTALL VARIABLE FREQUENCY DRIVE FOR SCREW COMPRESSORCATERING TO VARRYING DEMAND OF COMPRESSED AIR

Background and conceptVariable speed drives eg. (Variable frequency drives) can be installed for all types of aircompressors. However, they are best suited for screw air compressors.

The advantages of installing VFD for screw air compressors are:

• All the compressors connected to a common system operate at a constant pressure.The operating pressure will be lesser than the average operating pressure of loading /unloading system. Hence, energy saving is achieved due to pressure reduction.

• The compressors need not operate in load / unload condition. This saves the unloadpower consumption.

• Air leakages in the compressed air system also comes down since the average operatingpressure is less.

Generally, high capacity air compressors are operated with loading /unloading control, as in thecase of screw & reciprocating compressors and with inlet vane control for centrifugalcompressors.

In loading / unloading type of control receiver pressure is sensed and the compressor load /unload depending on the pressure. Hence a compressor operates within a band of pressurerange. Generally air compressors operate with 1 kg/cm2 pressure range.

By installing a VFD, it is possible to maintain a lesser bandwidth of say, 6 kg/cm2 to 6.1 Kg/cm2. The major advantage of variable speed derive is that if 4 or 5 compressors are connectedto a common header, then by installation of VFD in one compressor, the energy savingsachieved due to pressure reduction is cumulative in nature (power consumption comes downin all compressors). Since the average operating pressure with VFD is less (6kg/cm2 insteadof 6.5 kg/cm2 as per earlier example) the air leakages in the system is also minimized. Theinstallation of VFD facilitates in varying the speed of the compressor depending on therequirement. This completely avoids unloading and saves unload power consumption, whichis normally 25 to 35 % of the full load consumption.

Recently, screw compressors with built-in variable frequency drives have been introducedin the Indian market. This system facilitates fine – tuning of the compressor capacity preciselyto meet the fluctuating compressed air demand.It accurately measures the system pressureand adjusts the speed to automatically maintain a constant pressure.


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Package screw compressorPrevious statusIn an auto component manufacturing unit three screw compressors of 600 Cfm were availablefor compressed air supply through out the plant. Another compressor of 750 cfm was availableand the same was used to meet the peak demand.

Among the three screw compressors in continuous use, two compressors were always onloading. One compressor was getting loaded and unloaded.

The operating pressures of the compressors were

• Load pressure = 5.5 Kg/Cm2

• Unload Pressure = 6.5 Kg/Cm2

Average loading and unloading pattern was:

• Loading = 73%

• Unloading = 27%

The required compressed air pressure to be maintained in the plant was 5.5Kg/Cm2. Thecompressor had a power consumption of 98 kW on load and an unload 22 kW during unloadmode.

Energy Saving ProjectVariable Frequency drive with feed back control was installed for the screw compressor, whichwas operating in the load unload mode. The pressure sensor provided in the main headersensed the operating pressure and gave the feed back signal to the variable frequency drive,which, in turn varied the speed of the compressor to meet the plant compressed air requirement.

The operating pressure was reset to 5.5 kg/cm2

Project ImplementationThe installation of VFD for the compressor was done during the normal operation of the plantitself. The plant team did not face any problems in implementation of the project and insubsequent operating pressure reduction.

BenefitsThe unloading power consumption of the screw compressor was totally eliminated. The overall operating pressure was also reduced to 5.5Kg/cm2.

Financial AnalysisThe annual savings achieved amounted toRs 0.43 million . The required an investment ofRs 0.7 million for installing variable frequency drivewith feed back control, was paid back in 20 Months.





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Replication PotentialThis project can be implemented across all the sectors of the engineering industry, wherevera screw compressor is operating in the loading /unloading mode. Considering that at least 50% of the installed base of Screw compressors in the industry still operate in the load/unloadmode, without a VFD there is a tremendous potential for them to be retrofitted.



Case Study 3

SEGREGATE HIGH PRESSURE AND LOW PRESSURE COMPRESSED AIRUSERS

BackgroundIn compressors the power consumption is directly proportional to the operating pressure. Thepower consumption increases with increase in operating pressure and vice versa.

There is a good potential to save energy by dedicating compressors for the individual users,which need compressed air at a lower pressure. This eliminates the pressure loss due todistribution and hence energy loss.

Previous statusIIn an engineering unit, the compressed air was generated at an operating pressure of 6.2 kg/cm2, by operating 5 reciprocating compressors, each of capacity 1500 Cfm.

The maximum pressure requirement and quantity of compressed air requirement for the someof the users are given below.

Area Pressure- Receiving end Quantity

Kg/cm2 Cfm

Unit1 4.0 1900

Instrumentation in unit 2 4.5 600

The fall in pressures at the receiving end was mainly due to the losses, which were takingplace in the transmission line, which had a length of about 1.5 Km.

Energy Saving projectThe compressed air supply from the main header to the units 1 and 2 was segregated.Dedicated screw compressors of following specifications were installed and operated.

For unit 1

• Capacity - 2000 Cfm

• Operating pressure - 4.0 kg/cm2

For unit 2

• Capacity - 600 Cfm

• Operating pressure - 4.5 kg/cm2


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ImplementationThe installations of the new compressors were done during the normal operation of the plant.The new compressors were hooked to the compressed air supply lines of the respective unitsduring the scheduled preventive maintenance. The plant team did not face any problemsduring the implementation of the project.

BenefitsThe operation of two compressors of capacity 1500 Cfm each, in the compressor house wasavoided.

Financial Analysisof high pressure and low-pressure users of compressed air and installation of dedicatedcompressors for low-pressure users, led to an annual savings of Rs 1.04 million. This requiredan investment of Rs 1.5 millions, which got paid back in 18 Months.

Replication potentialThe project has tremendous replication potential in the case of all plants where

• There are centralised facilities for generating compressed air

• A combination of high pressure and low-pressure users connected to the common header

• Long transmission lines





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Case Study 4

REPLACE REFRIGERATION / DESSICANT TYPE AIR DRYERS WITH HEAT OFCOMPRESSION AIR DRYERS, IN CASE OF RECIPROCATING AIRCOMPRESSORS

BackgroundThe heat available in the compressed air (temperature of 120 deg C) is utilised for regenerationof the dissicant, which otherwise needs an electrical heater.

Heat of Compression type air dryer is a breakthrough in compressed air drying technology.Thus the need for a heater is eliminated and also there is no purge loss.

An atmospheric dew point of (-) 40 deg C can be easily achieved using HOC dryer. There isconsiderable power saving in this type of Air Dryers

Heat Of Compression (HOC) dryer

Previous status In an engineering unit, the compressed air to the plant was broadly classified into instrumentair and the process air.

The instrument air requirement was being met with using two 1100 cfm-reciprocatingcompressors. Usually, one of the two Compressors was operated continuously to cater theinstrument air requirements of the plant.

This compressed air was dried in desiccant heatless type (2 Nos) dryers before being used.

The estimated purge loss from the desiccant heatless dryers was about 15% of the compressorscapacity.



Energy saving ProjectHeat of Compression (HOC) dryers were Installed in place of the desiccant / heatless typedryers.

BenefitsThis has resulted in zero purge loss and achievement of (-)40 deg c atmospheric dew pointas required.

Financial AnalysisThe estimated annual savings achieved was Rs.1.23 million. The investment required amountedto Rs.2.00 million, which got paid back in 20 Months.

Replication PotentialHOC dryers can be installed in place of refrigeration/desiccant type dryers wherever thecapacity of the reciprocating compressor is above 500 cfm. The most recent developmenthas been the development of HOC dryers for screw compressors also. This is commerciallyavailable in India and this recent development gives HOC dryers a tremendous opportunity tobe used as a retrofit for screw compressors also.





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Case study 5

INSTALL VARIABLE FREQUENCY DRIVE FOR OIL PUMP IN HYDRAULIC POWERPACKS AND REDUCE IDLE OPERATIONBackgroundIn engineering Industry, hydraulic power packs are used for several applications like mouldingmachines, extrusion machines, pressing machines, die casing machines etc.

In the hydraulic system actuation takes place for holding the job only for about 20 - 30% of theoperating time. After the holding operation only the required operating pressure has to bemaintained.

During the rest of operating time the excess quantity of oil pumped by the hydraulic systemis recirculated back to the tank. The recirculation takes place for about 70-80% of the operatingtime, through a three-way reciculation valve provided for this purpose.

The % opening of the recirculation valve is governed by a continuous feed back signal, dependingon the amount of oil required for the process. Recirculation results in excess power consumptionin the hydraulic pump for pumping the excess quantity of oil.

Case StudyPrevious statusIn a pipe-manufacturing unit, there were 12 hydraulic power packs in the foundry section andat any point in time 7 were being operated, for actuating the die casting machines. For about60-70% of the operating time, oil was being recirculated.

Energy Saving ProjectVariable Frequency Drives (VFDs) were installed for the oil pumps with feed back control usinga pressure sensor provided at the discharge side of the pumps.

The VFD was operated in closed loop with a pressure sensor on the pump discharge header.The pressure sensor senses the process requirement and the pressure signal is given as theinput to the VFD. The VFD varies the speed of the (RPM) pump so that only that quantity ofthe fluid demanded by the process is pumped.

BenefitsInstallation of VFD for oil pumps in Hydraulic powerpacs resulted in an annual saving of Rs. 0.3 million.This required an investment of Rs 0.35 million forvariable frequency drives with feed back control,which got paid back in 15 Months.

Replication potentialThe project can be replicated in all the units whereoil pumps are installed for pumping oil in the hydraulic power packs.





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Case Study 6

INSTALL VARIABLE FREQUENCY DRIVES (VFD’s) FOR PUMPS CATERINGVARYING DEMAND INSTEAD OF OPERATING WITH RECIRCULATION /VALVETHROTTLING

BackgroundPumps are common equipment in any engineering industry. The load on a pump may eitherbe constant or variable. The variation in the load may be due to various factors like processvariations, changes in capacity or utilization etc.

Conventionally, the output of the pump is adjusted according to the process requirementsusing one of the following methods namely by pass / recirculation or valve throttling.

Variable speed drives are devices used for varying the speed of the driven equipment (likepump) to exactly match the process requirement.

Previous statusThe heating requirements of the electroplating section in an automobile unit were being metby oil-fired thermic fluid heating systems. In the section, thermic fluid is supplied throughheating coils to multiple numbers of tanks (10-12 tanks)

The requirement and hence the flow rate of the thermic fluid varied with the temperature andthe number of user points in operation. The flow was regulated through a 3-way valve.

Heating was not done in all the tanks continuously and simultaneously. So once the settemperature was achieved, the thermic fluid was recirculated, without going to the process.

The thermic fluid pump therefore was in continuous operation at its full capacity, irrespectiveof the number of users in operation.

Energy Saving ProjectA Variable Frequency Drive (VFD) was installed for the thermic fluid circulation pump.


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Implementation MethodologyVFD was operated in closed loop with a pressure sensor on the pump discharge header. Thepressure sensor senses the process requirement and the pressure signal is given as the inputto the VFD. The VFD varies the speed of the (RPM) pump so that only that quantity of the fluiddemanded by the process is pumped.

Installation of VFDs for the thermic fluid pumps was done during the regular operation of theplant itself. The recirculation valve was closed completely. The plant team did not face anyproblems during the implementation of the project.

BenefitsThe implementation of this project resulted in saving of energy consumption of the pump andalso better control of the system.

Financial AnalysisThe installation of VFD for the pump resulted in an annual saving Rs.0.20 Million. The investmentof Rs0.20 Million was paid back in 12 months.

Replication potentialInstallation of variable speed drives for pumps can be replicated in all applications where apump is supplying to variable demand, which is the normal case in many engineering industries.





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Case Study 7

REPLACE THE LOW EFFICIENCY EXHAUST FANS WITH NEW FANS OF HIGHEREFFICIENCYA fan is typically a mechanical device that causes a movement of air, vapour & other gasesin a given system. In electroplating sections, fumes, which are produced during the process,are forcefully sucked and let out into the atmosphere using exhaust fans. This is a typicalapplication where the volume of air to be handled becomes the only criterion for the selectionof fan.

Axial fans are ideally suited for such applications involving a lower head and higher volume ofair to be handled. Their efficiency is also much better compared to centrifugal fans.

Axial fan

Previous statusIn an engineering unit, manufacturing end rings for rotating equipment, the exhaust fan in theplating section was utilized to remove the fumes generated during the plating operation. Acentrifugal fan was used for the purpose.

The fan was catering to a head of 39 mm WC and delivering a flow of 14 m3/s, consuming17.8 kW. The corresponding efficiency was only 39%.

Energy Saving ProjectAxial fans are capable of meeting head requirements upto 75 mm WC. These fans havebetter operating efficiency than the centrifugal fans, both in full loads and in partial loads. Theminimum operating efficiency of an axial fan is about 65%.

The existing plating section exhaust fan was replaced with a new axial fan of higher efficiency,having a capacity 15 m3/s and capable of developing a pressure head of 40 mm WC.



Financial AnalysisImplementation of this project resulted in an annual savings of Rs. 0.18 millions. Theinvestment required for the fan was 0.1 million. The simple pay back period for the project was7 months.

Replication potential There is a tremendous potential to replace centrifugal fans with higher efficiency axial fans inapplications where the required head is lower than 75 mm of WC.





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Case study 8

INSTALL VFD’s for HOT AIR CIRCULATION FANS IN PREHEATING FURNACES

BackgroundHeat treatment is the process of altering the properties of a metal by subjecting it to a sequenceof temperature changes. Hence the time of retention at specific temperature and rate ofcooling are as important as the temperature itself. Heat treatment markedly affects strength,hardness, malleability and ductility and other similar properties of both metals and their alloys.Heat treatment finds applications across all the industries and sectors and is a commonprocess in all the engineering industries. The major equipment used in heat treatment of anymetal or alloy is the furnace.

Fans are used for forceful circulation of air to aid the heat transfer process. Fans ensureuniform heat transfer which result in faster heating. The operation of the fans can be alignedwith the operating cycle of the furnace, to optimise energy savings.

VFDs find applications in optimising the speed of the circulation air fans based on the temperaturecycle.

Previous statusIn an engineering unit, Preheating furnaces were used for heat treatment. The typical loadingof the furnace was in the range of 42 – 45 tons/ batch/ preheating furnace (max capacity 50T). The process is described below.

Each preheating furnace is divided into six zones, with each zone having a heater bank. Theheater banks are arranged in a vertical fashion on top of the furnace. The rating of the heatersin the different zones range from 270 amps to 450 amps

The typical batch time is about 12 hours. The temperature to be maintained inside the furnaceis about 620 deg C.

Each zone is also provided with circulating air fans for forced heat circulation. The desiredmetal temperature for hot rolling is about 530°C (minimum). After accounting for the ingotrolling time and temperature loss from preheating furnace outlet to the hot rolling mill of about40 – 60°C (between top ingot & bottom ingot), the metal is heated upto a temperature of 590-600°C. The air temperature required to maintain this metal temperature is 620°C.

Once the furnace charging is complete and the batch time starts, the heaters and fans areswitched “ON” automatically. It takes about 2 – 3 hours for the air temperature to be raisedfrom a starting temperature of 360 – 380°C to 620°C. The total time taken for heating the metalfrom the ambient temperature to 580-590°C is about 7 hrs.

Once the set temperature is achieved, the heaters get switched “OFF” automatically. Theingots are then allowed to “soak” for the remaining 5 hours. The heaters operate on thermostatcontrols in “ON-OFF” mode during this period, primarily to take care of the radiation and hotair losses.


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The average power consumption during the heating phase of then batch time is about 1000kWh, while that during the soaking phase is about 650 kWh.

The total heat transfer process takes place in the following sequence – from heater to air byconduction/ radiation and from air to metal by forced convection.

The convection phase of heat transfer is the critical step, which decides the quality of processing.The heat transfer rate is a function of (velocity of air)0.8 and the temperature differential betweenmetal and air.

The detailed analysis of time vs. temperature profile of the 6-zones revealed that, at the endof the heating cycle and during the soaking phase, the air velocity required to maintain the heattransfer rate between air and metal is lower, due to lower temperature differential.

Energy Saving ProjectVFDs were installed for the air circulating fans. All the circulating air fans were operated at alower RPM during the soaking period using programmed PLC controls. A 30% speed reduction(speed was reduced from 50 Hz to 35 Hz) was achieved.

Implementation of the ProjectVFDs for the circulating fans were installed during the normal operation of the plant itself. Theplant team did not face any problems at any stage during implementation of the project.

BenefitsThe annual savings achieved due to implementation of the project, amounted to Rs.0.36million. This required an investment of Rs.0.40 million, which had a simple payback periodof 14 months.

Replication potentialThe project finds tremendous replication potential in all furnaces where hot air circulation fansare in use for heat treatment. By conservative estimates, the project can be implemented atleast in 150 engineering units across the country.





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Case study 9PROVIDE CERAMIC FIBRE INSULATION FOR BATCH FURNACESBackgroundThe surface temperature of a furnace is an indicator of the insulation levels in the furnace. Foran electrical furnace the surface temperature should not be more than 50 degree C and fora thermal furnace the surface temperature could be around 60 degree C.

The heat loss due to radiation from the surface increases exponentially with the surfacetemperature. For eg in the radiation loss due to a surface temperature of 150 °C is 1500 Kcal/m2/hr as compared to 450 Kcal/m2/hr, at a surface temperature of 70 degree C.

Ceramic fibre is a lightweight material featuring low thermal conductivity and low heat capacity,making it a superior Insulating material. A furnace lined with this form of material providesexcellent thermal properties. Ceramic fibre is supplied in various forms; blanket, bulk, paper,and vacuum formed products as shown below.

Ceramic fibre material

Given below is a table, which gives a comparison between refractory brick, insulation brick andceramic fibre.

Property Refractory brink Insulation Brick Ceramic fibre

Specific heat

kCa/Kg Deg C 0.2 0.22 0.27

Themal conductivity

kCal/m Deg C 0.22 0.20 0.20

Density kg/m3 2000 1000 125

It is the low density of the ceramic fibre that makes it an excellent insulation material. Becauseof the low bulk density the space occupied by the ceramic fibre is also minimal compared tothe other two. This leads to a significant drop in the power consumed by the furnace, especiallyduring cold starts in case of batch furnaces.

Ceramic fibre can hold a temp of up to 1450 deg C and are not affected by chemicals.



The limitations of ceramic fibre are that it cannot take direct flame impingements and mechanicalstresses. So in case of any of these a layer of ceramic fibre can be sandwiched betweeninsulation bricks for achieving better insulation levels.

The best practise that is followed is to have a ceramic coating above the ceramic fibreinsulation so as to minimise the surface temperature.

Previous StatusIn an auto components manufacturing unit, a bell furnace was used for heat treatment of thematerial. The material was heated to a temperate of 650 deg C, using electrical heaters. Thefurnace was lined with refractory bricks for insulation. The measured surface temperature onthe outer sides of the furnace was around 150OC.

Batch operation was employed in this case and the cycle time for the process lasted to about12 hours.

The specific energy consumption of the furnace was around 250 kWh per ton of material.

Energy saving ProjectThe inner sides of the Annealing furnaces were insulated using ceramic fibre. Ceramic coatingwas also provided both in the inner surface area as well as in the outer surface area. The outersurface temperatures were maintained at around 50OC — 60OC.

ImplementationThe implementatin of the project was carried out during the scheduled preventive maintananceof the plant. The plant team did not face any hurdles in implementing the project.

BenefitsInsulation of the furnace with ceramic fibre and ceramic coating resulted in the specific energyconsumption coming down to 185 units per ton.

Financial AnalysisThe annual savings achieved was Rs 0.75 million. The investment required for ceramic fiberand ceramic coating was 15 was Rs. 0.15 million, which got paid back in 3 months.


• Investment - Rs. 0.15millions


Replication potentialThe project can be replicated in all furnaces,which are using either refractory bricks orinsulation bricks. In case there is a chance ofdirect flame impingement, a layer of ceramicfibre can be sandwiched between the inner andouter layer of the refractory.


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Case study 10

INSTALL RADIANT TUBE RECUPERATIVE BURNERS IN PLACE OF ELECTRICALHEATERS FOR APPLICATIONS REQUIRING TEMPERATURES LESS THAN 1000deg C

BackgroundElectrical energy is a high-grade energy and costlier as compared to thermal heating. In almostall cases, electrical heating is being done since the stock should not come in contact with theexhaust gases.

The cost comparison of thermal and electrical energy is given under:

• Cost of electrical energy - Rs 4773 / MM Kcal

• Cost of thermal energy - Rs 1966 / MM Kcal

Electrical energy is 2.4 times costlier than thermal energy. Hence there is a potentialof 50% of savings by replacing the electrical heating with thermal heating.

Before the advent of radiant recuperative heaters, electrical heating was the only viable alternativefor any applications involving temperatures greater than 300 deg C.

Radiant tube recuperative burners (ref fig below) are now available which are fired with oil andthe exhaust gases do not come in contact with the stock. The heat transfer is through radiationfrom the tube, which is at a high temperature of 900 to 1100 deg C. The exhaust heat is usedto preheat the combustion air.


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Previous statusIn a bicycle-manufacturing unit, annealing furnaces were used to for heating the components.Electrical heaters were being used in the annealing furnace to heat the material up to atemperature 900 deg C. The total rated capacity of the heaters was 2000 KW.

Radiant tube recuperative burners with LDO firing were installed in place of Electrical heaters.

Implementation StrategyThe implementation of this project took about 3 months.

BenefitsThe implementation resulted in reducing the cost of energy used for the furnace.

Financial AnalysisThe installation of Radiant tube recuperative burners resulted in an annual savings of Rs 6.0million. The investment required was Rs. 10.00 million, which got paid back in 20 months.

Replication potentialPrior to the radiant recuperative heaters, there was no reliable technology for applying thermalheating to achieve temperatures beyond 300 deg C. The replacement of electrical heating withthermal heating involving radiant recuperative heaters has a tremendous potential of replication.This proven technology can be easily replicated at least in 50 installations in India.





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Case study 11

REPLACE MOTOR – GENERATOR SETS WITH STATIC INVERTORS

Back groundWard-Leonard drives are very popular among the engineering industry, especially in machineshops. The system provides very smooth and reliable speed control, which is the basicrequirement for any application involving cutting tools. They are highly complex systems.

Ward-Leonard systems were introduced in 1890s. Schematically, the operation of the systemis as follows:

The synchronous AC motor drives the generator. The generator generates the terminal voltagefor the DC motor. This voltage can be modulated by modulating the field current on theGenerator. The field current is varied to achieve the speed control and direction reversal of theDC motor.

Solid-state converters and rectifiers have become available in recent years even in high-powercircuits. Such devices are gradually replacing the Ward-Leonard systems based on dedicatedmotor generator sets.

These controlled rectifiers are commonly referred to as Silicon Controlled Rectifiers or SCRs. By chopping the supply voltage, they produce a pulse train for the armature voltage rather thana continuous supply. This pulse train controls both the speed and the direction of operation ofthe DC motor.

Previous StatusIn an automobile manufacturing unit, across different machine shops, there were 30 numbersof M-G sets.

Energy saving ProjectAll the Motor – generator sets were replaced with static invertors, in a phased manner.

ImplementationThe project was implemented during the preventive maintenance periods. The plant teamfaced no hurdles in implementing the project. All the drives where replaced in a phasedmanner in a period of over 2 years.



BenefitsThe benefits were two fold -

- Energy Saving

- Easier maintenance as the thrysiter drives were easier to maintain than motor generatorsets.

Financial AnalysisReplacement of ward Leonard drives with Thyrister drives resulted in an annual savings ofRs. 0.48 million. The investment required of Rs.1.0 million, got paid back in 26 months.

Replication potentialThe project can be implemented across all industries where Ward Leonard systems are inuse. The replication potential is quite high in particularly the medium scale engineering industries.





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Case Study 12

REPLACE HIGH PRESSURE MERCURY VAPOUR (HPMV)_ LAMPS WITH HIGHPRESSURE SODIUM VAPOUR (HPSV) LAMPS

BackgroundHigh Pressure Sodium Vapour (HPSV) lamps are more efficient than HPMV lamps. Butt theColour property (Colour rendering index) of HPSV lamp is poor compared to HPMV lamp.Wherever colour is not a critical requirement the HPSV lamps can used.

The comparison is shown below.

S.No Lamp Watts Efficacy Illumination

1 HPMV 250 54 lumens/Watt 13,500 lumens

400 57.5 lumens/Watt 23,000 Lumens

2 HPSV 150 90 lumens/Watt 13,500 Lumens

250 100 lumens/Watt 25,000 Lumens

Comparison of mercury & sodium vapour lamps

HPSV lamp HPMV lamp

• Efficacy of HPSV lamps is double than HPMV lamps

• Colour Rendering properly of HPSV lamp is poor compared to HPMV lamp

• Wherever colour is not a critical one, we can replace HPMV lamps with HPSVlamps

There is a good potential to replace 400 Watt and 250-Watt HPMV lamp with 250 Watt and 150Watt HPSV lamps respectively.


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Case study

In an automobile manufacturing unit, there were three plants in which 60 HPMV lamps, of250W were used for lighting. The color was not a criterion in the above areas. Also about 20lamps were used for street lighting also.

Energy saving projectSince colour was not a criterion in these areas, it was recommended to replace the 250-wattHPMV lamps with 150-watt HPSV lamps.

ImplementationThe projects were implemented in all the 3 plants during the scheduled preventive maintenance.The plant team did not face any problems due to the implementation of the project.

BenefitsThe potential resulted in lower energy consumption of the lighting systems.

Financial AnalysisReplacement of HPMV lamps with HPSV lamps resulted in annual savings of Rs.0.09 million.This required an investment of Rs. 0.08 million, which got paid back in 10 months.

Replication potentialThe project can be implemented in all the areas where the colour-rendering index is not criticalto the plant operations.


• Investment - Rs. 0.08 million



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Case study 13

RECOVER WASTE HEAT FROM THE FLUE GAS OF FURNACES BY INSTALLINGAIR PREHEATER

BackgroundTypically, oil fired furnaces are used in engineering units for almost applications like melting,heat treatment, forging, billet reheating etc. The major losses that take place in the furnacesare the radiation losses and the flue gas losses. Among these, flue gas losses amount toalmost 70% of the total losses in a furnace.

The waste heat recovered from the flue gas can be used for various applications like Air preheating, oil preheating and metal preheating.

The flue gas temperature can be bought down to the range of 150 – 170 deg C before it isfinally let out into the atmosphere. The final temperature to which the flue gas can be boughtdown depends on the sulphur dew point of the type of fuel being used.

Present Status In an engineering unit, a Marconi furnace was used to melt aluminium ingotsconsuming about20 lit/hr of furnace oil. The flue gas from the furnace was directly let off into the stack. Theexhaust flue gas temperature was measured and is about 875oC.

Based on oil-firing rate and excess O2%, total flue gas quantity was estimated to be about445 kg/h. The total quantity of recoverable heat present in flue gas was estimated to be63421 kCal/h.

The Combustion air supplied to the furnace entered the furnace at an ambient temperature ofabout 35 deg C.

Also the furnace oil fired into the furnace was preheated to a temperature of about 80 deg Cusing electrical heaters. The total power consumed by these heaters was 6 kW.

Energy saving Project An air Preheater was Installed to preheat combustion air to the Marconi furnace to a temperatureof 180°C.

An aquatherm system was installed to preheat the furnace oil to the required temperature of80oC. The operation of electrical heaters was totally avoided and they were used only in caseof cold start-ups.

The system was modified accordingly as shown:




- Reduction of oil consumption

- Saving of power used for heating furnace oil

Financial AnalysisThe implementation of the waste heat recovery scheme led to an annual savings of Rs.0.30million. The investment of Rs. 0.60 million (for installing heat recovery equipments) had anattractive payback period of 24 months.

Project implementationProject implementation required modification in the exhaust flue gas line and the installation ofan air Preheater in the flue gas system. The aqua therm system was installed.

All these modifications where carried out during the normal course of operations itself, with aminimal shut down of operations. The plant team did not face any problems in implementingthe project.

Replication potentialThe potential for replicating the project exists in the case of all furnaces where the flue gasis directly let out into the stack, at high temperatures.

Pressurised water to preheat oil

Preheated Air

Air to preheat

Flue gas to stack

Aquatherm

F.O Heater

Flue gas

Cost benefit analysis• Annual Savings - Rs.0.30 million

• Investment - Rs.0.60 million



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530Energy Conservation in Sugar Industry

Sugar

Per Capita Consumption 17.75 kg/annum

Growth percentage 7.5%


Energy Costs Rs. 14000 million (US $ 290 million)

Energy saving potential Rs. 4200 Million (US $ 84 Million)

Investment potential onenergy saving projects Rs. 6000 Million (US $ 120 Million


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1.0 IntroductionIndia is the largest consumer and second largest producer of sugar in the world. With over 450sugar factories located throughout the country, the sugar industry is amongst the largest agroprocessing industries in India, with an annual turnover of Rs. 150 Billion (US $ 3.3 Billion).

Sugar is a controlled commodity in India under the Essential Commodities Act, 1955. Thegovernment controls sugar capacity additions through industrial licensing, determines the priceof the major input sugarcane, decides the quantity that can be sold in the open market, fixesthe prices of the levy quota sugar and determines maximum stock levels for wholesalers, etc.

Sugar prices are the lowest in India when compared to the leading sugar consuming countriesin the world. Converted in Indian rupees the price equivalent in China Rs. 25.78 per kg, inIndonesia Rs. 18.62 per kg and in Brazil and Pakistan it is Rs. 17.9 per kg. The price of sugarin India is Rs. 12.68 per kg.

With the price being lowest in India, the competitiveness of the industry lies in lowering thecost of production. One of the major area, almost all the major sugar industries have focusedon, is energy efficiency.

2.0 Historical Industry DevelopmentIndia has been known as the original home of sugarcane and sugar. Indians knew the art ofmaking sugar since the fourth century.

The Indian sugar industry has not only achieved the singular distinction of being one of thelargest producer of white plantation crystal sugar in the world but has also turned out to bea massive enterprise of gigantic dimensions.

Over 45 Million farmers, their dependants and a large mass of agricultural labor are involvedin sugarcane cultivation, harvesting and ancillary activities constituting 7.5% of the ruralpopulation. The sugar industry employs over 0.5 Million skilled and unskilled workmen, mostlyfrom the rural areas.

The average capacity of the sugar mills in the industry has considerably moved up from just644 ton per day in SY1930-31 to 2656 ton per day. But still the growth in the Indian sugarindustry was driven by horizontal growth ( increase in number of units) compared to thevertical growth witnessed in other countries (increase in average capacity).

3.0 Energy consumption in Sugar IndustrySugar industry is energy intensive in nature. The power & fuel consumption in the Indian sugarindustry is in the order of Rs. 124.0 Crores. This is the contribution of sugar plants operatingwithout co-generation facility.

The average energy consumption in an Indian sugar mill is about 38 units / ton of canecrushed. The average cane crushing in Indian mills is about 2700 TCD. The total powerrequirement in a standard sugar mill is in the order of 4.25 MW.

The total cane crushed in Indian sugar industry is about 360 Million tons. The total powerconsumption for this requirement is about 13.68 Billion kWh. This corresponds to equivalentpower of about 3250 MW (considering average crushing of 175 days).



Energy efficiency in sugar industry offers the following benefits:

• In plants having cogeneration facility and where the state utility is able to purchase additionalpower generated from sugar plants, any improvement in energy efficiency levels of theplant results in increased export to the grid. This reduces the equivalent reduction in powergeneration from fossil fuel based power plants. This has a significant reduction in carbonemissions.

• In plants having cogeneration facility, but the state utility is not ready to purchase power,improvement in energy efficiency in the plant results in saving in bagasse. This eithercould be exported to other sugar plants, having cogeneration facility with state utility readyto purchase power, or can be sold to paper plants.

• In plants which do not have cogeneration facility, energy efficiency directly results in reducedpower demand from the state utility. This results in higher profitability to the plant as wellas significant reduction in GHG emission. These plants, however, are very few in number.

The Indian sugar industry offers good potential for energy saving. The estimated energysaving potential in the Indian sugar industry is about 20%. This offers potential of about 650MW of electrical energy. This corresponds to about Rs. 2600 Crores investment, in newerpower plants.

The investment opportunity in the Indian sugar industry is estimated to be in the tune of aboutRs. 5000 Crores.

Per Capita Consumption of sugar in IndiaIndians by nature have a sweet tooth and sugar is a prime requirement in every household.

Almost 75% of the sugar available in the open market is consumed by bulk consumers likebakeries, candy makers, sweet makers and soft drink manufacturers.

The per Caipta sugar consumption in India is about 17.75 kg/annum. This is growing at arate of 7.5% every year, on an average.


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4.0 CogenerationThe sugar industry by its inherent nature can generate surplus energy in contrast to the otherindustries, which are only consumers of energy. With liberalization and increased competition,the generation and selling of excess power to the electricity board, offers an excellent sourceof revenue generation to the sugar plants. This is referred to as commercial cogeneration andhas been only marginally tapped in our country.

Integrated approach and Co-generationCo-generation in sugar plant

The sugar plants have been adopting co-generation right from the beginning. However, theco-generation has been restricted to generating power and steam only to meet the operationalrequirements of the plant. Only in the recent years, with the increasing power demand andshortage, commercial cogeneration has been found to be attractive, both from the state utilitypoint of view as well as the sugar plant point of view.

The sugar plant derives additional revenue by selling power to the grid, while the state is ableto marginally reduce the ‘demand-supply’ gap, with reduced investments.

The sugar plant co-generation system can be in the one of the following ways

i. Conventional system

The old sugar plants, installed particularly in the sixties in India, have this type of system.These plants are characterized by• 20 kg/cm2 boiler• Mill drives and shredder driven by individual turbines• One or two back pressure power turbines, for meeting the remaining power requirements

These systems have low operating efficiency and result in little bagasse saving, aftermeeting the plant requirements. The non-season power requirement is met from the grid.

ii. Partly modified system

This type of system is prevalent in the plants installed in the eighties. These plants arecharacterised by• 32 kg/cm2 or 42 kg/cm2 boiler• Mill drives are partly steam driven and partly DC motor driven• One / two back pressure turbines, meeting the power requirements of the plant.

These systems have slightly higher operating efficiency and result in little bagasse saving,after meeting the plant requirements. The non-season power requirement is met from thegrid.

iii. Commercial co-generation system-only season

This type of system is prevalent in the plants installed in the early nineties. These plantsare characterised by

• 42 kg/cm2 / 64 kg/cm2 boiler with bagasse and auxiliary fuel firing



• Mills are DC motor driven

• One/two back pressure turbines, for meeting the power requirements and the excesspower is sold to the grid.

These systems have much higher operating efficiencies and result in excess energybeing generated and sold to the grid during the season. The non-season power requirementof the plant is met from the grid.

iv. Commercial co-generation system – Both season and non-season

These are the latest systems installed very recently and operating in the sugar plants,predominantly in the state of Tamil Nadu.

These plants are characterised by

• 42 kg/cm2 / 64 kg/cm2 / 82 kg/cm2 boiler

• Bagasse firing during season & firing with other fuel during non-season

• Mill drives are hydraulic or DC drives

• One / two extraction - cum - condensing turbine

• Turbine operates with nil condensing during season and maximum condensing duringnon-season. This scheme can be a very attractive alternative, if some cheap sourceof fuel is available.

These plants have the highest operating efficiency and the excess energy generated issold to the grid during the season. During the non-season, the boilers are fired with theauxiliary fuel and the turbine is operated in the condensing mode. The excess power aftermeeting the plant requirements, is sold to the grid.

This alternative results in maximum revenue generation for the sugar plant and is veryattractive if the auxiliary fuel is available at a cheaper cost.

5.0 Manufacturing Process & Target energy consumptionThe target electrical and thermal energy consumption of a new sugar plant should be as givenbelow

Specific Electrical Energy consumption 30 units/ton of cane with electricmotors & DC Drives

24 units / ton of cane with diffusers

Specific Thermal Energy steam consumption 38% on cane

5.1 Electrical energyCane preparation

The cane preparation is the first operation in the production of sugar. The preparatory equipmentsinclude kicker, leveller, cutter, fibrizers and shredders. The degree of preparation has a majoreffect on the cane crushing capacity and extraction. The efficiency / capacity of the utilisation


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of the cane carrier system can be increased, with parallel loading of cane. The parallel loadingof cane is possible with sling type unloading and hydraulic tipper unloading.

The typical cane preparation devices suggested are kicker and cutter followed by a fibrizer /shredder. The cane carriers need a variable speed mechanism, to regulate the flow of caneto the shredders. The shredders also need a variable speed mechanism, to take care of thevarying load. The shredders have, either a steam turbine or a dynodrive for varying the speed,while the cane-carriers have a dynodrive. Both these systems are energy inefficient.

Hence, it is recommended to install DC motors or AC variable speed drives for the canecarriers.

Target energy consumption in cane preparation section – 4.00 kWh / ton

Milling – operation

The prepared cane is crushed, to separate the juice and bagasse. The crushed juice is thentaken up for further processing, while the bagasse is despatched to the boiler house.

The milling energy requirement, depends on the efficiency of conversion at the prime moverand the actual shaft power required at the mills.

The scrapper power and the pinion lossare standard for all mills, while theother three depend on the hydraulicpressure applied and the fibre loading.

The bearing loss of 15% in the caseof white metal bearings, can be totallyavoided, by replacing them with anti-friction roller bearings.

The power spent for compression ofbagasse and power absorbed by trashplate due to the friction with bagasse, depends on the power applied to the top roller and trashplate setting.

A latest development in this regard, is the development of a Low-Pressure Extraction (LPE)system. This new system comprises of, a long train of two roller bearings, operating underlow hydraulic pressure. The trash plates are eliminated, resulting in substantial reduction ofpower upto 35%.

Target milling power consumption – 9.5 units/ton of cane for conventional milling system.

Milling – prime mover

The installation of the right prime mover also has a major bearing on the energy efficiencyof a sugar plant. In the Indian sugar industry, presently 3 types of prime-movers are beingused as below

• Steam turbines

• Electric DC motors

• Hydraulic drives

Breakup of Energy Consumption

64%

15%14%2%

5%

Compression ofbagasseBearing loss

Trash plate

Scrapper

Pinion loss



Steam turbines

These have been used in all the older sugar units for driving the mills. These low capacityturbines are single stage turbines and have very low efficiencies of the order of 35-40%. Thelengthy transmission also involves additional losses, making it more inefficient. Hence, steamturbines are not recommended for prime movers in the milling section.

Electric DC motors

These have much higher efficiency than the steam turbines and with better control & cleaneroperations, are easily adaptable into any system. The DC drive also avoids the primary high-speed reduction gearbox, resulting in a higher overall efficiency of 51%. The steam turbineshave been replaced with electric DC drives, resulting in considerable benefits in many sugarplants.

Hydraulic drives

The utilization of hydraulic drives for the prime-moves in the mill section, is also gaining rapidpopularity among the sugar units. This involves a combination of an electric motor drivenpump and a hydraulic motor, which operates by the displacement of oil. The speed is controlled,by varying the flow in a fixed displacement pump and by changing the pump swash angle,in a variable displacement pump. The over-all efficiency of a hydraulic system is nearly about53%. The cost of hydraulic drives is higher than that of the DC drives. However, if the totalcost, comprising of the building, transformer etc. are taken into account, the cost of installationof a hydraulic drive and a DC drive are nearly comparable.

5.2 Latest development in manufacture of sugarCane Diffusers

Cane diffusers have been the latest and the most energy efficient method in cane preparation.Modern sugar mills have adopted cane diffusion, in lieu of conventional milling tandem,considering the multi-pronged advantages, diffusion process offers over conventional millingprocess.

In Cane Diffuser, prepared cane is directly sent to Diffuser, which acts both as primary andsecondary extraction equipment. Sugar in the prepared cane is systematically leached withwater and thin juice. At the end of the diffusion process, diffused bagasse discharged fromthe diffuser is conveyed to De watering mill where moisture is reduced to 50%. De-wateringmill outlet bagasse is sent to boiler and the mill juice is sent to Diffuser.

Cane diffusion Process

The Juice extraction process in the cane diffuser system is as follows:

i. Cane is prepared up to a Preparation Index (PI) of over 85 %.

ii. Prepared cane is delivered to the diffuser. The cane is heated at entry to the diffuser toa temperature of 83 Degree C by scalding juice. Scalding juice is the juice from the initialcompartment of the diffuser and is heated from a temperature of about 69oC to 90oC.

iii. The diffusion percolation bed is a moving conveyor on which the cane bed height isbetween 1200 mm to 1400 mm.


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iv. The diffuser is divided in 13 circulation compartments. Juice from each compartment isre-circulated in counter current direction to cane blanket movement, from low brix areato high brix area.

v. The scalding juice is limed in order to maintain a pH of about 6.5 in the diffuser in orderto prevent inversion of sucrose.

vi. Average temperature of the material inside the diffuser is about 78oC

vii. Draft juice from the diffuser is at about 69oC and is sent directly to the sulphitation vessel

viii. Diffusion bagasse at exit of the diffuser is at supersaturated moisture and is de-wateredin a single six-roller mill. Final bagasse moisture is about 51 %.

ix. Imbibition is applied directly in the diffuser. Hot condensate at 84oC from the evaporatorlast effect is used for imbibitions.

Draft juice is measured by a mass flow meter. Screening of draft juice is not necessarybecause the bagasse bed through which the juice percolates, itself acts as a screen.

Mill section – auxiliaries

The auxiliaries in the milling action are the juice transfer pumps, in between the drives andthe imbibitions water pump. In majority of the plants, the pumps are designed for the maximumcapacity, with a large cushion. This results in either the discharge valve being throttled or theinlet tank of the pump becoming empty at regular intervals. Both these are energy inefficientoperating methods.

Hence, it is recommended to install –

• High efficiency centrifugal pump and

• Variable Frequency Drive (VFD) for controlling the flow to the system for the juice transferpumps and imbibition water pumps.

Juice preparation

The juice preparation involves the weighing & heating of juice, sulphitation and clarification,to make it fit for the process of evaporation. The juice preparation section, comprising of thejuice pumps, is also a major electrical energy consumer.

Final juice heater Tubular/Plate heat exchanger (PHE)

The juice heaters over a period of time get scaled up and the pressure drop increases. Totake care of this, stand-by juice heater is to be installed for each of the primary and secondaryjuice heaters. In the case of the final juice heater, the stand-by is optional. Target energyconsumption in juice preparation section - 2.00 units / ton of cane.

Evaporator, crystalliser & pans

These are minor consumers of electricity primarily in the form of transfer pumps and recirculationpumps in FFE. The aspect that needs to be taken care is the installation of the right capacity& head pumps with high efficiency.

Target energy consumption - 1.00 unit / ton of cane



Pump house (Evaporator and Vacuum Pans)

The juice after preparation goes to the evaporator, for further concentration into syrup, whichgets further concentrated in the vacuum pans. The evaporators and the vacuum pans aremaintained at lower pressures, through injection water pumps.

It is recommended to use multi-jet condensers with hot water spray for jet water. The water-cooling system can be one of the following

• Cooling tower

• Mist cooling/spray pond cooling

Target energy consumption for pump house - 3.50 units / ton of cane

Boiler house

The boiler and its auxiliaries are also major consumers of power in a sugar plant. The majorpower consumers in the boiler house are the I.D, F.D, P.A & S.A fans and the BFW pumps.The energy consumption can be kept at a bare minimum, by adopting the energy efficiencyaspects at the design stage itself.

Target energy consumption for boiler house - 2 units/ton of cane

Centrifugals

The centrifuge section, where the sugar is separated and washed from molasses, is also amajor consumer of power. Presently, two types of centrifuges are in operation in the industry– batch and continuous centrifugals.

Target power consumption in centrifugals – 6.00 units/ton of cane

5.3 Steam ConsumptionThe sugar industry is a major consumer of steam, with the evaporators and vacuum pansconsuming substantially quantities for concentration of juice and manufacture of sugar. Apartfrom these, the juice heaters, centrifuges, sugar dryers and sugar melting also consume somesteam. The washing of pans and other equipment need some marginal steam.

Evaporator

The evaporator is the major steam consumer in a sugar plant. The evaporator concentratesthe juice from a level of 14 – 16 Brix to a level of 60 – 65 brix. The exhaust steam is usedfor this purpose. Further to the concentration to a higher level, the concentrated syrup istransferred to the vacuum pan section, for evapo-crystallisation, to produce sugar.

Several types of evaporators are used in the sugar industry. The commonly used are thequadruple and quintuple-effect short-tube evaporators. Typically, the steam enters the firsteffect at a pressure of 1.1 kg/cm2, at a temperature of 105oC and the vacuum in the last effectis around 650 mm Hg.

The multiple effect evaporators have higher steam economies of 3 to 5, depending on thenumber of effects.


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Falling film evaporators (FFE)

This is another popular evaporator, which is being considered by many sugar industries. In thistype the juice travels from top to bottom and as it descends, it takes the entrained vapour alongwith it to a lower chamber, where the vapour and liquid are separated.

The falling film evaporators have many advantages over the conventional evaporators as below

• The FFE’s have better heat transfer, as there is no elevation in boiling point due to hydrostaticpressure.

• The average contact time between juice and steam in a falling film evaporator is about 30seconds as against 3 minutes in the Kestner evaporator and 6-8 minutes in the conventionalshort tube evaporator.

• The design of the evaporators is such that, the juice is in contact with the heating surfacein a thin layer over the length of the heating surface.

The installation of falling film evaporator has therefore, immense potential for installation inthe Indian sugar industry for achieving substantial savings in steam. Hence, all new plantsshould strongly consider installation of FFE for the first three effects and at-least for the firsttwo effects to begin with.

Target steam consumption in evaporators – 34% on cane

Vacuum pans

The vacuum pans are used for further concentrating the massecuite produced in theevaporators, to finally produce sugar and molasses. Conventionally, the Indian sugar industrieshave been using the batch pan. With the recent introduction of the continuous pans, there hasbeen a reduction in the steam consumption to the extent of 15 – 20%.

Apart from the steam reduction, the utilization of continuous vacuum pans also result in

• Improved grain

• Reduced sugar loss

• Better control and systems.

• Reduced power consumption for injection water pumps.

Hence, by design all new plants should install only continuous vacuum pans. Other steamconsumers The other miscellaneous steam consumers in a sugar plant are

• Sugar dryers

• Sugar melter

• Centrifuge wash water super heater

• Other washing /cleaning application



6.0 Energy Saving Projects in Sugar IndustryThe energy saving projects in sugar industry are detailed below:

Cane Preparation & Juice Extraction

Short Term Projects

• Avoid recirculation in the filtrate juice by installing next lower size impeller

Medium Term Projects

• Install lower size pump for weighted juice pump/Install VFD for weighed juice pump

• Install correct size pump for crusher

• Install correct size pump for imbibition water pump

• Install lower capacity pump for juice transfer at III mill and minimize recirculation

• Install lower head pump with VFD for raw juice pump

• Install next lower size impeller for mill IV juice transfer pump

• Install right size pump for imbibition water pumping

• Install Variable Frequency Drive for Imbibition Water Pump

• Install variable frequency drive(VFD) for cane carrier drives

• Install VFD for weighed juice pump

Long Term Projects

• Install DC drives/hydraulic for mill drives & shredder

• Install electronic mass flow meters for all three mills and avoid use of weighed juice transferpump.

Juice Heating, Sulphitation, Clarification & Crystallization

Short Term Projects

• Reduce rpm of existing reciprocating compressors (centrifugal house) by 20%

• Utilize L P steam for sugar dryer and sugar melting


• Avoid condensate water pumps at juice heaters and evaporators

• Commission load/unload mechanism for sulphur air compressors

• Improve flash steam utilization for S K condensate and quad-1

• Improve sealing of the stand-by blower, avoid damper control and reduce impeller size ofthe sugar drier blower


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• Install lower size pump for clarified pumping/install VFD for clarified juice pump

• Install lower size pump for sulphite juice tank/install VFD for sulphite juice pump

• Install right pump for filter condenser water pumping

• Install rotary blower in place of Compressor for supplying air to syrup sulphur burner

• Install thermic fluid /pressurized hot water heat recovery system for utilizing sulphur furnaceexhaust steam for sulphur melts

• Install Variable Frequency Drive for super heated wash water pump

• Install VFD/small size pump/lower size impeller for mill IV juice transfer pump

• Optimize operation of spray pump

• Provide VFD for booster vacuum pump of vacuum pans (1-12)

• Provide VFD for rotary blowers of sulphur burner

• Reduce RPM of sulphur burner compressor

• Reduce rpm of vacuum pumps for drum filter

• Segregate high vacuum and low vacuum requirements of Oliver filter

• Segregate spray water and jet water and use cold water only for spray

Long Term Projects

• Modify new injection pumping system and avoid use of cooling tower pumps

Cogeneration system

Short Term Projects

• Arrest air infiltration in boilers

• Arrest identified steam leaks and improve the working of steam traps in identified areas

• Avoid recirculation of boiler feed water pump in WIL boiler

• Down size impeller of SA fan

• Improve combustion efficiency of all the boilers

• Improve insulation in identified areas

• Rationalize condensate collection system

• Reduce RPM of power plant air compressor

• Replace feed water make-up pump with low duty ump

• Use exhaust steam for deaerator water heating


• Convert identified MP steam users to LP steam users



• Install a flash vessel to recover the flash from the boiler continuous blow down & HP steamheader traps drain and connect to exhaust header

• Install correct size pump for the condensate transfer pump

• Install L P steam heater in delivery of boiler feed water pump

• Install steam jet ejectors in place of vacuum pumps for vacuum filters

• Install thermo compressors with 150 psi steam for compressing 8 psi and 12 psi exhaustvapors to 16 psi

• Install variable fluid coupling for boiler ID fans

• Install Variable Frequency Drive for Auxiliary Cooling Water (ACW) pump

• Install Variable Frequency Drive for Condenser Water pump

• Install Variable Frequency Drive for SA & PS fans and operate in open loop control

• Install VFD for Boiler feed water pump

• Optimize capacity of boiler house compressor

• Replace identified fans with correct size high efficiency fans

Long Term Projects

• Commission de-aerator and utilize L P steam for heating condensate water in de-aerator

• Install heat exchanger to preheat boiler feed water

• Install small turbine for utilizing 43/8 ata steam

Distillery

Short Term Projects

• Increase the temperature of fermented wash from 83 degree C to 90 Degree C by installingAdditional plates

• Install additional standby PHE for fermented wash heating

• Install lower head pump for fomenter circulation pump

Long Term Projects

• Install steam ejector and utilize LP steam for distilleries

Auxiliary areasShort Term Projects

• Avoid/reduce over flow of cold water OH tank by installing next lower size impeller for pump

• Install level based ON / OFF control for service water pumps


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• Install LIC for service tank/Install correct size pump for service tank

• Install temperature cut-off switch for cooling tower fans


• Arrest compressed air leakages at packing section

• Convert ‘V’ belt to flat belt drive at the identified equipment

• Install auto drain valve for instrument air compressor

• Install correct size pumps for hot water pumping at cooling tower

• Install FRP blades for process Cooling Tower fans

• Install next lower size impeller for hot water process cooling tower pump

• Install Variable Frequency Drive for Cooling Tower fans

• Install Variable Frequency Drive for service water pump

• Provide cooling tower for identified equipments and stop use of fresh water

• Segregate the low vacuum and high vacuum of Oliver filter

Electrical

Short Term Projects

• Convert delta to permanent star connection for the identified lightly loaded motors

• Install automatic star - delta - star converter in the identified lightly loaded motors

• Optimize the plant operating frequency, if operating in island mode

• Optimize the plant operating voltage


• Improve the P.F of the Identified feeders and reduce the cable loss

• Install automatic slip ring controller for the cane leveler

• Install soft starter cum energy saver at the lightly loaded motors

• Replace filament lamps installed in panel on/off indications with energy efficient led lamps

• Replace identified faulty capacitor banks

Energy Efficient EquipmentMedium Term Projects

• Replace dyno drives with variable frequency drives in identified equipments

• Replace eddy current drive in cane carrier with variable frequency drive



• Replace old rewound motors with Energy Efficient motors

LightingShort Term Projects

• Avoid daytime lighting in identified areas

• Increase the natural lighting by installing translucent sheets and switch off the identified light

• Install 50 KVA step down transformer at the main lighting circuit


• Convert the 100 incandescent lamps with 40W fluorescent lamps

• Convert the existing 200 W 300W & 500 W incandescent lamps with 160W choke less LMLlamps

• Convert the existing 40W fluorescent tubes with 36 W slim tubes

• Covert the 400 W high pressure mercury vapor lamps (HPMV) with 250 W energy efficienthigh pressure sodium vapor lamps (HPSV)

• Install automatic voltage stabilizer in lighting feeder and operate at 205 -210 volts

• Install energy efficient Copper chokes for identified fluorescent lamps

7.0 Detailed description of capital intensive energy saving projects13 no of capital intensive energy saving projects are described in detail. These projects havebeen chosen as they have high saving and investment potential with high replication possibility.


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Case study 1

Install diffusers in lieu of milling tandemBackgroundInstallation of milling tandem is practiced conventionallyin sugar plants in India. Milling is highly power andlabour oriented equipment. The present trend is toadopt diffusion as an alternative to Milling, consideringseveral advantages diffusion offers over milling.

It is a low cost extraction process. In conventionalmilling mass transfer operation is by leaching followedby high pressure squeezing. In diffusion process, thephysico-chemical principle of diffusion is adopted. Heresugar molecules moves from higher concentration tolower concentration due to concentration gradient.

Rate of diffusion is proportional to the temperature, concentration gradient and the area ofliquid and solid contact.

The Juice extraction process in the cane diffuser system is as follows:

1. Cane is prepared to a Preparation Index (PI) of 85 %+, ensuring long fiber preparation.The heavy duty swing hammer fibrizor described above is suitable for meeting thisrequirement.

2. Prepared cane is delivered to the diffuser. The cane is heated at entry to the diffuser toa temperature of 83oC by scalding juice, which is at a temperature of about 90oC.

3. The diffusion percolation bed is a moving conveyor on which the cane mat height isbetween 1200 mm to 1400 mm.

4. The diffuser is divided in 13 circulation compartments. Juice from each compartment isre-circulated in counter current manner to cane blanket movement, from low brix area tohigh brix area.

5. The scalding juice is limed in order to maintain a pH of about 6.5 in the diffuser in orderto prevent inversion of sucrose.

6. Average temperature of the material inside the diffuser is about 78 Degree C

7. Draft juice from the diffuser is at about 69 Degree C and therefore is sent directly to thesulphitation vessel because it is already at the required temperature for sulphitation.

8. Diffusion bagasse at exit of the diffuser is at supersaturated moisture and is de-wateredin a single six-roller mill. Final bagasse moisture is 51 % plus.

9. Imbibition is applied directly in the diffuser. Hot condensate at 84 Degree C from the evaporatorlast effect is used for this. Imbibition quantity at Andhra Sugars is 320 % on Fiber.

10. Draft juice is measured by a mass flow meter. Hence the juice is delivered to the sulphitationvessel in a closed pipe without appreciable loss of temperature. Screening of draft juiceis found to be not necessary because the bagasse bed through which the juice percolates,itself acts as a screen.



Energy Saving ProjectA 2500 TCD plant in India has installed cane diffuser by design. The power consumption ina standard sugar mill, utilizing a milling tandem for juice extraction is 17.8 kWh / ton. In theplant under discussion, the average power consumption in the juice extraction section is 11.4kWh / Ton. This results in a decrease of 6.4 kWh / Ton of cane crushed.

The other spin off benefits on installation of diffuser are:

• Increased extraction

• Lower power consumption

• Lower maintenance cost

• Reduction in Unknown loss

• Reduction in Lubrication Cost

• Reduction in Sugar Loss in filter cake

• Availability of More Bagasse

Financial AnalysisThe additional .. saving benefit was Rs 8.0 million. Considering an average crushing of 2500TCD for an operating season of 180 days, the reduction in power consumption is 28.8 Lakhunits. This results in an energy cost saving of Rs. 8.0 million / season (Considering powerexport cost of Rs. 2.75 / kWh). The diffuser was installed by design.

Replication PotentialThis project has tremendous replication potential. In India, the number of sugar mills over 2500TCD capacity is more than 320. Considering an average crushing of 150 days and powerexport cost of Rs. 2.75 / kWh, the total energy saving potential is over Rs. 2.112 Billion/season.

Considering an investment of Rs. 90 Million per diffuser, the investment potential for installationof diffusers in Indian sugar industry is Rs. 28.8 Billion.




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Case study 2

Utilisation of Exhaust Steam for Sugar Drier and Sugar Melter

BackgroundThe sugar manufacturing process needs substantial amount of thermal energy, in the form of

steam. The majority of steam requirement isat low pressures (0.6 to 1.5 ksc), while a smallpercentage of the steam consumption is atmedium pressure of about 7.0 ksc.

In the sugar mills, the requirement of steamat lower pressures is met from the exhaust ofthe turbine; while the medium pressure (MP)steam, in most of the plants, is generated bypassing the live steam generated from theboiler, through a pressure-reducing valve. Thisis schematically indicated below:

Benefits of using exhaust steam for sugar drier and melter• Increased co-generation• Additional power export to grid

With the installation of commercial cogeneration systems, the projects for additional cogenerationhave become attractive, as additional power can be sold to the grid.

One of the methods of improving cogeneration, is the replacement of high-pressure steamwith low-pressure steam, wherever feasible. In a sugar mill, there is a good possibility ofreplacing some quantity of MP steam users with exhaust steam, resulting in increased powergeneration.

This case study describes one such project implemented in a 2500 TCD sugar mill.

Previous StatusIn one of the 2500 TCD sugar mills, medium pressure steam at 7.0 ksc, generated by passinglive steam at 42 ksc, through a pressure reducing valve (PRV), was being used in the followingprocess users:• Hot water superheating for use in the centrifuges• Sugar drier blower• Sugar melter

The temperature requirements for sugar drier blower and sugar melter are about 80°C and90°C respectively. The centrifuge hot water was to be heated to a temperature of about115 - 125°C.


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Exhaust steam generated by passing live steam through a turbine was available at around1.2 ksc.

Energy Saving ProjectThe exhaust steam was utilised in place of live steam for sugar melting (blow-up) and sugardrying.

Concept of the projectThe sugar melting requires a temperature of 90°C and sugar drying needs about 80°C. Theheat required for these two process users, can be easily achieved by exhaust steam.

Replacement of live steam with exhaust steam in these two users can increase the co-generation. Every ton of medium pressure steam replaced with exhaust steam can aid ingeneration of additional 120 units of power.

Implementation Methodology, Problems faced and Time frameThe steam distribution network was modified, to install steam line from the exhaust headerto sugar melter and sugar drier blower.

There were no problems faced during the implementation of this project, as the modificationinvolved only the laying of new steam pipelines and hooking it to the main steam distributionsystem. The entire modification was carried out in 15 days time.

Benefits

The live steam consumption, amounting to about 0.3 TPH, in the sugar melter and sugar drierblowers, was replaced with exhaust steam. This resulted in additional power generation ofabout 35 units, which could be sold to the grid.

Financial AnalysisThe annual energy saving achieved was Rs. 0.2 million. This required an investment ofRs. 0.02 million, which had a very attractive simple payback period of 2 months.

NoteSimilarly, exhaust steam can partly substitute the use of live steam for hot water heating incentrifuges. The centrifuge hot water heater requires a temperature of about 115 -125°C.Exhaust steam can be used for heating the centrifuge wash water to atleast 105°C. Theheating, from 105°C to 125°C can be carried out by live steam. This will partly substitute theuse of live steam and will increase the cogeneration power.





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Case study 3

Installation of Conical Jet Nozzles for Mist Cooling System

BackgroundThe spray pond is one of the most common typeof cooling system in a sugar mill. In a spray pond,warm water is broken into a spray by means ofnozzles. The evaporation and the contact of theambient air with the fine drops of water producethe required degree of cooling. There are manytypes of nozzle onfigurations available for differentspraying applications. Most of them aim to give awater spray the form of a hollow cone. A goodspray nozzle should be

of simple design, high capacity and high efficiency. Of the various types of spray nozzles, theconical jet nozzles have been found far superior on all the above parameters. Hence, therecent trend among the new sugar mills is to install the conical jet nozzles, to achieve maximumdispersion of water particles and cooling.

Mist Cooling SystemPrevious status

In a 4000 TCD sugar mill, the cooling systemconsisted of a spray pond. There were 5 pumpsof 75 HP rating operating continuously, to achieve the desired cooling parameters. Thematerials of construction of the spray nozzles were Cast Iron (C.I). These nozzles had thedisadvantages of low capacity and high head requirements (of the order of 1.0 - 1.2 ksc or

10 -12 m of water column). The maximum cooling that could be achieved with the spray pndwas about 34 - 35 °C. To achieve better cooling, higher efficiency and energy savings, theconical jet nozzles were considered.

Energy Saving ProjectThe spray pond system was modified and conical jet nozzles were installed to achieve mistCooling.

Concept of the proposal

The water particle dispersion is so fine that, it gives a mist like appearance. The surface areaof the water particles in contact with the ambient air is increased tremendously. Hence, bettercooling is achieved with the mist cooling system.

The material of construction of the latest conical jet nozzles is PVC, which enables achievebetter nozzle configuration. They will also help attain the same operating characteristics as thecast iron nozzles, but at a much lower pressure drop or head (0.5 - 0.8 ksc) requirement.



This reduces the cooling water pump power consumption substantially.

Implementation Status, Problems faced and Time frameThe earlier CI nozzles of 40 mm diameter were replaced with PVC conical jet nozzles of 22mm diameter, in phases. There were no problems faced during the implementation of thisproject.

As the project was implemented in phases, it was implemented in totality over 2 sugarseasons.

Benefits AchievedThe cooling achieved with the mist cooling system was about 31 - 32 °C (i.e., a sub-coolingof 2 - 4 °C was achieved). This resulted in avoiding the operation of one 75 HP pumpcompletely.

In addition, significant process benefits were achieved. The better cooling water temperatures,helped in maintaining steady vacuum conditions in the condensers. This minimised the frequentvacuum breaks, which occurred in the condensers (on account of the high cooling watertemperatures) and also ensured better operating process parameters.

Financial AnalysisThe annual energy savings achieved were Rs.0.32 million (assuming a cogeneration systemwith 120 days of sugar season and saleable unit cost of Rs.2.50/kWh). This required aninvestment of Rs.0.50 million, which had a simple payback period of 19 months.





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Case study 4

Installation of Regenerative Type Continuous Flat Bottom HighSpeed Centrifugal for A - Massecuite Curing

BackgroundThe syrup after concentration to its maximum permissible brix levelsin the vacuum pans is passed to the crystallisers. From thecrystallisers, the concentrated and cooled mass, comprising ofmolasses and crystals are fed to the centrifugal, so that the motherliquor and the crystals are separated, to obtain the sugar in thecommercial form.

The recent trend among the sugar mills is to install fully automaticcentrifugal. The many operations involved in the centrifuge are -starting, charging, control of charging speed, closing These centrifugalhad the conventional type of braking system, with no provisions forrecovery of energy expended during changeover to low speed ordischarging speed.

The power consumption in these centrifugal were of the themassecuite gate, acceleration, washing with superheated wash water‚& steam, drying at high speed, change to low speed & control ofdischarging speed, opening the discharge cone, drying out the sugar, and starting the nextcharge. All these are carried out by an assembly of controls, programmed to operate in thecorrect sequence.

At the end of the drying period, the centrifugal is stopped by means of a brake, which generallyconsists of brake shoes provided with a suitable friction lining and surrounding a drum, onwhich they tighten when released. Substantial amount of energy is expended in the process.Of late, regenerative braking systems have been developed, which will permit the partialrecovery of the energy expended.

Previous statusOne of the 4000 TCD sugar mills, had DC drives for their flat bottom high speed centrifugalof 1200 kg/h capacity used for A - massecuite separation.

Benefits of regenerative type continuous centrifuge

Reduction in centrifuge power consumption

These centrifugal had the conventional type of braking system, with no provisions for recoveryof energy expended during changeover to low speed or discharging speed. The powerconsumption in these centrifugal were of the partially recover the energy expended during thedischarge cycle.


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Energy saving projectThe regenerative type of braking system was installed for all the flat bottom high speedcentrifugal used for A - massecuite curing.

Concept of the projectOne of the most important characteristics of a regenerative braking system in an electriccentrifugal is that, it permits the partial recovery of the energy expended, during the dischargecycle.

With AC current, this is obtained by means of a motor of double polarity, which can work withhalf the normal number of poles. This regeneration is effective only down to about 60% of thenormal speed. However, this corresponds to more than half the stored energy. With DCmotors, a much greater proportion of the stored energy can be recovered.

With the present day motors, supplied with thyristor controls, regenerative braking is obtainedby reversing the direction of the excitation current, as the supply is unidirectional. The motor,thus, works as a generator and the power generated (by recovery of energy during braking)is fed back into the system.

Implementation status, problems faced and time frameThe regenerative type of braking system was installed for one of the flat bottom DC motordriven high-speed centrifugal on a trial basis. Once, the satisfactory and stable operatingparameters were achieved, it was extended to the remaining centrifugal also.

There were no particular problems faced during the implementation of this project. Theimplementation of the project was carried out over two sugar seasons.

Benefits achievedThe regenerative braking system recovers about 1.34 kW/100 kg of sugar produced, during thedischarge cycle and feeds it back into the system. Hence, the net power consumption of thecentrifugal with the regenerative braking system, is only 0.66 kW/100 kg of sugar produced.

Financial analysisThis project was implemented as a technology upgradation measure.

Replication PotentialThis project has a high replication potential of implementation in more than 75 plants in thecountry.



Case study 5

Installation of Jet Condenser with External Extraction of Air

BackgroundThe evaporators and pans are maintained at low pressures,through injection water pumps. These are one of the highestelectrical energy consumers in a sugar mill. The multi-jetcondenser, which are presently used in the sugar plants, do boththe jobs of providing the barometric leg, as well as removing thenon-condensibles.

The water injected into these condensers comprise of, spraywater for condensation and jet water for creating vacuum. Thewater used for condensation needs to be cool, while the jet watercan be either hot or cold. So only a part of the water used in thecondenser needs to be cooled.

However, the vacuum levels which they give is less uniform and varies slightly with thetemperature of the hot water, which in turn depends on the quantity of vapour to be condensed.of 3200 TCD.

With the expansion plans, for increasing the installed crushing capacity to 4000 TCD, theinstallation of jet condensers with external air extractor was considered.

They have a higher water consumption and require more powerful pumps, with consequenthigh electric power demand.

To overcome these disadvantages, the latest trend among the major sugar mills has been toreplace these multi-jet condensers with a jet condenser with external extraction of air.

Previous statusOne of the sugar mills with an installed capacity of 2500 TCD, had the multi-jet condensersfor the creation of vacuum and condensation of vapours, from the vacuum pans and evaporator.

There were 11 injection water pumps of 100 HP rating, catering to the cooling water requirementsof these condensers. These pumps were designed to handle an average maximum crushingcapacity of 3200 TCD.

Benefits of jet condenser with external extraction of air Reduction in injection water pumppower consumption

Energy saving projectAlong with the expansion plans of 4000 TCD crushing capacity, the multi-jet condensers werereplaced with jet condensers having external air extractor facility


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Concept of the projectThe jet condensers with external extraction of air also works on the same principle as thatof the jet condensers. The nozzle is placed at such a height that the water discharged by itcan be aspirated into the condenser. Since the quantity of air is very small, the water leavesthe nozzle at a temperature, practically equal to that at which it enters. The difference is noteasily detectable, by a thermometer.

Hence, a pump of low head can be utilised and it may be arranged, so that, it is not necessaryto pump the water, leaving the water actuated ejector condenser (which is used to ensurecondensation in the barometric column).

For this, it is sufficient that the water level in the intermediate channel below the ejector shouldbe about 4 m above the level in the channel at the foot of the barometric column.

The water in the intermediate channel is, thus aspirated into the condenser, as soon as thevacuum approaches its normal value.

Implementation status, problems faced and time frame There were no problems faced duringthe implementation of this project, except for the initial problem of identifying the ideal layout.The entire project was taken up during the sugar off-season.

Benefits achievedThere was a significant drop in water consumption in these condensers, inspite of an increasein crushing capacity (average maximum crushing of 4800 TCD). This resulted in reduction inthe number of injection water pumps in operation.

The new injection water pumping system includes - 5 nos. of 100 HP pump and 1 no. of 250HP pump. Thus, there is a net reduction in the installed injection water pumping capacity ofabout 350 HP (30% eduction). The actual average power consumption also has registered asignificant drop of nearly 180 kW, which amounts to an annual energy saving of 5,18,400 units(for 120 days of sugar season).

Financial analysisThe annual benefits achieved are Rs.1.30 million (assuming a cogeneration system with 120days of sugar season and saleable unit cost of Rs.2.50/kWh). This required an investment ofRs.2.53 million, which had a simple payback period of 24 months.





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Case study 6

Installation of 30 MW Commercial Co-generation Plant

BackgroundThe Indian sugar industry by its inherent nature, can generatesurplus power, in contrast to the other industries, which areonly consumers of energy. This is mainly possible becauseof the 30 % fibre content in the sugar cane used by thesugar mills. This fibre, referred to as bagasse, has goodfuel value and is used for generation of the energy required,for the operation of the sugar mill.

The bagasse is fired in the boiler, for producing steam athigh pressures, which is extracted through various back-pressure turbines and used in the process. Thissimultaneous generation of Commercial

co-generation plant steam and power, commonly referred to as Co-generation. Conventionally,the co-generation system was designed to cater to the in-house

requirements of the sugar mill only. The excess bagasse generated, was sold to the outsidemarket.

In the recent years, with the increasing power‚ Demand-Supply™ gap, the generation of powerfrom the excess bagasse, has been found to be attractive. This also offers an excellent opportunityfor the sugar mills to generate additional revenue. Co-generation option has been adopted inmany of the sugar mills, with substantial additional revenue for the mills. This also contributesto serve the national cause in a small way, by bridging the ‚Demand- Supply™ gap.

This case study describes the installation of acommercial co-generation plant in a 5000 TCD mill.

Previous statusA 5000 TCD sugar mill in Tamilnadu operating for about200 days in a year had the following equipment:

Boilers• 2 numbers of 18 TPH, 12 ATA• 2 numbers of 29 TPH, 15 ATA• 1 number of 50 TPH, 15 ATA

Turbines1 number 2.5 MW1 number 2.0 MW1 number 1.5 MW



Mill drives• 6 numbers 750 BHP steam turbines• 1 number 900 BHP shredder turbine

The plant had an average steam consumption of 52%. The powerrequirement of the plantduring the sugar-season was met by the internal generation and during the non- season fromthe grid.

Energy saving projectThe plant went in for a commercial co-generation plant. The old boilers and turbine werereplaced with high- pressure boilers and a single high capacity turbine. The new turbineinstalled was an extraction-cum- condensing turbine. A provision was also made, for exporting(transmitting) the excess power generated, to the state grid. The mill steam turbines, werereplaced with DC drives. The details of the new boilers, turbines and the steam distributionare as indicated below:

Boilers• 2 numbers of 70 TPH, 67 ATA• Multi-fuel fired boilers

Turbines1 number of 30 MW turbo-alternator set (Extraction-cum-condensing type)

Mill drives4 numbers of 900 HP DC motors for mills 2 numbers of 750 HP DC motors for mills 2numbers of 1100 kW AC motors for fibrizer

Implementation methodology, problems faced and time frameTwo high capacity, high-pressure boilers and a 30 MW turbine was installed in place of theold boilers and smaller turbine.

While selecting the turbo-generator, it was decided to have the provision for operation of theco-generation plant, during the off-season also. This could be achieved, by utilising the surplusbagasse generated during the season, as well as by purchasing surplus bagasse, from othersugar mills and biomass fuels, such as, groundnut shell, paddy husk, cane trash etc.

The shortfall of bagasse during the off-season was a problem initially. The purchase of biomassfuels from the nearby areas and the use of lignite solved this problem.

The entire project was completed and commissioned in 30 months time.

BenefitsThe installation of high-pressure boilers and high-pressure turbo-generators has enhanced thepower generation from 9 MW to 23 MW. Thus, surplus power of 14 MW is available forexporting to the grid.


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The following operating parameters were achieved:

Typical (average) crushing rate = 5003 TCD

Typical power generation

• During season = 5,18,321 units/day

• During off-season = 2,49,929 units/day

Typical power exported to grid

• During season = 3,18,892 units/day (13.29 MW/day)

• During off-season = 1,97,625 units/day (8.23 MW/day)

Typical no. of days of operation = 219 days (season) = 52 (off-season)

The summary of the benefits achieved (expressed as value addition per ton of bagasse fired)is as follows:

Financial analysisThe annual monetary benefits achieved are Rs.204.13 million (based on cost of power soldto the grid @ Rs.2.548/unit, sugar season of 219 days and off-season of 52 days). Thisrequired an investment of Rs.820.6 million. The investment had an attractive simple paybackperiod of 48 months.





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Note :Critical factors affecting power generation

The efficient operation of a co-generation system depends on various factors. This has a directbearing on the loss in power generation and the power exported to the grid. Some of thesecritical factors affecting the power generation (quantified as loss in generation per day) are asfollows:

• 1% drop in bagasse % in cane : 18300 units

• 1% increase in moisture content of bagasse : 6800 to 10200 units

• 1% increase in process steam consumption : 4200 units

• 1% drop in crushing rate : 5000 to 7400 units

• 1 hour downtime : 20600 units

• Drop in 1 ton of cane availability : 60 units

The above figures are based on the following operational parameters:

• Crushing rate : 5000 TCD

• Steam to bagasse ratio : 1 : 2.2

• NCV of bagasse (50% moisture) : 1804 kCal/kg

• Bagasse content, in % cane : 27%

Replication PotentialThe sugar plants in India have tremendous potential for commercial cogeneration ie producingsteam at a higher pressure and selling the extra power generated to the grid. The totalcogeneration potential yet to be tapped in India has been estimated to be about 100 MW. Theinvestment potential for alteast say about 50 plants is Rs 4000 million.



Case study 7

Replacement of Steam Driven Mill Drives with Electric DCMotor

BackgroundConventionally, steam turbines, are used as the primemovers for the mills, in a sugar industry. These steamturbines are typically, single stage impulse type turbineshaving about 25 - 30% efficiency.

The recent installation of commercial cogenerationsystem, with provision for selling the excess power tothe grid, has made the generation of excess power in asugar mill, very attractive. One of the methods ofincreasing the cogeneration power in a sugar mill, is toreplace the smaller Previous status A 5000 TCD sugarmill had six numbers of 750 HP mill turbines and one number of 900 HP shredder turbine.

The average steam consumption per mill (average load of 300 kW) was about 7.5 TPH steam@ 15 Ata. The steam driven mill drives had an low efficiency mill turbines, with betterefficiency drives, such as, DC motors or hydraulic drives.

The power turbines (multi-stage steam turbines) can operate at efficiencies of about 65 - 70%.Hence, the equivalent quantity of steam saved by the installation of DC motors or hydraulicdrives, can be passed through the power turbine, to generate additional power.

This replacement can aid in increase of net saleable power to the grid, resulting in additionalrevenue for the sugar plant. This case study, highlights the details of one such project,implemented in a 5000 TCD sugar plant.

Benefits of electric DC drives for mill prime movers• Increased drive efficiency• Additional power export to grid

Previous statusA 5000 TCD sugar mill had six numbers of 750 HP mill turbines and one number of 900 HPshredder turbine.

The average steam consumption per mill (average load of 300 kW) was about 7.5 TPH steam@ 15 Ata. The steam driven mill drives had an efficiency of about 35%, in the case of single-stage turbine and about 50%, in the case of two-stage turbines.

The plant team was planning to commission a commercial cogeneration plant. This offered anexcellent opportunity for the plant team to replace the low efficiency steam turbine driven mills,with DC motors or hydraulic drives and maximise the cogeneration potential.


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Energy saving projectThe plant team contemplated the replacement of the steam driven mills with electric DCmotors, along with the commissioning of the cogeneration plant.

Concept of the projectThe conventional single stage impulse type steam turbines have very low efficiencies of 35%.Hence, the steam consumption per unit of power output is very high.

A single high capacity steam turbine is more efficient as compared to multiple number ofsmaller capacity steam turbines. Hence, the steam can be passed through the larger capacitysteam turbine to generate more saleable power.

The latest drives, such as, DC drives and hydraulic drives have very high efficiencies of 90%.The steam saved by the installation of DC drives, can be passed through the larger capacitypower turbines of higher efficiency (about 65 - 70%), to generate additional saleable power.

Implementation methodology, problems faced and time frameThe steam turbine mill drives were replaced with DC drives, once the cogeneration plant wascommissioned. The modifications carried were as follows:

• Four numbers of 900 HP and two numbers of 750 HP DC motors were installed in placeof the six numbers of 750 HP mill turbines

• Two numbers of 1100 kW AC motors were installed for the fibrizer, in place of the single900 HP shredder turbine

• There were no major problems faced during the implementation of this project. Theimplementation of the project was completed in 24 months.

Benefits achievedThe comparative analysis of the operational parameters before and after the modification is asfollows:



The steam consumption indicated, is the equivalent steam consumption in a power turbine, forgeneration of additional power

The equivalent power saved (850 kW/mill) by the implementation of this project, could beexported to the grid, to realise maximum savings. This amounts to about

Financial analysisThe annual energy saving achieved was Rs.62.37 million. This required an investment ofRs.42.00 million, which had an attractive simple payback period of 9 months.





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Case study 8

Installation of an Extensive Vapour Bleeding System at theEvaporators

BackgroundThe sugar industry is a major consumer of thermalenergy in the form of steam for the process.The steam consumers in the process are -evaporators and juice heaters (mixed juice,sulphited juice and clear juice).

Out of these consumers, the evaporators whichconcentrate the juice, typically from a brix contentof 10 - 11 to about 55 - 60 brix, consume themaximum steam. The evaporators are multipleeffect evaporators,with the vapour of one stage

used as the heating medium in the subsequent stages. In the older mills, the evaporators aretriple/quadruple effect and the vapour from the first effectis used for the vacuum pans andfrom the second effect for juice heating.

In the modern sugar mills, efforts have been taken to reduce the steam consumption. Thefollowing approach has been adopted in the boiling house for reducing the steam consumption:

Increasing the number of evaporator effects the higher the number of effects, the greater willbe the steam economy (i.e., kilograms of solvent evaporated per ton of steam).

Typically, the present day mills, use a quintuple effect evaporator system.

Extensive vapour bleeding - the extensive use of vapour coming out of the different effects ofthe evaporators are used for juice heaters and vacuum pans. The later the effect, the betteris the steam economy in the system.

Additionally, the following aspects were also considered in the cane preparation section andmilling section:

• Installation of heavy duty shredders, to achieve better preparatory index (> 92+ as comparedto the conventional 85+) for cane

• Installation of Grooved Roller Pressure Feeder (GRPF) for pressure feed to the mills. Thisallows for better juice extraction from the cane.

• Lesser imbibition water addition, on account of the better juice extraction by the GRPF,resulting in reduction of boiling house steam consumption

This case study pertains to a sugar mill of 2500 TCD, where the above approach has beenadopted at the design stage itself, resulting in lower steam consumption.


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Conventional systemIn a typical sugar mill, the most commonly used evaporators are the quintuple effect evaporators.

The typical vapour utilisation system in the evaporators comprises of:

• Vapour bleeding from II- or III- effect for heating (from 35 °C to 70 °C) in the raw (ordynamic) juice heaters

• Vapour bleeding from I- effect for heating (from 65 °C to 90 °C) in the first stage of thesulphited juice heater

• Exhaust steam for heating (from 90 °C to 105 °C) in the second stage of the sulphited juiceheater

• Exhaust steam for heating (from 94 °C to 105 °C) in the clear juice heaters

• Exhaust steam for heating in the vacuum pans (C pans)

The specific steam consumption with such a system for a 2500 TCD sugar mill is about 45to 53 % on cane, depending on the crushing rate. However, maximum steam economy isachieved, if the vapour from the last two effects can be effectively utilised in the process, asthe vapour would be otherwise lost. Also, the load on the evaporator condenser will reducedrastically.

Many of the energy efficient sugar mills, especially those having commercial cogenerationsystem, have adopted this practise and achieved tremendous benefits. The reduced steamconsumption in the process, can result in additional power generation, which can be exportedto the grid.

Present systemIn a 2500 TCD sugar mill, the extensive use of vapour bleeding at evaporators, was adoptedat the design stage itself. The plant has a quintuple-effect evaporator system. This systemcomprises of:

• Vapour bleeding from the V- effect, for heating (from 30 °C to 45 °C) in the first stage ofthe raw juice heater

• Vapour bleeding from the IV- effect, for heating (from 45 °C to 70 °C) in the second stageof the raw juice heater

• Vapour bleeding from the II- effect, for heating in the A-pans, B-pans and first stage ofsulphited juice heater

• Vapour bleeding from the I- effect, for heating in the C-pans, graining pan and second stageof sulphited juice heater n Exhaust steam for heating in the clear juice heater

However, to ensure the efficient and stable operation of such a system, the exhaust steampressure has to be maintained uniformly at an average of 1.2 - 1.4 ksc.

In this particular plant, this was being achieved, through an electronic governor control systemfor the turbo-alternator sets, in closed loop with the exhaust steam pressure. Whenever, the



exhaust steam pressure decreases, the control system will send a signal to the alternator, toreduce the speed. This will reduce the power export to the grid and help achieve steadyexhaust pressure and vice-versa.

Benefits achievedThe installation of the extensive vapour utilisation system at the evaporators has resulted inimproved steam economy. The specific steam consumption achieved (as % cane crushed) atvarious crushing rates are as follows:

• At 2500 to 2700 TCD : 41% on cane

• At 2700 to 2800 TCD : 40% on cane

• At 2800 to 3000 TCD : 39% on cane

• At 3000 TCD and above : 38% on cane

Thus, the specific steam consumption (% on cane) is lower by atleast 7%. This means asaving of 3.5% of bagasse percent cane (or 35 kg of bagasse per ton of cane crushed).

Financial analysisThe annual benefits on account of sale of bagasse (@ Rs.350/- per ton of bagasse and 120days of operation) works out to Rs.4.50 million. This project was installed at the design stageitself. The actual incremental investment, over the conventional system, was not available.

Note :In another sugar mill of 5000 TCD, the same project was implemented. The annual savingachieved was Rs.11.00 million. This required an investment of Rs.6.50 million, which had anattractive simple payback period of 8 months.





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Case study 9

Installation of Variable Speed Drive (VSD) for the WeighedJuice PumpBackgroundThe sugarcane is crushed in the mill house, to separate the juice and thebagasse. The juice obtained from the mill house is known as raw juice.The raw juice is screened, to remove all suspended matter and anyentrained fibres. The juice is at this stage, known as strained juice.

The strained juice is then sent to a weigh scale, from where it getstransferred to a weighed juice tank. This weighed juice is passed throughthe primary/ raw juice heaters to the sulphiters, with the help of weighedjuice pumps. In the sulphiter, SO2 is injected continuously for colourremoval.

The flow of the weighed juice to the sulphiters through the juice heaters,has to be maintained at a steady flow rate, to achieve uniform heating andquality.

Previous statusIn a 2600 TCD sugar mill, there was a weighed juice pump operating continuously to meet theprocess requirements.

The pump had the following specifications:• Capacity : 27.77 lps• Head : 45 m• Power consumed : 23 kW

Benefits of variable speed drive for weighed juice pump• Reduction in juice pump power consumption• Steady juice flow to juice heaters and Sulphitor

• Better quality of sulphitation

The flow from the weighed juice tank was not uniform. On one hand, the tank was gettingemptied, whenever the time between the tips of the weigh scale was more. On the other hand,whenever the time between the tips was less, the level of juice in the tank builds-up. The tipof the weigh scale is governed by, the cane crushing rateand also the quality (juice content)of cane.

Moreover, the pump was designed for handling the maximum cane-crushing rate. The maximumhead requirement is only 25 m (equivalent to 2.5 ksc), while the pump had a design head of45 m. This also contributed to the excess margins in the pump, leading to operation withrecirculation control.

Hence, to keep the juice flow smooth and avoid the tank from getting emptied, the pump wasoperated with recirculation control. The pressure in the juice heater supply header, is maintainedby periodically throttling and adjusting the control valve in the recirculation line.


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The operations of a centrifugal pump with valve control or recirculation, are energy inefficientmethods of capacity control, as energy is wasted in pumping more quantity, than is actuallydesired. In the above context, it is advisable to have a uniform flow of juice and also avoidwastage of energy through re-circulation. This can be achieved in an energy efficient manner,by varying the RPM of the pump.

Energy Saving ProjectThe plant team decided to conduct trials with a suitable variable speed mechanism for theweighed juice pumps. A variable speed system will help achieve the RPM variation of the pumpand exactly match the varying capacity requirements.

Concept of the ProjectThe installation of a variable speed system, will not only ensure a consistent flow, resultinginimproved quality of the product, but also, offer substantial energy savings.

Among the different variable speed systems, the installation of a variable frequency drive (VFD)can result in maximum energy savings. The VFD can be put in a closed loop with the dischargepressure.

This will enable constant flow of juice to the juice heater and sulphiter, irrespective of the levelin the juice tank. The discharge pressure set point can be adjusted periodically,depending onthe crushing rate or number of tips manually. In the new sugar mills, the number of tips andtime interval between the tips is measured. This can be used by the VFD, for automaticallyvarying the juice flow through the system, according to the rate of crushing.

Benefits AchievedThe installation of a Variable Frequency Drive for the weighed juice pump, resulted in thefollowing benefits:

• Consistent and steady flow to the juice heaters• Improved quality of sulphitation, as the juice flow was steady• Reduced power consumption by an average of 11 kW (a reduction of about 30 - 40%).

However, the installation of a VFD at a later stage, can result in maximum energy savings. Theinstallation of a VFD, can result in the reduction of the average power consumption by atleastanother 40 - 50%.

Financial AnalysisThe annual energy saving achieved (with theinstallation of a dyno-drive) wasRs.0.236 million. The investment made waRs 0.25 million, with an attractive paybackperiod of 12 months.

Replication PotentialEvery sugar plant has about 10 -12 juice pumpsin operation. The potential for application for VFD exists in atleast 3 pumps. This project hasbeen taken up only in few of the newer sugar plants. The investment potential (100 plants xRs 0.5 million/plant) is Rs 50 million.





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Case study 10

Installation of Thermo-compressor for use of Low PressureSteam

BackgroundThe sugar industry has many steam users - both iolivelymedium pressure (MP) steam and exhaust steam. Some ofthese live steam users can be totally replaced with exhauststeam, while in some other users, the live steam consumptioncan be partially replaced with exhaust steam.

One such live steam user in a sugar mill is the adjoiningdistillery. A typical distillery requires steam at about 0.7 - 0.9ksc for the distillation column and about 1.0 - 1.2 ksc for theENA column. The exhaust steam pressure of 0.4 ksc availablefrom the sugar mill, will not be able to cater to this requirement.Hence, live steam is drawn from the 8.0 ksc header anddropped to 1.5 ksc, through a pressure-reducing valve, for usein the distillery.

Any conservation measure, which can replace/ minimise thelive MP steam consumption, can result in maximising thecogeneration in a sugar mill. One such method of minimizing the MP steam consumption isby the installation of a thermo- compressor.

The thermo-compressor, by passing a very small quantity of MP steam can iacompresslr thewaste exhaust steam (typically about 0.4 ksc) available in the sugar mill. The resultant LPsteam (typically about 1.5 ksc) can be utilised for any process steam requirement, such asthe distillation column and ENA column in a distillery.

This modification can result in minimising the usage of MP steam consumption, effectivelyutilise the heat value of exhaust steam and maximise the cogeneration potential.

Previous statusIn a typical 4000 TCD sugar millin Maharashtra, the turbineexhaust steam at 0.40 ksc, wascontinuously vented out. Thequantity of the steam vented,amounted to about 6300 kg/h.There were no process usersin the sugar mill or the distillery,which could utilise this exhauststeam of 0.40 ksc.



The distillery required 10 TPH of steam at 1.5 ksc. A separate boiler was meeting the steamrequirements of the distillery. The sugar mill boiler met any additional requirement of steam.In both the cases, steam was generated at 8 ksc and reduced to 1.5 ksc through a pressure-reducing valve.

Benefits of thermo compressor• Increased co-generation

• Additional power export to grid

The expansion of steam through a pressure-reducing valve is not a good system, as no poweris generated with pressure reduction. The turbine exhausts steam, instead of being ventingout, could be converted to medium /high-pressure steam through thermo-compression andused to meet the steam requirements of the distillery.

Energy saving projectA thermo-compressor system was installed, for reusing the turbine exhaust steam, in thedistillery. The resultant MP steam saved in the distillery, was passed through the power generatingturbines, for generation of additional power.

Concept of the projectIn the thermo-compressor body, high or medium pressure motive steam accelerates throughthenozzle. As it enters the suction chamber at supersonic speeds, it entrains and mixes withlow-pressure exhaust steam, entering from the suction inlet.

The resultant steam mixture then enters the convergent-divergent diffuser. In this section, thevelocity reduces and its kinetic energy is converted to pressure energy. The steam dischargedby the thermo-compressor is then recycled to a localised process.

The resultant discharge steam is available at a pressure, suiting the particular processapplication.The outlet steam pressure and quantity can be designed, by varying the velocityand quantity of the motive steam and fine-tuning the configuration of the thermo-compressor.

Implementation methodology, problems faced and time frameA thermo-compressor system along with the associated mechanical hardware including traps,strainers, safety valves etc., and flow control instrumentation on the motive steam, was installed.The thermo-compressor operating parameters are

• Motive steam : 3700 kg/h at 20 ksc

• Suction steam : 6300 kg/h at 0.4 ksc

• Discharge steam : 10000 kg/h at 1.5 ksc

There were no problems faced during the implementation of this project. Moreover, the thermo-compressor operation is maintenance free. The system was installed in 6 months time.


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BenefitsThe resultant 1.5 ksc steam obtained by thermo-compression of exhaust steam, was directlyused in the distillery. This reduced the passing of high/ medium-pressure steam through thepressure-reducing valve.

Financial analysisThe annual energy saving achieved was Rs.6.00 million. This required an investment of Rs.2.00million, which had a very attractive simple payback period of 4 months.

Replication Potentialthere are about 50 plants in India with distillery integrated with the sugar mill. The possibilityof installing a thermo compressor exists in majority of the plants. The investment potential forthis project is therefore Rs 100 million.





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Case Study 11

Installation of Hydraulic Drives for Mill Prime Movers

BackgroundThe mill prime movers in sugar mills are typically steam turbines. Theuse of steam turbines as prime movers gained popularity over theearlier steam engines, on account of its simple design and operationalflexibility, even though it has a very high specific steam consumption.

These steam turbines are single stage impulse type turbines. Theyare characterised by very low efficiencies of 35 to 40%. The efficiencyof the steam turbines remains at optimum levels, only when the inputsteam parameters and speed are kept at the rated level. Even withmoderate steady steam parameters and speed, the steam turbinedriven mills require about 25 - 30% more running power over thatactually required.

With the normally prevalent steam pressure fluctuations in the sugarmills, its consequent effect on efficiency of the steam turbines and theincreasing trend towards commercial cogeneration systems, the trend

of late, is to replace these steam turbines with either DC drives or hydraulic drives.

The benefits of installing DC drives, have already been discussed in the other case studydescribed. This case study highlights the benefits of installing hydraulic drives in place ofsteam turbines for themill prime movers.

Benefits of hydraulic drives for mill prime movers• Increased drive efficiency

• Stable operation

• Reduced maintenance

One of the sugar mills had the following mill drive configuration:

• For 6 mill system- 600 BHP rating steam turbine x 3 nos. (2 mills driven by a single steamturbine)

• For 4 mill system - 600 BHP rating steam turbine x 2 Nos. (2 mills driven by a single steamturbine) This configuration was designed to cater to the initial installed capacity of 2500TCD.

The following operational parameters were observed:

• The specific steam consumption of these steam turbines were 24 kg/kW, as compared tothe specific steam consumption of 13 kg/kW in the power turbines.

• Speed range and speed accuracy were very poor

• Adaptability to complex system is difficult



• Monitoring of power consumption is not possible

• The overall efficiency is only of the order of 27 to 30%

• Maintenance and lubrication requirements are very high

• Space requirements are large

The plant teams had plans to increase the cane crushing capacity to 4000 TCD. The inherentdisadvantages of the steam turbines can be overcome, especially after the proposed increasein cane crushing rate, by the installation of hydraulic drives.

Energy saving projectThe steam turbines used as mill drives were partially replaced by hydraulic drives, during thecapacity upgradation activity.

Concept of the projectThe hydraulic drives are a combination of two components - the pump normally driven by anelectric motor and the hydraulic motor, which runs by the displacement of oil. The speed ofthe motor depends on the rate at which the displacement of oil takes place. The hydraulic driveworks on the principle of high torque delivery at low speeds. The torquedelivered is directlyproportional to the system pressure and the speed is directly proportional to the oil flow.

The advantages of hydraulic drives are as follows:

• High transmission efficiency - the overall efficiency of converting steam power into shaftpower for a hydraulic system is about 58%. This results in substantial power savings

• Very low inertia enabling the system operation on load

• Upgradable modular design

• Easy adaptability on existing mills

• Simple to operate

• Instantaneous and unlimited reversal of rotation, enabling quick response to load changes

• Compact unit, resulting in space savings

• Reliable and rugged design

• Minimal foundation work

• Alignment problems eliminated, thereby minimising maintenance

Due to the above-mentioned advantages, hydraulic drives are increasingly replacing theconventional steam turbine mill drives.


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Implementation status, problems faced and time frameThe mill configuration was altered, to cater to the capacity upgradation of 4000 TCD, as perthe following:

The second mill drive of the 6-mill system was removed and added as the fifth mill drive ofthe 4-mill system, thus, making two 5-mill systems.

The last four mill steam turbine drives (of the old 6-mill system) were replaced with hydraulicdrives of 300 kW each.

The new fifth mill drive (of the modified 4-mill system) was provided with an hydraulic driveof 600 kW rating.

There were initial technical problems related to the oil-pumping unit, which was rectified by thesupplier. Apart from this, there were no particular problems faced during the implementationof this project.

The entire implementation was taken up during the off-season and was completed in 6 monthstime.

Benefits achievedThe net installed power consumption reduced from 0.895 kW/TCD (for average crushing of2500 TCD) to 0.509 kW/TCD (for average crushing of 4800 TCD). In addition, very stableoperating conditions (constant crushing) are being achieved, at almost negligible maintenancecosts.

Financial analysisThis project was implemented as a technology upgradation measure. The installation of hydraulicdrives helps in achieving mechanical, electrical and process benefits. Hence, the saving achievedcould not be exactly quantified. The entire modification required an investment of Rs. 25.00million.

Cost benefit analysis• Investment - Rs. 25.00 millions



Case study 12

Install nozzle governing system for multi jet condensers

BackgroundSugar Syrups are normally boiled at 0.15 bar absolute pressure generating water vapours at52 degree C saturation temperature. Each Sugar factory releases 30 - 200 Ton Vapoursthrough 5 - 30 boiling vessels called Vacuum Pans. Latent Heat of these vapours is absorbedby cold water sprayed in the individual Condenser attached to each vessel. Air and non-condensable gases are removed by inbuilt Water Jet Ejectors of the Condenser. Temperatureof water increases due to absorption of Latent Heat of the Vapour. Either Cooling Tower orSpray Pond cools this heated water by transferring this heat to ambient air by heat and masstransfer.

The Condenser consists of multiple Spray and Jet Nozzles. Spray & Jet Nozzles are primarilyneeded for condensation and for non-condensable gas/air ejection through tail pipe for thecreation of vacuum in the Pan. The cold water flowing in from Spray-Pond /Cooling Tower issupplied to the Condenser by Injection Pumps under pressure for the said purpose.

Conventional SystemsFollowing methods are adopted to control the flow of water in the Condenser to maintaincorrect vacuum and reduce consumption of water. Both the methods use pressure governingto regulate water flow.

Single Valve ControlA common control valve regulates pressure to both Jet & Spray Nozzles. Control valve startsregulating water pressure when both vapour and non-condensable gases load aresimultaneously within limits of the Condenser. Any increase in either vapour or air load beyondCondenser capacity at reduced pressure will lead to 100% opening of valve. Thus vacuum ismaintained with set values.

Double Valve ControlTwo separate control valve regulate the pressure of Jet & Spray Nozzles separately. At lowervapour load the Spray Nozzles control valve starts regulating the water pressure. Similarly atlower non-condensable gases load it’s control valves saves water and controls vacuum bylowering jet box pressure. Any increase in vapour or air load beyond Condenser capacity atreduced pressure will lead to 100% opening of that valve. Thus vacuum is maintained withinthe set values.

Drawbacks in Conventional SystemsThe efficiency of Condenser is reduced due to loss of pressure Head and lowering in SprayingPressure owing to throttling of valve and the basic purpose of the equipment to create thedesired vacuum fails.


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The vapour and air load variation in Condenser is 0 to 125% of designed capacity separately.Initially, air load is more, in the middle vapour load more and by the end there is no air/ vapourload. So Condenser’s requirement varies from time to time.

Proposed nozzle governing systemSpray & Jet Nozzles should always work at high differential pressure to achieve mist formation(for condensing) and impact (air extraction). In the proposed automation system, water supplyis controlled by opening or closing of number of Spray & Jet Nozzles. So a Nozzle alwaysworks at high pressure and efficiency. Here all the Nozzles are transferring entire pressureenergy into the Condenser resulting in good efficiency even at 15% capacity. Here there is noloss of energy in the throttling. where almost 75% energy loss takes place after the valve at50% flow rate (92% Energy loss at 25% flow rate). So nozzle governing system is far superiorthen controlling system.

Advantage in this systemThe nozzle governing system for Multi-jet Condenser will ensure optimum utilisation of hydraulicenergy of water provided to it by the Pumps. It also ensures best Condenser efficiency evenat 25% load.

Energy Saving ProjectIn a 6750 TCD plant, a nozzle governing system was introduced for controlling the water flowto the condenser. A 6750 TCD [Tons (Cane) Crushing per Day) Plant was consuming 1150kWh of Power at Cooling & Condensing System, which has now been brought down to 450kWh, after the installation.

Benefits of the projectThere was a substantial reduction in power consumption of the injection water pumps. Thepower consumption of injection with pumps reduced from 1150 units/ton to 450 units/ton.

Financial AnalysisThe annual saving achieved on account of the automation system resulted in Rs 19.0 millions.The investment made was Rs 5.0 millions, which was paid back in 3 months.


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Case Study 13

Installation of Fully Automated Continuous Vacuum Pans forCuring

BackgroundThe vacuum pan is vital equipment, used in themanufacture of sugar. The concentrated syrup comingout of the evaporator at around 60-65 Brix is furtherconcentrated in these pans. This is a critical processfor the production of good quality sugar and involvesremoval of water and deposition of sugar moleculeson the nuclei.

Massecuite boiling is conventionally carried out bybatch process in the Indian sugar industry.

These pans are characterised by the following:

• The hydrostatic head requirement is high

• Higher hydrostatic heads necessitate higher massecuite boiling temperatures, which aidcolour formation

• Massecuite looses its fluidity, especially towards the end of the batch cycle

• Higher boiling point elevation results in lower heat flux, for a given steam condition

• Consumes very high steam, by design - due to the non-uniform loading cycle, unloadingcycle and pan washing cycle times

Of late, the continuous vacuum pans have been developed and installed in many sugar plantswith substantial benefits. This case study highlights the benefits of installing a continuousvacuum pan for curing.

Previous statusOne of the sugar mills, had the following pan configuration for the massecuite curing:.

v Batch vacuum pans of 40 Tons holding capacity (11 nos.)• 5/ 6 nos. for A – massecuite• 4 nos. for B - massecuite• 2/ 3 nos. for C - massecuite

v Batch vacuum pans of 80 Tons holding capacity (3 nos.)• 2 nos. for A - massecuite• 1 no for B massecuite

v Continuous vacuum pan of 135 tons holding capacity

• 1 no. for C - massecuite



The above configuration was designed for 6000 TCD capacity. The following operationalparameters were observed:

• The steam consumption was erratic, as it was dependent on various factors, such as,loading time, unloading time, pan washing and cleaning.

• The evaporation rates are erratic - they are high during start-up and progressively reducestowards the end of the batch cycle

• The S/V ratio is low (~ 6)

• Hydrostatic head requirement is high (about 3.0 - 3.5 m)

• Average retention time is very high

• Requires very frequent cleaning of the pan body

• Less adaptable to automation

To overcome these inherent shortcomings and to cater to their capacity upgradation plans to8000 TCD, continuous vacuum pans were installed for all three types of massecuite curing.

Energy saving projectConsequent to the capacity upgradation to 8000 TCD, continuous vacuum pans were installedfor A- massecuite, B- massecuite and C- massecuite curing.

Concept of the projectA continuous operation of a vacuum pan means, a complete integrated system comprising ofthe sub-systems, covering total control of the inputs and outputs. The operation of the panin a continuous manner, makes it easy for automation and installing control systems.

The latest continuous vacuum pans are being installed with predictive control systems, whichensure a steady and more consistent operation of the pan. Besides these automation facilities,the continuous vacuum pans have many advantages:

• There is no heat injury to the sugar crystal, due to reduced hydrostatic head and lowerboiling point elevation

• The use of smaller diameter tubes provides greater heating area per unit of calendria. Thisaspect gives more flexibility on thermal conditions of the steam that can be used.

• This also allows maximum evaporation rates, commensurate with maximum possiblecrystallisation rates

• Facilitates the use of low pressure steam, on account of increased transmission coefficient,brought about by higher circulation rate of massecuite

• Reduction in steam consumption by 10-20%, as compared to the batch pans

• On account of reduction in steam consumption, the condensing and cooling water powerconsumption also gets reduced

• There is no draining, rinsing as in batch process, which cause thermal losses and dilution


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• The coefficient of variation of crystal size is equivalent to or better than in batch pans, onaccount of plug flow conditions and multi-compartment design

• The continuous vacuum pan is automated, resultingin simpler operation

• They are compact and hence, the spacerequirement is much lower

The continuous vacuum pans have gained immensepopularity on account of the salient features mentionedabove.

Implementation status, problems faced and time frameDuring the expansion stage (8000 TCD), the batch pans were replaced in phases and the newconfiguration is as follows:

v Continuous vacuum pans of 40 tons holding capacity (5 nos.)

• 1 no. for A - massecuite

• 2 nos. for B - massecuite

• 2 nos. for C - massecuite

v Continuous vacuum pans of 80 tons holding capacity (2 nos.)

• 2 nos. for A - massecuite

v Continuous vacuum pan of 135 tons holding capacity (4 nos.)

• 2 nos. for A - massecuite

• 1 no. for B - massecuite

• 1 no. for C - massecuite

The experience of having operated a continuous vacuum pan for the C- massecuite, enabledthe operators to gain first hand working knowledge and trouble-shooting skills. Hence, therewere no particular problems faced, during the phased replacement of the remaining batchvacuum pans, with continuous vacuum pans.

The replacement of all the batch vacuum pans with continuous vacuum pans was completedin two sugar seasons.

Benefits achievedThe following benefits were achieved by the installation of continuous vacuum pans:

v The continuous pans facilitate the use of low-pressure steam.



• The vapour bleeding from the II - effect of evaporator, for heating in the A - pans andB- pans

v The vapour bleeding from the I - effect of evaporator, for heating in the C- pans

• The continuous pans enable stabilised operation of the evaporators

v Reduction (10 - 20%) in steam consumption as mentioned below:

Identity Steam consumption (kg/ ton of massecuite)

With batch With continuousvacuum pan vacuum pan

A - massecuite Not available Not available

B - massecuite 242 229

C - massecuite 354 313

• Improved grain size quality

• Reduced sugar loss

• Heat balance optimisation

Financial analysisThe annual equivalent energy saving achieved was Rs.19.26 million (for 120 days sugarseason and bagasse cost of Rs.250/MT). This required an investment of Rs.100.00 million,which had a simple payback period of 63 months.

Replication PotentialThe installation of continuous vacuum pans through a proven project has been taken up onlyin about 20% of the plants. The potential of replication is therefore very high. However, thecommercial viability of the project is high, only in case of plants with commercial cogeneration.





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Sugar Consultants

BoilersAVANT – GARDE ENGINEERS ANDCONSULTANTS (P) LTD.No. 58, Fourth Avenue,Ashok Nagar,Chennai – 600083,INDIATel : 91 44 4894457, 4894460, 4894474,Fax : 91 44 4894432E Mail :[email protected],Web Site : www.ag-india.com

M/S J . P. MUKERJEE & ASSOCIATES PVT.LTD.JYOTI HOUSE,172, DHANUKAR COLONY,KOTHRUD , ‘PUNE - 411029,INDIATEL: 91 212 347303,FAX : 91 212 347307

M/S K.S.PROJECTS & PROCESSENGINEERS (P) LTD.A-1/18, SECTOR - BALIGANJ EXTENSION,LUCKNOW - 226024.INDIATEL : 91 522 375042, 377166. FAX : 91 522 377166

P.J.INTERNATIONAL GROUP CONSULTANTSA-101,YAMUNA APARTMENTS,ALAKNANDA,NEW DELHI-110019INDIATEL: 91 11 6461081,FAX:91 11 6474514

M/S SUCRO CONSULT INTERNATIONALSACCHARUM ,E- 1, Greater Kailash Enclave 1,New Delhi - 110048,INDIATel : 91 11 641616

NATIONAL FEDERATION OFCOOP.SUGAR MILLSVAIKUNTH, IIIRD FLOOR,82-83, NEHRU PLACE,NEW DELHI-110 019INDIA

Shri A.P.ChinnaswamyPonn Ram Sugar House,Krishnamal Cross Street No 1, PO :

K.K.Pudur, Sai Baba ColonyCOIMBATORE - 641038,INDIA

SHRI M.G.JOSHI3, Vasant Bagh Society,Bimbewadi,PUNE- 411037INDIATel: 91 20 4214945

Shri Mydur Anand27/106, 11-B, 11th Main,Malleshwar,BANGLORE - 560 003INDIATel : 91 11 3311223, 3346873Fax : 91 11 3349573

SHRI P.K.JHINGANM/S SUPRABHAT CONSULTANTS43-B,Pocket A,SFS Flats, Mayur Vihar Phase 3NEW DELHI - 110049,INDIATEL: 91 11 2610094,2610072,Fax: 91 11 2614559E Mail: [email protected]

SHRI VIKRAM SINGHC-2/2305,VASANT KUNJNEW DELHI.INDIATel: 91 11 6898884

Alfred BartholomaiHansen ConsultingAtlanta, Georgia USA

Consultants to the food industrywww.hansenconsulting.com

Equipment ManufacturersATV PROJECTS INDIA LIMITEDD-8, MIDC, STREETNO.16, MAROL, ANDHERI (EAST),MUMBAI-400 093.INDIATEL : 91 22 8351761,FAX : 91 22 8365786, 8387592

FCB-K.C.P.LTD.RAMAKRISHNA BUILDING,2, DR.P.V.CHERIAN CRESCENT,CHENNAI-600 105.INDIATEL : 91 44 8241633,


591

FAX : 91 44 8230306EMAIL : [email protected]

KRUPP INDUSTRIES INDIA LTD.PIMPRI,PUNE-411 018, INDIATEL : 91 212 774461,FAX : 91 212 771150EMAIL : [email protected]

NATIONAL HEAVY ENGINEERINGCO-OPERATIVE LTD.16, MAHATMA GANDHI ROAD,PUNE-411 001, INDIATEL : 91 2114 22261,FAX : (0212) 644920E Mail : [email protected]

PRAJ INDUSTRIES LIMITEDPRAJ HOUSE, BAVDHAN,PUNE- 411 021, INDIATEL: 91 2139 51511, 52214,FAX: 91 2139 51718, 51515E MAIL : [email protected] : www.praj.net

ALCOHOL / DISTILLERY PLANT :Turnkey plant and equipment supplierfor molasses and starch based alcohol plantsB-196, OKHLA INDL.AREA,PHASE-I, NEW DELHI-110 020. INDIATEL : 91 11 6811878, 6811721, 6815047,FAX : 91 11 6812280E Mail: [email protected]

TEXMACO LTD.Sugar Division, Birla Bldg.,9/1,R.N.Mukerjee Marg,CALCUTTA - 700 001,INDIATEL: 91 33 205712, 205553

UTTAM INDUSTRIAL ENGG. LTD.7C, J-BLOCK SHOPPING CENTRE,SAKET, NEW DELHI-110 017.INDIA TEL : 91 11 6563860, 6856721, 6858578, FAX : 91 11 6856721

WALCHANDNAGAR INDUSTRIES LTD.16, M.G. ROAD, PUNE-411 001.INDIA TEL : 91 212 631801,FAX : 91 212 631747

Chemical suppliers for sugar industryAQUA CHEMICALSB-237 A, Road No :6-D,V.K.Industrial Area,

Jaipur 302013, Rajashtan,INDIA Tel:91-141-331542,260183260184(O)517574,700909(R),FAX:91-141-331543E Mail: [email protected] Contact Person: Mr.Jayant RajvanshiSPECIALIST IN: Boiler Water TreatmentChemicals, Cooling Water TreatmentChemicals, Effluent Treatment Chemicals ,Sugar Specialty Chemicals, Industrial SafetyEquipments

AISHWARYAA CHEMICALS101/12, Om Apartments,Medavakkam Tank Road,Kilpauck, Chennai 600010,INDIA TEL: 91 44 6422851,6414419,FAX: 91 44 6431605E mail: [email protected] IN:Process Chemicals

CENTRAL AGENCIESAll kind of Sugar Process Chemicals4672 / 21, DARYA GANJ,NEW DELHI - 110002 - INDIATEL : 91 11 3273662,3266023,FAX : 91 11 3278554EMAIL : [email protected]

INDUSTRY AID PRODUCTS160, Dr. D N ROAD, FORT,MUMBAI 400001 - INDIATEL : 91 22 207747,FAX : 91 22 2074249E Mail: [email protected]

CHEMICAL SYSTEMSD 57-58, Amar Colony,Lajpat Nagar-IV,New Delhi – 110024, INDIATel : 91 11 6476344, 6438807Fax : 91 11 6476352E Mail [email protected] IN: CHEMICALS FORBETTER SUGAR PRODUCTION

ION EXCHANGE (INDIA) LTD.Tiecicon House, Dr. E Moses Road,Mahalaxmi Mumbai – 400011Tel :91 22 4939520/23/25,Fax : 91 22 4938737SPECIALISTS IN: Process Chemicals

MULTITRADE CORPORATION401, GORADIA HOUSE,100/104, KAZI SAYAD STREET,MUMBAI 400003 - INDIATEL : 91 22 3439360,



FAX : 91 22 3429140

CHEMICAL CENTRE (INDIA)7/26 ANSARI ROADDARYA GANJNEW DELHI -110002 - INDIATEL : 91 11 3267775 3253336,FAX : 98-11 -3268834

KULKARNI ORGANICS PVT. LTD172, SHANIWAR PETH,TRIMBAKESHWAR CO-OP. HOUSINGSOCIETY,PUNE - 411 030 - INDIATEL : 91 212 450934 / 532090

P.K.B. TRADERS75, NAGDEVI CROSS LANE,2ND FLOOR, R B. NO. 13043, MUMBAI - 400003 - INDIATEL : 91-22-3400581, 344T228, 3 (R) 5163635 ,FAX : 91-22-3401630

King – Win Hydro Chem Ltd.C-26-B, Malviya Industrial Area,JAIPUR 302017, INDIATel : 91 141 521205, 522924 ,Fax : 91 141 522694E Mail :[email protected]

SURYA CORPORATION27, Chetty Street,PONDICHERRY 605001, INDIATEL: 91 413 220309, 345221FAX: 91 413 339733,345221E MAIL: [email protected]

Sugar MachineryAVANT – GARDE ENGINEERS ANDCONSULTANTS (P) LTD.No. 58, Fourth Avenue,Ashok Nagar, Chennai – 600083,Tel : 91 44 4894457, 4894460, 4894474,Fax : 91 44 4894432E Mail :[email protected],Web Site : www.ag-india.comSPECIALIST IN :’CONTINUOUSBAGASSE FEEDING SYSTEM FOR BOILERS”.,

Abrasion Resistant Materials Pty LtdPO Box 546, Archerfield,Queensland, 4108,AUSTRALIA 39 Randolph Street, Rocklea,Queensland, 4106,AUSTRALIAPhone: 07 3277 9630,Fax: 07 3277 9640

International callers:Phone: +61 7 3277 9630,Fax: +61 7 3277 9640 E Mail:[email protected] IN : Maintenance free sugar millrollers

GOEL TRADELINES14 RANI JHANSI ROAD,NEW DELHI 110055INDIATEL: 91 11 3551444,3679444,3613075,FAX: 91 11 3613075E MAIL : [email protected] IN : WEDGE WIRE SCREENS,ROTARY JUICE SCREENS

FLENDER LIMITED41, Nelson Manickam Road,AminjikaraiChennai – 600029,INDIATel : 91 44 4810476/78/79/80Fax : 91 44 4810473SPECIALISTS IN Hydraulic Drives

Hagglunds Hydraulic Drives (India) Pvt. Ltd.18/4 & 19/4, HadpasarIndustrial Estate, Hadapsar ,PUNE -411013, INDIATEL: 91 212 613841, 613842FAX: 91 212 613844

Jeffress Engineering Pty Ltd351 Melton Road, NorthgateQueensland Australia 4013Phone +61 7 3266 1677,Fax:+61 7 3260 5487Email: [email protected] Grinders, Disintegrators

KAMAL ENGINERRING CORPORATION56, Industrial Estate,Yamuna Nagar –135001Tel : 91 1732 50300/1/2/3,Fax : 91 1732 50304SPECIALISTS IN: Weighing Scales, SugarGraders etc.

NATIONAL HEAVY ENGINEERINGCO-OPERATIVE LTD.16, MAHATMA GANDHI ROAD,PUNE-411 001,INDIA TEL : 91 2114 22261,FAX : 91 212 644920, 91 2114 22762E Mail: [email protected] SPECIALIST IN : CENTRIFUGAL MACHINES


593

NEON INNOVATIVE PVT. LTD.31. Latif House, S.T.Road,Carnac Bunder,MUMBAI 400009 .INDIATEL : 91 22 3426851,FAX : 91 22 3429011 E Mail: [email protected] IN: CANE MILLINGLow Pressure Extraction Systems

Maddocks and Associates Pty Ltd,GDT Lining Systems SPECIALIST IN :LOW COST MOLASSES STORAGE

PRAJ INDUSTRIES LIMITEDPRAJ HOUSE, BAVDHANPUNE- 411 021, INDIATEL: 91 2139 51511, 52214,FAX: 91 2139 51718, 51515E MAIL : [email protected] : www.praj.netALCOHAL / DISTILLERY PLANT :Turnkey plant and equipment supplierfor molasses and starch based alcohol plants Single Tray Juice Clarifiers Filtrate Clarification SystemsRotary Juice Screen

Suviron Equipments Pvt.Ltd.Swaroop Kala, 23/11, Renavikarnagar, Savedi,Ahmednagar 414 003 (India)Telephone 91 241-423582 / 778711 Fax : 91241-778711E-mail : [email protected] Web :www.suviron.comPerson : Shri Subodh V. Joshi

SPRAY ENGINEERING DEVICESCooling & Condensing systems forSugar & Processing Plants25, Industrial Area, Phase- IIChandigarh INDIA – 160002Tel : 91 172 652415Fax : 91 172 653247

S.S. ENGINEERSJ – 179, M.I.D.C. Bhosari,Pune – 411026,INDIATel :91 212 327567,Fax : 91 212 328572 E Mail: [email protected] SPECIALISTS IN: Five/Six Roller MILLS

SNEHA ENGINEERSF – 46, M.I.D.C.Industrial Area,Waluj, Aurangabad –431136,MAHARASHTRAINDIATel : 0240 – 332585, 331695, Fax : 332796 SPECIALISTS IN:Evaporators & Vacuum Pans

SHRIJEE ENGINEERING WORKS1-9, Everest, 156 Tardeo Road,MUMBAI - 400034, INDIATel:91 22 4952248,4954699,4954715,Fax: 91 22 4952249E Mail: [email protected] IN: Process House

Equipments, Sugar Driers526, Narayan Peth,PUNE 411030 INDIATel: 91 20 453360,454790,Fax: 91 20 453970SPECIALISTS IN: TRFCane Mill Feeding System.UTTAM INDUSTRIAL ENGG.LTD.7C, J-BLOCK SHOPPING CENTRE,SAKET, NEW DELHI-110 017.INDIA TEL : 91 11 6563860, 6856721, 6858578,FAX : 91 11 6856721 SPECIALISTS IN: CANEMILLING

GOEL ENGINEERS (INDIA)INDIA’S FIRST MANUFACTURERSOF CENTRIFUGAL LINERSF-11/A OKHLA IND.AREA, PHASE 1,NEW DELHI 110020 INDIATEL: 91 11 2 6815109, 2 6812004,FAX: 91 11 2 6811176E MAIL : [email protected]: www.goelka.com SPECIALIST IN : Screens forBATCH CENTRIFUGALS &FILTERS, BACKING WIRES Suviron Equipments Pvt.Ltd.Swaroop Kala, 23/11, Renavikarnagar, Savedi,Ahmednagar 414 003 (India)Telephone 91 241-2423582 / 2 Fax : 91 241-2778711E-mail : [email protected] Web :www.suviron.comPerson : Shri Subodh V. JoshiRotary Juice Screens,Single Tray JuiceClarifiers Filtrate Clarification Systems Rotary JuiceScreens



ATUL ELECTROFORMERS PVT. LTD11,KUBERA ESTATE , 408/14 ,CTS 10, Gultekadi Road,PUNE 411037,INDIATEL : 91 20 2466398, 2464589 , 2468982,Fax : 91 20 2462835E Mail:[email protected] IN : Nickel Screens

FINE PERFORATORS14 RANI JHANSI ROAD,NEW DELHI 110055 INDIATEL: 91 11 23551444, 23679444,FAX: 91 11 23613075E MAIL : [email protected] IN : Batch Centrifugal & FilterScreens

SHRADDHA ENGINEERING COMPANY.11,Rajgrah Apt. Krushinager,College Road, Nashik-422005.India“Jyoti” Sitarramnager,NearJaikranti College, Latur-4413531Telefax : 91 253 355009 , 91 238 240759.E Mail :[email protected],[email protected], [email protected] :Satish S. Sonar, Kishor M.Bhujbal.Product Details : Designer and manufacturerof Continuous Sulphur Burner, PressureReducing and Desuperheather ,Juiceand Syrup Sulphitation Unit, Mollassesconditioner, Superheated Wash Water System,Boiler Automation, Auto Mill Imbibition ControlSystem.

CHEMICAL SYSTEMSD 57-58, Amar Colony,Lajpat Nagar-IV,New Delhi – 110024, INDIATel : 91 11 6476344, 6438807Fax : 91 11 6476352E Mail :[email protected] Electric Controls Pvt. LtdSUGAR PROCESS ENGINEERSE / 12-13, M.I.D.CIndustrial Area,NASHIK – 422 007, INDIATel : 91 253 351072 / 77, Fax : 91 253 351079E Mail :[email protected]

SPRAY ENGINEERING DEVICES25, Industrial Area, Phase- IIChandigarh 160002 INDIATel : 91 172 652415Fax : 91 172 653247SPECIALIST IN Cooling & Condensingsystems for Sugar & Processing Plants

SHIVA HITECH NON CONVENTIONALSYSTEMS PVT. LTD.107, Vijaya Towers,Nagarjunanagar, Ameerpet,Hyderabad 500073 INDIATel : 91 40 3744675, 3740224, 3740432Fax : 91 40 3745833SPECIALISTS IN Magneto Hydro DynamicSystems

VISHWA Systems Pvt LtdW-155, M.I.D.C., Ambad,Nashik 422010, INDIATel: 91 253 385243, 380802, 380673.Fax: 91 253 385243E Mail: [email protected] IN: Process Control Equipment& Control Systems.Manufacturer of SulphurBurner, PRD Station, Transient Heater /PH Control Systems, Molasses conditioner /Juice Flow Stablisation Systems, SuperheatedWash water Systems, Lime Classifier

FORBES MARSHALLKasarwadi, , Pune – 411034, INDIATel :91 212 794495, Fax : 91 212797413SPECIALISTS IN: INSTRUMENTATION &FLOW TECHNOLOGY

BELLISS INDIA LIMITED18, Community Centre, East Of Kailash,NEW DELHI 110065, INDIATEL: 91 11 6431836,FAX: 91 11 6468089E Mail : [email protected] IN Steam Turbine

DLF Industries Ltd.Model Town, Sector 11,FARIDABAD 121 006, INDIASPECIALIST IN Steam TurbineTRIVENI ENGINEERING & INDUSTRIES LTD.12-A, Peenya Industrial Area,Peenya, Bangalore 560058, INDIATel :91 80 8394721, 8394771, 8395278 Fax : 91 80 8395211E Mail: [email protected] IN Steam Turbine

Associations in IndiaTHE SUGAR TECHNOLOGISTS’ ASSOCIATION OF INDIAC Block, 2nd Floor, Ansal Plaza,August Kranti Marg,New DelhiI-110 049,India. TEL : 91 11 6263694-95


595

FAX : 91 11 6263694 [email protected]: www.staionline.org

THE DECCAN SUGAR TECHNOLOGISTSASSOCIATION17/1, Opp.ShivajinagarS.T.Bus Stand,Pune-411 005Tel : 91 20 58575

The South Indian Sugarcane And SugarTechnologists Association21, Door No.5, Iiird Main Road,Gandhi Nagar,Chennai-600 020,IndiaTel : 91 44 4415934Fax : 91 44 4402324,E Mail:[email protected]

INDIAN SUGAR MILLS ASSOCIATIONSUGAR HOUSE, 39,NEHRU PLACE,NEW DELHI-110 019,INDIA TEL : 91 11 6472554, 641671, 6462096Other organizations in India

INDIA INDIAN SUGAR AND GENERALINDUSTRY EXPORT IMPORT CORP. LTD.C Block, 2nd Floor,Ansal Plaza, August Kranti Marg,New DelhiI-110 049,IndiaTel: 91 11 6263421 - 24, E Mail: [email protected]

NATIONAL FEDERATION OFCOOP.SUGAR MILLS LTD.C Block, 2nd Floor, Ansal Plaza,August Kranti Marg,New DelhiI-110 049,IndiaTel: 6263425, 6263426Fax: 91 11 6463425E Mail: [email protected]

NATIONAL COOP. DEVELOPMENT CORPN.4, Sirifort Instn. Area,Hauz Khas,New Delhi-110 016.India Tel : 6567475

SUGAR TECHNOLOGY MISSIONDepartment of Science &Technology, Govt. of IndiaD-5, Apartment, Qutab Hotel,New Mehrauli Road,New Delhi -110016, IndiaTel:91 11 6960599, 6960617 Fax: 91 11 6863866

TAMILNADU COOPERATIVE SUGAR FEDERATION LTD.474, Anna Salai, Nandanam,CHENNAI 600035,INDIA TEL:91 44 4330222

WINROCK INTERNATIONAL INDIA.7 Poorvi Marg, Vasant Vihar,NEW DELHI-110057,INDIA TEL:91 11 6142965,FAX:91 11 6146004E Mail:[email protected] for Alternative Baggasse Cogeneration


596 Energy Conservation in Power Plant Sector

Power plant

Per Capita Consumption 350 kWh (277 kg of oil equivalent)

Energy Intensity 6 – 8% of power generation

Energy saving potential Rs.3000 Million (US $ 60 Million)

Investment potential onenergy saving projects Rs. 5000 Million (US $ 1000 Million)


597

POWER PLANT SECTOR

INTRODUCTION

1.0 Energy ScenarioThe power sector has always been high on India’s priority as it is a growing sector, offeringtremendous potential for improvements and new investments.

As per the recent projections by CEA, The total generating capacity which is today at about1,07,000 MW is expected to reach 2,15,000 MW by 2012. The share of various sources inmeeting this requirement is shown in Table-1.

Table 1: Power Sector Growth Projection in MW

Coal Gas Nuclear Hydro Others Total

Installed Capacityas on Feb 2003 63800 11560 2720 26760 2800 107644

Additional Capacityto be increased(2003-2012) 50690 19860 8380 27050 2170 108150

Total Capacityby 2012 114490 31420 11100 53810 4970 215800

Source: CEA

Economic growth in India crucially depends on the long-term availability of energy in increasingquantities from sources that are dependable, safe and environmentally friendly.

India, like many other developing countries, is a net importer of energy, 20 per cent of primaryenergy needs being met through imports mainly in the form of crude oil and natural gas.



Currently, thermal power plants accounts for major share of about 70%. Coal is the mainstayfuel in India for power generation. With total coal reserve around 220 billion tones, of which84.4 billion tonnes are proven, coal will continue to be an assured energy source for the nextcentury and beyond.

Though coal based plants account for major share in power generation, recently there is anincreasing trend in going for gas-based power plants also, particularly in the private sector.

1.1 Power Generation CapacityThe power generating capacity in India has increased over 80-fold, from 1,362 MW in 1947 to1,07,644 MW in 2003.

The share of various sources of power generated is pictorially shown in figure 1.

(Source: Ministry of Power)

The industrial sector is the highest consumer of electricity (34 percent) followed by agriculture(30 percent) and domestic (18 percent) sector.

1.2 Per-Capita Energy ConsumptionPer capita energy consumption in India is about 277 Kg of oil equivalent, which is 3.5 per centof that in the USA, 6.8 per cent of Japan, 37 percent of Asia and 18.7 per cent of the worldaverage. Per-capita consumption of electricity for various countries is shown in figure 2.

Figure 2: Per-capita consumption in Kwh

(Source: Ministry of Power)


599

But, energy intensity, which is energy consumption per unit of GDP, is one of the highest incomparison to other developed and developing countries. For example, it is 3.7 times that ofJapan, 1.55 times of the USA and 1.5 times of the World average. This signifies that thereis tremendous scope for energy conservation in the country.

1.3 Thermal Power Plants in IndiaIn India, size of thermal power plants started with ratings of 60/70 MW during 1965, whichtouched 500MW rating in 1979. At present National Thermal Power Corporation (NTPC) isplanning to install units in the range of 660MW rating, operating with supercritical parametersat Sipet in Chattishgarh State by the year 2005.

There are about 85 major thermal power plants installed in India. The eastern belt being coalabundant, major plants are located in that region.

Figure 3: Thermal Power Plants

(Info: http://www.osc.edu/research/pcrm/emissions/thermalemissions)

Apart from private and public utilities and IPP’s, most of the industries have there own captivegeneration.



1.3.1 Captive Power PlantsIndustrial Sector is the largest consumer of energy. Besides consuming power from Utilities,a number of industries which are primary producers of infrastructure material such as Aluminium,Cement, Fertilizers, Iron & Steel, Paper and Sugar etc. have their own captive power plants.

The installation of captive generation plants has been either to supplement the electricitypurchased from the Utilities or for emergency use in case of power outages or for producingenergy from by-product of the industrial process (e.g., Sugar Plants).

Table 3 shows sector wise captive power plant installed in the country.

Table 3: The break up of Captive Power Plants

Installed Percentage ofSl.No. Name of Industry Capacity TotalInstalled

(MW) Capacity

1 Chemicals, Mineral Oil &

Petroleum 1993 13.86

2 Textile 1884 14.54

3 Aluminium 1742 12.32

4 Iron & Steel 1686 15.78

5 Cement 1466 10.16

6 Fertilizers 1155 9.02

7 Sugar 7862.66

8 Paper 5994.06

9 Heavy & Light Engineering 4532.50

10 Non-Ferrous Metal 4243.94

11 Automobiles 2311.13

12 Food 115 0.53

13 Mining & Quarrying 38 0.68

14 Other Industries 1360 8.82

Total 13932 100.00

Source: CEA

India has a total capacity of 2500 MW thermal based Independent power plants (IPP’s)


601

CHAPTER II

PROCESS, TECHNOLOGY AND TRENDS

2.1 Technology TrendsThermal power generation started with ratings of 60/70 MW rating units in the year 1965,simultaneously raised to 110/120 MW units by the year 1966. The next size of 200/210 MWplants, which are widely installed all over India from the year 1972 onwards grew into 500 MWunits by the year 1979.

As the unit ratings grew, the boiler parameters supplying steam to such turbines have alsoincreased. Following table 4 shows the trends in super heater outlet pressures and temperaturesfor various unit sizes.

Table 4: Turbine Sizes and Pressure Parameters

Unit Size Steam Flow Super Heater Super heater(T/H) Outlet Pressure / Re Heater Outlet

(KG/CM2) Temperature (oC)

30 MW 150 63 490

60/70 MW 260 96 540

110/120 MW 375 139 540

200/210 MW 690 137/156 540

250 MW 805 156 540

500 MW 1670 179 540

Source: BHEL

The over all efficiencies of power plants with sub critical parameters fall in the range of 35-39 percent which can be improved to 45 percent using supercritical parameters with conventionalsteam turbines. Using combined cycle mode, the maximum efficiency that can be attained isabout 50 percent.

Table 5 shows the heat rate for various capacities of turbines achieved in power plants.



Table 5: Turbine Sizes and Heat Rate

Unit capacity Turbine inlet Turbine Heat Rateparameter (Kcal/Kwh)

60/100 MW 90 ata 535oC 2315

110/120 MW 130 ata 535oC 2180

200/210 MW 130 ata 535oC 2025

210/250 MW 150 ata 535oC 1975

500 MW 170 ata 535oC 1950

Source : BHEL

Power plants are adopting several latest technologies to improve the efficiency and operatingpractices. Some of the power plants are installed with multi fuel capabilities by design for thefollowing benefits.

• Flexibility to use depending on availability and price

• To address environmental issues like Nox and Sox reduction

2.2 Clean Coal TechnologiesEnvironmental performance of thermal power plants is accorded tremendous importance tomeet global emission standards and need for balancing development and social obligations.

Clean coal technologies for power generation that posses the potential to contain pollutantseither at the combustion or pre-combustion stage will be the technologies that would eventuallyreplace the conventional PC firing.

India’s experience in clean coal technology started with the development of AFBC (AtmosphericFluidized Bed Combustion) for high ash coals. CFBC (Circulating Fluidized Bed Combustion)was later introduced to cater to higher capacity power plants and to realize higher efficiency.


603

It has been a challenge for the Indian power plants to adopt several measures to bring downthe ash disposal and to meet the stringent environmental regulations, some of which areshown below• Importing high grade coal• Lower emission technologies• Improving efficiency of equipment

Power plants are also exploring various possibilities to utilize the fly ash as by-product forsome processes like• Utilising in cement preparation as substitute for clinker• Manufacturing of Flyash bricks

2.2.1 AFBC BoilersAtmospheric fluidized bed Combustion (AFBC), promises to provide a viable alternative toconventional coal fired boilers for utility and industrial application.

The advantages of AFBC boilers are

• Suitable to burn variety of fuels

• Combustion efficiency is higher

• It can completely burn fine particle (Fuel size range:6-12 mm)

• Losses due to unburnt are avoided

• Simple auxiliaries i.e., Lower operating cost

2.2.2 CFBC BoilersCirculating Fluidized Bed Combustion (CFBC) boiler is normally designed for high reliabilityand availability with low maintenance.

Some of the advantages of CFBC boilers are

• Thermal efficiency is higher than AFBC

• Technology is suitable to burn a wide range of fuels (high ash coal, high sulphur coal,lignite, pet, coke, anthracite clum, wood paste, etc.)

• CFBC boiler availability is more than 95%.

• Lesser Sox, Nox emissions

• Auxiliary power consumption of these boilers is relatively lower (do not require high pressureblowers)



2.2.3 Super Critical BoilersSuper critical boilers operate at main steam pressures exceeding 225 ata i.e., critical pressureat which there is spontaneous changeover from liquid phase to vapour phase.

Supercritical units normally operate around pressure of 240-250 ata. The main steam temperature& reheat temperature for these units are normally in the range of 535-565oC. Boilers withsteam pressures and temperatures beyond 250 ata/565oC are termed as ultra supercriticalboilers.

Some of the excellent features of supercritical boilers are

• Enhanced boiler efficiency

• Operational flexibility to respond quickly to load changes

• Reduced emissions

2.4 Renovation & Modernization

Old power plants are modernized to keep up the operation of the equipment and its efficiencies.The advantages of Renovation & modernization are

• Enhancement of operational efficiency

• Improvement in Plant Load Factor (PLF)

• Meeting stringent environmental pollution control standards

• Extend plant life

• Capacity augmentation

Some of the renovation and retrofitting techniques that are followed by the power plants are

1. Steam turbine retrofitting (blades replacement and improvement of the labyrinths’ operationand turbine control system, etc)

2. Improvement of the fuel preparation and firing system

3. Implementation of techniques for further reduction of the Nox emissions and for the flue gasde-sulphurization


605

4. Improvement of particles collecting systems

5. Optimization of the existing fuel drying system or implementation of new effective dryingtechniques

6. Replacement, rearrangement or size change of heat exchange surfaces

7. Supplementary heat exchange surfaces for further heat recovery from flue gas

8. Improvement of the air preheating system

CHAPTER III

ENERGY SAVING PROJECTS

3.1 Energy Saving & Investment Potential in Power plantsThe consumption of electricity by power plant auxiliaries depends on factors such as unit size,level of technology, plant load factor, fuel quality etc.

The auxiliary consumption in general varies between 3 to 6% for larger plants and close to 10% for smaller captive power plants.

CII studies indicate that the energy saving potential in small size power plants (CPP’s & IPP’s)varies between 6% - 10% of auxiliary consumption. It is estimated that the saving potential is150 MW of power amounting to Rs.300 crores annually.

CII study also indicates that the investment potential for energy efficiency in small sizepower plants is Rs.500 crores. This does not include saving potential in utility plants.

3.2 List of ProjectsAll energy saving projects are classified in to three categories namely Short term, Medium termand Long term based on the investment and returns available in each project.

These projects apply to IPP’s & CPP’s and can be easily implemented. Some of theseprojects are equally applicable in utility power plants.

3.2.1 Short Term Projects

A) Boilers1. Install online O2 analyser and improve combustion efficiency of the boilers

2. Arrest air infiltration in boiler flue gas path, particularly economiser and air preheater section

3. Install water heating system for preheating gas through waste heat recovery from Boilerexhaust

4. Install waste heat recovery system for boiler blow down

5. Install LP steam air heater for FD fan air inlet to boiler

6. Optimise the operating breakdown voltage of ESP’s



B) Steam & Condensate Systems1. Avoid steam leakages



4. In case coal has higher percentage of fines, ensure wetting is done.

5. Install flash vessels for heat recovery from hot condensate vapours

6. Replace electric heaters with LP steam heaters for RFO tracing lines

C) Electrical Areas1. Install delta to star converters for lightly loaded motors

2. Use translucent sheets to make use of day lighting




6. Group the lighting circuits for better control

7. Operate at maximum power factor

8. Switching ‘OFF’ transformers based on loading

9. Optimise TG sets operating frequency, depending on user needs

10. Optimise TG sets operating voltage

D) Miscellaneous1. Replace Aluminium blades with FRP blades in cooling tower fans




5. Segregate the service air &

instrument air and optimise optimise operating pressure

6. Reduce system pressure of the compressed air system close to operating pressure ofthe users

7. Install variable frequency drive for hot well makeup water pump

8. Install Variable Frequency Drive (VFD) for cooling tower make up pump with water levelcontrol feed back

9. Install Variable Frequency Drive for DM water transfer pump


607

10. Close Suction Dampers at Stand-By Equipment and Reduce RPM of Dust ExtractionBlowers in the Coal Handling Plant

11. Install the next lower size impeller for the chilled water pumps

12. Avoid idle flow of cooling water in stand by DG sets and compressors

13. Install chlorine dosing and HCL dosing for circulating water

3.2.2 Medium Term Projects

A) Boilers1. Install economiser/air preheater for boilers




5. Segregate Intermediate Pressure & High Pressure Boiler Feed Water Pump

6. Install Variable Frequency Drive (VFD) for CCW pump and operate in closed loop control,based on the discharge header pressure.

7. Reduce Heat rate of gas turbines by optimizing NOx water injection and arresting ofleakages through bypass dampers

8. Install Turbine inlet air cooling to increase power output of gas turbines

9. Install Low excess air burners

10. Reduce one stage of feed water pump or install variable frequency drive with feed backcontrol to exactly match with the system pressure

11. Install lower head fan for power plant boiler ID fan

B) Steam & Condensate Systems1. Convert medium pressure steam users to LP steam users to increase co-generation

2. Install condensate recovery systems in air heaters

3. Utilise waste condensate for de-superheating the process steam

4. Install Variable Fluid Coupling or variable frequency drive for condensate extraction pump

5. Utilise flash steam from boiler blow down for deaerator heating



C) Electrical & Miscellaneous Areas1. Install maximum demand controller to optimise maximum demand




5. Install Sodium vapour lamps instead of MV lamps for Yard, Street and General Lighting


7. Install neutral compensator in lighting circuit

8. Optimise voltage in lighting circuit by installing servo voltage stabilisers

9. Minimise overall distribution losses, by proper cable sizing and addition of capacitor banks

10. Replace V-belts with synthetic flat belts/Cog ‘V’ belts

11. Replace heater - purge type air dryer with heat of compression (HOC) dryer forcompressed air requirement above 500 cfm


3.2.3 Long Term Projects1. Install VFD for Boiler ID/FD fans

2. Install VFD for Boiler feed water pump

3. Install Circulating Fluidised bed boilers for Efficient combustion

4. Install steam driven equipment to prevent HP steam flow through pressure reducing valves

5. Convert chain grate/spreader stoker boilers to AFBC technology

6. Install high efficiency turbines

7. Install vapour absorption system to utilise LP steam for air-conditioning

8. Install Distributed control system (DCS) for Power Plant Operation and monitoring


609

3.2 Case Studies

Case Study: 1

Convert Spreader Stoker Boilers to Fluidised Bed Boilers

BackgroundIn the older power plants, the boilers are the conventional stoker boilers.

These boilers were characterised by:

• Higher unburnts in ash

• Lower thermal efficiency

The latest trend has been to install the fluidised bed boilers or conversion of the existing chain/ spreader stocker boilers, which have the following advantages:

• Coal having high ash content/ low calorific value can be used

• Biomass fuels can also be used

• Lesser unburnts in ash

• Higher thermal efficiency

Hence, the older plants are also in a phased manner, converting their old stoker-fired boilersto fluidised bed boilers. This case study describes one such project implemented.

Previous StatusA power plant had four numbers of spreader stoker boilers, operating to meet steamrequirements of the plant. These spreader stoker boilers, were designed for high calorific valuecoal (4780 kCal/kg) with low ash content.

Due to non-availability of this type of coal, these boilers had to be fired with coal of low calorificvalue and high ash content. This resulted in the capacity down-gradation and loss in efficiency.The steam generation was only 14 TPH, as against the design rating of 30 TPH. The boilerefficiency achieved was only 65%.

Energy saving projectThe plant team modified two of the spreader stoker boilers into fluidised bed combustionboilers.



Benefits of the ProjectIn addition to the benefits of fluidised bed combustion mentioned earlier, they also enable theuse of biomass fuels, such as saw dust, generated in the chipper house.

The steam generation capacity increased to 27 TPH and the thermal efficiency improved to78%, with this modification. The improved thermal efficiency has resulted in an annual coalsaving of 5639 MT. Additionally, the use of saw dust (calorific value of about 3000 kCal/kg) hasresulted in an annual coal savings of 3600 MT.

Finalcial AnalysisThe annual benefits achieved were Rs.10.50 million. This required an investment of Rs.27.0million (for the conversion of two spreader stoker boilers to fluidised bed combustion boilers),which had a simple payback period of 31 months.

Implementation StrategyThe plant took up implementation of the project after a detailed planning with the EPC contractor.The modification was taken up during the annual shut down (30 days). The shut down had tobe extended to avoid 30 days to complete the project. The commissioning of the new boilertook about 4 days and there were no problem during implementation.





611



Case Study: 2

Install VFD for Boiler ID fans and PA fans

BackgroundIn a major captive power plant, three irculating fluidised bed combustor (CFBC) were inoperation. Each boiler has two ID fans and three PA fans.

• All these fans had higher capacity & head by design and controlled either by IGV’s orDampers to meet the operating requirements.

• The IGV opening of the ID fans varied between 50-60%, resulting in tremendous energyloss. The measured pressure loss across the damper & IGV was of the order of 40-45%of the total pressure rise of the fan.

Concept of the Project• The operation of a fan with damper control or IGV control is an energy inefficient practise,

as a part of the energy supplied to the fan is lost across the damper or IGV.

• Also, the operation of a fan operating with IGV or damper control will result in operation ofthe fan in an energy inefficient zone on the fan performance curve. Instead the speed of thefan can be varied to meet the operating condition of the boiler by installing variable frequencydrives.

• The estimated operating efficiency of the fans was in the range of 60% - 65% as againstdesign efficiency of 80%. It was confirmed that the fans were operating in an energyinefficient zone.

Energy Saving ProjectVariable frequency drives were installed for 6 nos of ID fans and 9 nos of PA fans to controlthe speed of the fan with respect to operation of the boiler.


613

Implementation StrategyThe VFD’s were installed during the stoppage of the plant for maintenance. The plant personnelwere well trained in operation and maintenance of VSD’s (prior to the installation of VFD) andtherefore no problems were faced with implementation. The inlet guide vanes were kept fullyopened after the VFD was installed.

Benefits of the Project• The advantage of installing a variable frequency drive for the boiler ID fans are as follows:

Energy saving

Precise control of parameters

Financial AnalysisThe annual energy savings achieved was Rs 6.0 million and the investment was Rs 10.0million for installing 15 nos of variable frequency drives, which got paid back in 20 Months.

Replication PotentialSimilar projects can be taken up for FD & Secondary air fans also. The project has highreplication potential in majority of the captive power plant and IPPs. For ID, FD, secondary airand primary air fans





615

Case Study: 3Install steam drives to prevent HP steam flow through pressure reducing valves

Background• In a major captive power plant, the auxiliary steam requirement was at a pressure of 24 kg/

cm2 and 4100C.

• The quantity of process steam requirement was about 11.5 kg/cm2. To meet the processrequirement the steam from extraction was passed through PRDS.

• When steam pressure is reduced by passing through a pressure reducing valve, the enthalpyof the steam remains constant. But due to pressure loss, the opportunity for converting thelow grade energy (thermal energy) to high grade energy (mechanical energy) is lost.

• The quantity of steam passed through the pressure reducing valve was varied dependingupon the process requirement.

• Instead of dropping the high pressure to low pressure by throttling, the same energy canbe used for power production.

Energy Saving Project• The potential available was tapped by installing 2 back pressure steam turbines which were

used for driving the drip pumps (2 Nos.). The exhaust steam from the back pressure turbinewas utilised for auxiliary steam requirements.

Implementation MethodologyIn a captive power plant the modification of the plant on a continuous basis is essential. Astoppage for replacing the motor with a turbine for drip pump was not possible. Therefore 2new drip pumps with back pressure turbines (300 kW) each were installed and the systemwas hooked up during a maintenance shut down. Though the investment was high the stoppageof plant could be avoided.



BenefitsThe implementation of the project resulted in improving the co-generation potential.

Finalcial AnalysisThe annual energy savings achieved was Rs 27.5 million and the investment was Rs 12.5million for installing back pressure turbines, Generator and steam piping, which had a payback of 6 Months.





617



Case Study: 4

INSTALL VAPOUR ABSORPTION HEAT PUMP IN PLACE OF VAPOURCOMPRESSION SYSTEM

BackgroundIn a captive power plant (of 21 MW capacity) of a large integrated paper plant, certain areas,viz., the boiler & TG control room, static excitation room, ESP/Ash handling plant control roomand coal handling plant control room required a temperature of 26 ± 2 °C to be maintained.

The total air-conditioning load was 60 TR. Since, this power plant was in the project stage, theplant team had the option of choosing between a vapour compression system and a vapourabsorption system, for maintaining these conditions. A techno-economic study favoured theinstallation of a vapour absorption system.

Concept of the projectThe vapour absorption system scores over vapour compression system when:

• Back pressure steam from a turbine is available

• Any waste source of heat is available on a continuous basis e.g. DG exhaust

• Cost of a electricity is high

In this case study, the turbine had the capacity to accept additional 300 kg/hr of low cost lowpressure steam. This gives an excellent spin-off benefit by generating additional power in theturbine.

Energy saving projectThe plant team installed a 60 TR vapour absorption system for meeting the air conditioningrequirements of the various control rooms. This project was taken up at the design stage itself.

Comparison of Vapour Absorption Vs Vapour CompressionThe comparative analysis of a vapour compression system and a vapour absorption system,for achieving the same amount of air-conditioning, are as follows:


619

Parameter Units Vapour Vapour

compression absorptionsystem system

Rating TR 60 60

Power consumption kW 60 60

Steam consumption at

4 ksc kg/h - 300

Annual operating cost * Rs.lakhs 16.80 6.60

Annual savings Rs.lakhs - 10.20

Investment required Rs.lakhs 12.00 19.00

* Operating cost based on steam cost @ Rs.250/MTand electricity cost @ Rs.3.50/kWh

In addition to the above, other benefits achieved were as follows:

• The room conditions were met as desired

• No maintenance shut down required, since there are no moving parts

Benefits & Financial AnalysisThe annual energy saving achieved was Rs.1.0 million. This required an investment ofRs.1.9 million, which had a simple payback period of 23 months.

Replication PotentialThe installation of vapour absorption refrigeration system is in its nascent stage in the Indianindustry. The potential for installation of vapour absorption system in combination with a co-generation system is tremendous in Indian industry and therefore needs to be pursued.





621

CHAPTER IV

Service Agencies in the sector

4.1 List Of Suppliers

1. Bharat Heavy Electricals Ltd (BHEL)Building BHEL Building

Street Siri Fort Road

City 110 049 New Delhi

Country India

Telephone (+91) 11 - 649 30 31

Facsimile (+91) 11 - 649 30 21

E-Mail [email protected]

Internet www.bhelis.com

Description Power Generation and New & Renewable Energy Technologies

2. Thermax Babcock & Wilcox Ltd (TBW)Building Sagar Complex

Street Mumbai Pune Road

Place Kasarwadi, Nasik Phata

City 411 034 Pune

Country India

Telephone (+91) 20 - 712 57 45

Facsimile (+91) 20 - 712 55 33


Internet www.tbwindia.com

Description Heat Recovery Steam Generators, Circulating Fluid Bed Boilers,Grate & Gas Fired Boilers

3. Thermax LtdBuilding Thermax House

Street 4, Mumbai Pune Road

Place Shivaji nagar

City 411 005 Pune



Country India

Telephone (+91) 20 - 551 21 22

Facsimile (+91) 20 - 551 22 42


Internet www.thermaxindia.com

Description Boilers & Heaters, Captive Power, Cooling, Water & WasteSolutions, Air Pollution Control and Chemicals

4. Larsen & Toubro Ltd – EPC CentreBuilding Ashish Complex

Steet NH8, Chhani

City 391 740, Vadodara-Gujarat

Country India

Telephone (+91) 265 – 2775317 /2774941-5

Facsimile (+91) 265 - 27773898/5286

E-Mail [email protected],

Internet www.lntenc.com

Description Power Projects Development, Renovation & Modernisation,Hydro Projects

5. Foster Wheeler India Pvt LtdBuilding Prakash Presidium

Street 110, Mahatma Gandhi Road

Place Nungambakkam

City 600 034 Chennai

Country India

Telephone (+91) 44 - 28227341

Facsimile (+91) 44 - 28227340


Internet www.fwc.com

Description PC Fired & FBC Boilers, HRSG, Gasifiers


623

6. TurboTech Precision Engineering Pvt LtdStreet No 28/29, 2nd Main Road

Place Industrial Town, Rajajinagar

City 560 044 Bangalore

Country India

Telephone (+91) 80 - 320 07 89

Facsimile (+91) 80 - 330 72 27


Internet www.turbotech-india.com

Description Manufacturers of Small, Efficient Steam and GasTurbines

7. Neptunus Power Plant Services Pvt Ltd (NPPS)Building 511, Arenja Corner

Street Plot 71, Sector 17

Place Vashi

City 400 705 Navi Mumbai

Country India

Telephone (+91) 22 - 789 32 58

Facsimile (+91) 22 - 790 60 81


Internet www.neptunus-power.com

Description Captive Power Plants, Power Generation, Co-Generation etc

8. Aravinthraajan Energy SystemsBuilding Madhurams Flat

Street 17/1 Senthil Andavar Street

Place Vadapalani


Country India

Telephone (+91) 44 - 484 46 27

Facsimile (+91) 44 - 484 46 27




Internet www.geocities.com/powerfulsolution/

Description Power Plant System Design and OptimisationSoftware

9. Turbo Engineers (TE)Street 2/C/1, Picnic Garden 3rd Lane

City 700 039 Kolkata

Country India

Telephone (+91) 33 - 343 49 48

Facsimile (+91) 33 - 343 44 11


Internet www.maxpages.com/turboengineers/

Description Thermal & Hydro Power Generation

10. DUKJIN E & CBuilding 277, Nonhyun-Dong

Street Kangnam-GU

City Seoul

Country Korea

Telephone 82-02-3443-0692 to 5

Facsimile 82-02-3443-0696


Internet www.dukjinec.com

Description Water Treatment & Ultra Filtration system

4.2 List of consultant in the sector

1. TCE Consulting Engineers LimitedBuilding Sherif Center

Street 73/1 St, Marks Road


Country India

Telephone (+91) 80 – 2274721


625

Facsimile (+91) 80 - 2274873


Internet www.tce.co.in

Description Consultancy Services in Power Generation, Transmission& Distribution

2. Avant-Garde Engineers and Consultants Pvt Ltd (AGEC)Street 68a, Porur-Kundrathur High Road

Place Porur


Country India

Telephone (+91) 44 - 482 87 17

Facsimile (+91) 44 - 482 85 31


Internet www.avantgarde-india.com

Description Concept to Commissioning of Renewable Energy Projects

3. FICHTNER Consulting Engineers (India) Private LtdStreet 64, Eldams Road


Country India

Telephone (+91) 44 – 2435 9158

Facsimile (+91) 44 – 2434 4579


Internet www.fichtner.co.in

Description Consultancy Services in Gas & Thermal Power Plants

4. Acon Power ConsultantsStreet 45 Satyanand Vihar

District Rampur

City 482 008 Jabalpur

Country India

Telephone (+91) 761 - 66 72 61



Facsimile (+91) 761 - 66 42 07


Internet www.acon4power.com

Description Engineering Consultancy Services, Specializing in Power(Thermal/Hydro/Non-Conventional Energy Source)

5. Mitsui Babcock Energy (India) Private LtdBuilding Alsa Tower

Street 186-187 Poonamalle High Road

Place Kilpauk


Country India

Telephone (+91) 44 - 26612901

Facsimile (+91) 44 - 26612907


Internet www.mitsuibabcock.com

Description Thermal Power Plants

6. L&T - Sargent & Lundy LtdBuilding L&T-Energy Centre

Street Near Chhani Jakat Naka

District Baroda

City 390 002 Vadodara

Country India

Telephone (+91) 265 - 77 23 90

Facsimile (+91) 265 - 79 52 35


Internet www.lntsnl.com

Description Complete Consultancy Services in the Field of PowerGeneration from Concept to Commissioning for PowerProjects


627

7. Mantech Synergies Pvt LtdStreet 73, Sardar Patel Road

Place Guindy


Country India

Telephone (+91) 44 - 220 02 45

Facsimile (+91) 44 - 220 02 46


Internet www.mantechsynergies.com

Description Project Development Consultants for Independent PowerProjects from 100 MW to 350 MW

8. Energy Economy & Environmental ConsultantsStreet #506, 15th Cross

Place Indiranagar 2nd Stage


Country India

Telephone (+91) 80 - 525 61 71

Facsimile (+91) 80 - 525 91 72


Description Consulting Services for Cogeneration Plants, Distribution LossReduction, Waste Minimisation


628List of Suppliers

List of SuppliersList of Energy Auditors

List of Energy Service Companies


629

AC DRIVESMr Ranjan Kumar DeCountry ManagerALLEN BRADLEY INDIA LTDC - 11, Industrial AreaSite IV,shahiabadGhaziabad 201 010Tel: +91-120-471112 / 0103 / 0105 / 0164Fax: +91-120-4770822Email: [email protected],[email protected]

Cegelec India Ltd.A - 21/24, Sector 16Noida 201 301Tel: 011 - 852 5643Fax: 011 - 852 0405

Mr Sandeep MaityBusiness Unit Manager (VSD)Danfoss Industries Pvt. Ltd.296, Old Mahabalipuram RoadSholinganallur, Chennai 600 119Tel: 44 450 3511Fax: 44 450 351844 450 3521Email: [email protected]

EMCO Lenze Pvt. Ltd.106, Sion Koliwada RoadSion (East)Mumbai 400 022Tel: 022 - 407 6432/ 1816Fax: 022 - 409 0423

Energytek Electronics Pvt. Ltd.A - 31, GIDC Electronics ZoneGandhinagar 382 044Tel: 02712 - 25562Fax: 02712 – 30544

Messung Systems Pvt LtdS - 615, 6th Floor, Manipal CentreDickinson RoadBangalore 560042080 – 5320480Email: [email protected]

Ador Powertron Industries Ltd.Plot 51, Ramnagar ComplexD - 11 Block,MIDC, ChinchwadPune 411 019Tel: 020 - 772 532, 773 778Fax: 020 - 775 817

Mr K N BalajiChief Operating OfficerEurotherm Del India Ltd152, Developed Plots EstatePerungudiChennai - 600 096Tel: 044-4961129Fax: 044-4961831Email: [email protected]

Mr. Sudhir NaikVice President - Corporate Mktg.Hi-Rel Electronics LimitedB -117 & 118, GIDC,Electronics Zone, Sector-25Gandhi Nagar 382044Tel: 02712-21636, 22531Fax: 02712-24698Email:[email protected]

Mr N C AgrawalManaging DirectorMEDITRONSIRTDO Industrial EstateP O BIT, MesraRanchi 835 215Tel: +91-651-275875 / 628Fax: +91-651-275841Email: [email protected],[email protected]

Adsorption Dryers.Mr. Rajnish JoshiExe. Vice PresidentDelair India Pvt. Ltd.20, Rajpur Road,New Delhi 110054Tel: 011-2912800Fax: 011-2915127, 2521754Email: [email protected]

AFBC Boilers,Mr K KuppurajuPresident-TechnicalCetharVessels Pvt ltd4,Dindigul road,tiruchirappillyTel: 0431-482452/53Fax: 0431-481079Email: [email protected]

air & gas compressors,Mr Andre SchmitzManaging DirectorAtlas Copco (India) LtdMahatma Gandhi Memorial BuildingNetaji Subhas RoadMumbai 400 002Tel: +91-22-796416 / 17Fax: +91-22-797928Email: [email protected]

Air compressorsMr M RaveendranDirectorCoimbatore Compressor Engineering CoPvt LtdS F No 429, ThanneerpandalPeelameduCoimbatore 641 004Tel: +91-422-570323Fax: +91-422-571447Email: [email protected]

Dr Jairam VaradarajManaging DirectorELGI EQUIPMENT LTDElgi Industrial ComplexTrichy RoadSinganallur P OCoimbatore 641 005Tel: +91-422-574691 to 5Fax: +91-422-573697Email: [email protected]

Mr. Rahul C KirloskarChairman & Managing DirectorKirloskar Pneumatic Co LimitedHadapsar Industrial EstatePune 411 031Tel: 91-20-670133, 670341Fax: 91-20-670297, 670634Email: [email protected]

Mr Amol ParkheProduct managerKirlosker Copeland (EE)1202/1,Ghole RoadNear Ramchandra SabhagurhaPune-411004Tel: 020-5536350Fax: 020-5534988Email: [email protected]

Air conditioning systemsMr Anand EkbotePresidentTATA LIEBERT LTDPlot No C - 20, Road No 19Wagle Industrial EstateThane (W)Mumbai 400 604Tel: +91-22-5828405, 5802388Fax: +91-22-5828358, 5800829Email: [email protected]

Ms Sajitha M NairMarketing executivePresvi Controls Pvt ltdno 8, 2nd street,Venkatram nagar extnAdayarChennai 600 020Tel: 91-044-24420977/ 93Fax: 91-044-24410289

Mr J P SinghManaging DirectorYOKOGAWA BLUE STAR LTD40/4, Lavelle RoadBangalore 560 001Tel: +91-80-2271513Fax: +91-80-2274270Email: [email protected]



Mr. B G RaghupathyVice ChairmanGEA Cooling Tower Technologies (India) PvtLtd443, Anna Salai, TeynampetChennai-600018Tel: 044-4326171Fax: 044-4360576Email: [email protected]

Mr Ashok M AdvaniChairman & Chief ExecutiveBLUE STAR LTDKasturi BuildingsMohan T Advani ChowkJ Tata RoadMumbai 400 020Tel: +91-22-2020868Fax: +91-22-2874498, 2824043Email: [email protected]

Mr Anil K SrivastavaManaging DirectorCARRIER AIRCON LTDChiller Business Unit114, Shahpur JatNear Asian Games VillageNew Delhi 110 049Tel: +91-11-6497131 to 34Fax: +91-11-6497140

K N A ChandrasekarRegional ManagerAmtrex Hitachi Appliances LtdTulsi Apartments47,II Main Road, R A PuramChennai 600 028Tel: 044 - 4937483Fax: 044- 4935534Email:[email protected]

Mr T NakamotoManaging DirectorDaikin-Shriram Air Conditioning Pvt Ltd12th floor, Surya Kiran Building19KG MargNew Delhi 110 001Tel: 011-375-2647Fax: 011-375-2646

Mr. Seichi YoshiiManaging DirectorMatsushita Air-conditioning India Pvt LtdA 11& 12, SIPCOT Industrial ParkIrungattukottaiChennai 600 001Tel: (91)-(44)-56039/5603940/5603941/5603942Fax: (91)-(44)-56041

AmbiatorMr. A VaidyanathanManaging DirectorHMX - SUMAYA SystemsA 422, Peenya Industrial estate!st cross, 1 st stageBangalore 560058Tel: 080-3722325, 1065Fax: 080-3722326Email: [email protected]

Ash handling systems; high aluminaceramicsMr K R NatuManaging DirectorDEMECH LTD78, Bhosari Industrial EstatePune 411 026Tel: +91-20-7120994, 7120020Fax: +91-20-7120774, 5654185Email:

ATOMISERS FOR HUMIDIFICATIONSYSTEMSTechno PlastSpin free SystemNo.1 Krishna flatsB/H Ambika hotel,Near Mothibai Highschool,AmraiwadiAhmedabad – 26Tel: 079 – 5850898

Automatic oil fired burnersMr. R. RawatPartnerBurnax India338, Balmukund Khand,Giri Nagar, Kalkaji,New Delhi 110019Tel: 011-6215124, 6230498Fax: 011-6215124

Automatic Power Factor ControllerMr. Vipin SuriIManaging DirectorSylvan ElectronicsA-92/1, Naraina Indl. Area,Phase-INew Delhi 110028Tel: 011-5791044/2324Fax: 011-5794617

A Square Incorporation11 (Old: 7) ‘Subramanyaa”1st Floor, 3rd StreetSanthi Nagar,AadambakkamChennai 600 088Tel: 044 – 2451853Email: [email protected]

Automatic voltage regulators (AVR)Mr B.V.Subba RaoAddl. GMBHELRC PuramHyderabad

AUTOMATIC VOLTAGE STABILIZERMr Dilip DharmasthalManaging DirectorAlacrity Electronics Limited“Suresh Mahal”, 12 - BValmiki StreetT NagarChennai 600 017Tel: 044 - 823 6620Fax: 044 - 825 9406

Consul Consolidated Pvt., Ltd.,4/329-A, Old Mahabalipuram RoadThiruvanmiyurChennai 600 041Tel: 044 – 4926651 / 2 / 3Fax: 044- 4925754Email: [email protected]

Automation /Mr P S SridharanManaging DirectorMEGATECH CONTROL PVT LTDAlsha Complex51, 1st Main RoadGandhi NagarChennai 600 020Tel: +91-44-4996733 / 5654Fax: +91-44-4341668, 4996215Email: [email protected]

AXIAL FLOW FANSAmalgamated Indl. Composites Pvt. Ltd.Unit No.111/112Ashok Service Industrial EstateL B S Marg, Bhandup (West)Mumbai 400 078Tel: 022-591 3591/04565, 534 6919Fax: 022-591 3611, 5346920

Mr V S RajendranIn charge- Engg and marketing,After marketbusinessFlakt India ltd147, Poonamalle high roadVillage NumbalChennai 600077Tel: 044-26272023, 2216Fax: 044-26272606Email: [email protected]

Paru Engineers Private LimitedB-56, Durgabai Deshmukh ColonyHyderabad 500 007Tel: 040 - 764 4174Fax: 040 - 764 4174


631

Basic Refractories

Mr V K GopalakrishnanDirectorVRW INDUSTRIES LTDNo 15, Reddy StreetVirugambakkamChennai 600 092Tel: +91-44-4838638 / 385Fax: +91-44-4833153

BlowersMr R P SoodManaging DirectorENCON FURNANCES PVT LTD14/6, Mathura RoadFaridabad 121 003Tel: +91-129-274408, 275307 / 607Fax: +91-129-276448

Mr L ChandrashekarManaging PartnerMYSORE ENGINEERINGENTERPRISESNo 169, Industrial SuburbII StageP B No 5859, Peenya PostBangalore 560 058Tel: +91-80-8394423Fax: +91-80-3349746Email: [email protected]

Boilers & AxuliariesMr. Ashok TannaManaging DirectorVinosha Boilers Pvt. Ltd. And Taurus HeatSystemsBaarat House, Ist Floor,104, Apollo Street, Fort,Mumbai 400001Tel: 022-2674590, 2676447Fax: 022-2611515:

Mr Michael H W BandExecutive DirectorMitsui Babcock Energy (India) Pvt Ltd516-520, International Trade TowerNehru PlaceNew Delhi 110 019Tel: +91-11-6436790, 6446118Fax: +91-11-6489793Email:[email protected]

Krupp Industries India Ltd.V Floor, Temple Tower,672, Anna Salai, NandanamChennai 600 035Tel: (91)-(44)-4339482/4346993Fax: 91)-(44)-4348198

Mr J P SinghManaging DirectorYOKOGAWA BLUE STAR LTD40/4, Lavelle Road

Bangalore 560 001Tel: +91-80-2271513Fax: +91-80-2274270Email: [email protected]

Mr K C RanaManaging DirectorAVU ENGINEERING PVT LTDA - 15, APIEBalanagarHyderabad 500 037Tel: +91-40-3773235 / 2343Fax: +91-40-3772343 / 3235Email: [email protected]

MrC S RadhakrishnanExecutive DirectorFoster Wheeler India PvtPrakash Presidium110 Mahatma Gandhi Road, NungambakkamChennai 600 034Tel: 91-44-822-7341Fax: 91-44-822-7340Email: [email protected]

Mr B PattabhiramanManaging DirectorGB Engineering Enterprises Pvt LtdD - 99, Developed Plots EstateThuvakudiTrichy 620 015Tel: +91-431-501111 (8 lines)Fax: +91-431-500311Email: [email protected]

Mr Ranjit PuriChairman & Mg DirectorINDIAN SUGAR & GENERALENGINEERING CORPORATION (THE)A - 4, Sector 24Noida 201 301Tel: +91-118-4524071 / 72Fax: +91-118-4528630, 4529215Email: [email protected]

Mr. Cyrus EngineerVice PresidentIndustrial Boilers Ltd.701-C, Poonam Chambers,Dr. Annie Besant Road, Worli,Mumbai 400018Tel: 022-4926629Fax: 022-4937505

Mr Prakash KulkarniManaging DirectorTHERMAX BABCOCK & WILCOX LTDSagar ComplexKasarwadiPune 411 034Tel: +91-20-7125745Fax: +91-20-7125533Email: [email protected],[email protected]

Mr Chakor L DoshiChairmanWALCHANDNAGAR INDUSTRIES LTD3, Walchand TerracesOpp Air Conditioned MarketTardeoMumbai 400 034Tel: +91-22-4939498, 4934800Fax: +91-22-4936655

Mr. Arun GandhiProprietorCrescent Engineering Corporation49, H-32, Sector - 3,Rohini,New Delhi 110085Tel: 011-7164109, 7276448Fax: 011-7274553, 7162490

Krupp Industries India Ltd.V Floor, Temple Tower,672, Anna Salai, NandanamChennai 600 035Tel: (91)-(44)-4339482/4346993Fax: 91)-(44)-4348198

BurnersMr S M JainVice PresidentADOR TECHNOLOGIES LTDPlot No 53, 54 & 55F - II Block, MIDC Area, pimpriPune 411 018Tel: +91-20-7470225, 7476009Fax: +91-20-7470224 / 7358Email: [email protected]

Mr B S AdisheshWholetime DirectorIAEC INDUSTRIES MADRAS LTDRajamangalamVillivakkamChennai 600 049Tel: +91-44-655725, 6257783Fax: +91-44-4451537, 4995762Email: [email protected]

CalorifiersMr. Dinesh HarjaiPartnerCrupp MetalsKh. No. 56/1, Mundka,Rohtak Road,New Delhi 110041Tel: 011-5189024, 5474133Fax: 011-5183085

CapacitorsAuric Engineering Pvt ltd8-4-368/A SanathnagarHyderabad 500018Tel: 040-3814035Fax: 040-3811829Email: [email protected]



Mr R G DeshpandeManaging DirectorBC COMPONENTS INDIA PVT LTDLoni - Kalbhor, (Central Railway)Pune 412 201Tel: +91-20-6913451, 6913285Fax: +91-20-6913609Email: [email protected]

Shri. S K NevatiaHind Rectifiers LtdLake RoadBhandup WestMumbaiTel: 22 - 564 41 22Fax: 22 - 564 41 14Email: [email protected]

Momaya Capacitors401, Madhav ApartmentsJawahar Road, Opp. Rly. Stn.Ghatkopar (East)Mumbai 400 077Tel: 022 - 516 2899/ 1005/ 0745Fax: 022 - 516 0758Shakti Capacitors Pvt LtdPlot No 104/105PB No 176Industrial EstateSangli 416 416Tel: 91-233-310-915Fax: 91-233-310-984Email: [email protected]

Mr. S. JayaramanSr. General Manager-Mktg.Kapsales Electricals LimitedKhatau House,Plot No. 410-411, Mogul Lane, Mahim,Mumbai 400016Tel: 022-4461975, 4450050Fax: 022-4450016

Centrifugal & axial fansMr J B KamdarChief ExecutiveNADI AIRTECHNICS26, G N T RoadErukkencheryChennai 600 118Tel: +91-44-5570264 / 771Fax: +91-44-5371149Email: [email protected]

Mr A P GokhaleDirectorAutowin systems povt ltdPlot no 2, Vedant NagariKarve nagarPune-411052Tel: 020-5431052, 5423358Fax: 020-5467041Email: [email protected]

Centrifugal PumpsMr BSS Rao/rajivSr General managerBeacon Weir ltdno 28, Industrial estateAmbatturchennai-600098Tel: 044-6250739Email: [email protected] P U K MenonExecutive DirectorMATHER & PLATT INDIA LTDP B No 7ChinchwadPune 411 019Tel: +91-20-7476196 to 98, 7477434 (D)Fax: +91-20-7462519Email: [email protected]

CERAMIC COATINGRAVI Thermal Engineers Pvt. Ltd.No.11, 4th Cross, Central Excise LayoutVijaynagarBangalore 560 047Tel: 080 - 330 5794Fax: 080 - 330 3964

CERAMIC FIBREMinwool Rock Fibres Limited204, Kings ApartmentsJuhu Tara RoadJuhuMumbai 400 049Tel: 022-6154809Fax: 022-6178921

Ceramic Fibre productsMr.Mahesh ChavdaSales ManagerMurugappa Morgan Thermal Ceramics LtdTiam House-Annexe Building’-3rd FloorNo.28 Rajaji Salai,Chennai-600001Tel: 044-5224897,5272781Fax: 044-5213709,5227093Email: [email protected]

CFLMr Vinay MahendruA-39, Hosiery ComplexIndo Asian fuse gear ltdphase II extnNoida-201305Tel: 0120-2568471, 2568093-98Fax: 0120-2568473Email: [email protected]

ChillersHarshlal SuragneEr-MarketingKirloskar Mcquay pvt ltdPB No 1239,Hadapsar industrial estatepune 411013

Tel: 020 6821502,03-06Fax: 020-6821509Email: [email protected]

CLEATED BELT CONVEYORKraft Engg. & Projects Ltd189, Arcot Road, VadapalaniChennai 600 026Tel: 044 - 484 5811Fax: 044 - 484 7838

coalesorSiemag Hi tech filtersR k Industry houseWalbhat RoadGoregaon (E)Mumbai 400 063Tel: 022-26851885, 3231Fax: 022-26851048Email: [email protected]

cogeneration power plants based onwaste heatMr Pinaki BhadurySenior ManagerThermax Limited Cogen DivisionSai Chambers, 15 Mumbai-Pune RoadWakdewadiPune 411003Tel: 020-205511010Fax: 020-205511042

COMPRESSED AIR SYSTEMMAINTENANCEOrchid Energy Systems1141 – B, Trichy RoadCoimbatore 641 045Tel: 0422 – 318389Fax: 0422 – 312073

Compressed air systemsMr K.S. NatarajanManaging DirectorTrident Pneumatics Pvt Ltd.5/232, K.N.G. Pudur RoadSomayampalayam PostCoimbatore 641 108Tel: 0422 2400492Fax: 0422 2401376Email: [email protected]

CondenserMr M SreenivasanChief ExecutiveSUPER ENGINEERING COMPANYB - 1, Industrial EstateAriamangalamTrichy 620 010Tel: +91-431-441131Fax: +91-431-441366

Cooling Tower


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Mr RaviselvanManaging DirectorGem Cooling Towers Private LimitedSF. No. 100/AArasurCoimbatore 641407Tel: 0422-887059/880129Fax: 0422-888247

Mr Vikram SwarupManaging DirectorPaharpur Cooling Towers Ltd.Paharpur House8/1/B Diamond Harbour RoadKolkata 700027Tel: 91-33-24792050Fax: 91-33-24792188Email: [email protected]

Mr S BansalChief ExecutivePaltech Cooling Towers & Equipments Ltd.A-502 & 601ANSAL CHAMBER - IBHIKAJI CAMA PLACENEW DELHI 110066Tel: 011-6108114 / 6174250Fax: 91-11-6174250

Mr Pankaj BhargavaManaging DirectorParag Fans & Cooling Systems LimitedPlot no. 1/2b & 1b/3aIndustrial Area no. 1A.B. roadDewas 455 001Tel: 07272-58135 / 58131Fax: 91 - 7272 - 30273, 58850Email: [email protected]

Cooling Tower water treatmentHercules Speciality Chemicals Ltd5TH FLOOR, VAYUDNOOTHCHAMBERS15/16, MAHATMA GANDHI ROADBANGALORE 560001

Cooling water SystemsMr M Amjad ShariffDirectorShriram Epc LtdNo 9 Vanagaram Road,AyanambakkamChennai 602 102Tel: 6533109/3313/1592Fax: 653 2780/826 2416Email: [email protected]

Cooling water treatment chemicalsMr JayantRajvanshiDirectorAqua ChemicalsB-237A Road No. 6DV.K.I.Area

Jaipur 302013Tel: 0141-2331542,5061909Fax: 0141-2331543Email: [email protected]

Nalco chemicals india ltd20/A Park StreetKOLKATA 700 016Tel: 033-2172494Fax: 033-2171709

DC DRIVESSiemens Ltd.Motors, Drives & UPS DivisionSector - 11, Plot 11Kharghar ModeNavi Mumbai 410 208Tel: 022 – 757 7030/ 31/ 32Fax: 022 – 757 7106:

DC DRIVESLarsen & Toubro LtdControl & Automation Section10, Club House RoadAnna SalaiChennai 600 002Tel: 044 – 852 2141Fax: 044 – 852 0769

DG setsMr Mohan M GujrarManaging DirectorGurjar Power Engineers Pvt ltdno 18, Ist Floor,Corporation BuildingResidency RoadBangalore-560025Tel: 080-2216416, 7469Fax: 022-2216416Email: [email protected]

Powerica Limited115 Mittal CourtB-Wing Nariman PointMumbai 400021Tel: 022-2825949Fax: 91-22-22043782

Mr Pradeep MallickManaging DirectorWARTSILA INDIA LTD76, Free Press HouseNariman PointMumbai 400 021Tel: +91-22-2815601 / 5598, 28175995 / 5601Fax: +91-22-2842083Email: [email protected]

Mr D R DhingraManaging DirectorCONTINENTAL GENERATORS PVT LTD3869, Behind Primary SchoolG B RoadDelhi 110 006

Tel: +91-11-7535566 to 68, 525632, 522983,528510Fax: +91-11-7516598, 528510

Mr Girish MohanDirectorTIMKEN SERVICES PVT LTD725, Udyog ViharPhase VGurgaon 122 016Tel: +91-124-347725 / 6, 342840Fax: +91-124-342320, 348086

Mr K C DhingraManaging DirectorWESTERN INDIA MACHINERY CO PVTLTDPark PlazaNorth Block, 6E, 6th Floor71, Park StreetKolkata 700 016Tel: +91-33-2468913 / 9674Fax: +91-33-2468914

Mr Sumit MazumderManaging DirectorTIL LTD1, Taratolla RoadGarden ReachKolkata 700 024Tel: +91-33-4693732 to 36, 4696497 to 99Fax: +91-33-4692143 / 3731Email: [email protected]

Mr Anand KothanethGeneral ManagerBATLIBOI ENGINEERS PVT LTD99/2 & 99/3, N R RoadBangalore 560 002Tel: +91-80-2235061 to 63Fax: +91-80-2235085Email: [email protected]

DiffuserSiemag Hi tech filtersR k Industry houseWalbhat RoadGoregaon (E)Mumbai 400 063Tel: 022-26851885, 3231Fax: 022-26851048Email: [email protected]

DryersMr A D ParekhGeneral ManagerHDO PROCESS EQUIPMENT ANDSYSTEMS LTD5/1/2, GIDC Industrial EstateVatvaAhmedabad 382 445Tel: +91-79-5830591 to 94Fax: +91-79-5833286Email: [email protected]



ECONOMISERSMegatherm Engineers & Consultants Pvt.Ltd.10, Kodambakkam High RoadChennai 600 034Tel: 044 - 823 3528/ 3707Fax: 044 - 825 8559

Mr B P DebooManaging PartnerALBAJ ENGINEERING CORPORATION340, Clover CentreMoledina RoadPune 411 001Tel: +91-20-6131511, 6133018, 6121542Fax: +91-20-6137255Email: [email protected]

Eddy current control systemsDr. M. J. DavisExecutive DirectorEddy Current Controls (India) LimitedEddypuram, Chalakudy,District ThrissurThrissur 680722Tel: 0488-842882/716/698Fax: 0488-842716

Efficiency enhancement coating forpumpsMr G V MuralidharaSBU Head(Anti Corrosion ProductsDivision)Kirloskar Brothers Limited408/15, ChintanMukundnagarPune-411037Tel: 020-4402137Email: [email protected]

Electric motorsMr Rahul N AminChairman & Mg DirectorJYOTI LTDIndustrial AreaP O Chemical IndustriesVadodara 390 003Tel: +91-265-380633, 380627Fax: +91-265-380671, 381871Email: [email protected]

Electrical Measuring InstrumentsMr R R DhootChairmanIMP POWER LTDAdvent, 7th Floor12 - A, General J Bhosale MargNariman PointMumbai 400 021Tel: +91-22-2021890 / 886 / 697Fax: +91-22-2026775Email: [email protected]

Electronic ballastsMr Shantilal patelPropreitorNishan Power convertersKrishna Vijay saw mill compoundOpp S T stand, Agra RoadBhivandi-421302Tel: 91-2522-257201Fax: 91-2522-222032Email: [email protected]

Mr V RamarajManaging PartnerOPALNO 5, rajeswari streetMehta nagarchennai 600029Tel: 044-23742036 / 1218Fax: 044-23742036 / 1218Email: [email protected]

Mr. K. G. MadhuManaging DirectorAmmini Energy System Pvt. Ltd.Industrial Estate,Pappanamcode,Trivandrum 695019Tel: 0471-490508Fax: 0471-490832Email: [email protected]

Mr.P.S.SasidharanManaging DirectorPamba Electronic Systems Pvt Ltd.1/40A, Pamba House, Kureekkad P.OThiruvankulamErnakulam-682 305Tel: 0484-711129,712721Fax: 0484-711398Email: [email protected]

Electronic energy metersMr I C AgarwalChairman & Mg DirectorGENUS OVERSEAS ELECTRONICSLTDSPL - 3, RIICO Industrial AreaTonk RoadSitapuraJaipur 302 022Tel: +91-141-580003 / 4 / 9Fax: +91-141-580319Email: [email protected]

Energy Efficiency & ESCO ServicesMr R B SinhaChief ExecutiveEnergy Audit Services1116Sector No 17Faridabad -121 002Tel: 0129 - 2282132/2284125/2224504Fax: 0129 2262576Email: [email protected]

Energy efficient coolers for cementIndustryMR. PRADEEP KAPOORDirectorFuller India ltdJ-11, IIND FLOOR,REAR FLAT, SAKETNEW DELHI 110017

Mr Madhusudan RasirajuI K N engineering India pvt ltdThree star Business CentreA14 A, II nd AvenueAnna NagarChennai 600102Tel: 044-26218994,6210960Fax: 044-26284567,0439Email: [email protected]

Energy efficient drying systemMukesh ShahDirectorMecord Systems and Services (P) Ltd.314 Hill View Industrial EstateGhatkopar WestMumbai 400086Tel: (022)-5008604Fax: (022)-5007560

Energy Efficient Induction MotorsMr. Sanjeev GuptaProprietorOxford Engineering IndustriesG-27, East Gokalpur,Loni Road,New Delhi 110094Tel: 011-2280434, 2299979Fax: 011-2293370

Energy efficient lighting systemsMr R NandakishoreSr General Manager MarketingPhilips India LtdMotorola excellence centre, 5th floor 415/2,Mehrauli Gurgaon Road, Sector 14,Gurgaon-122001Tel: 0124-8991980Fax: 0124-8991993Email: [email protected]

ENERGY EFFICIENT MOTORSAsea Brown Boveri ltdPlot No 5 & 6, II PhasePeenya Industrial AreaP B no 5806, PeenyaBangalore 560058Tel: 080-8370416 / 8394734 extn 2322 /6691375Fax: 080-8399178 / 8396537

Mr N J DananiVice Chairman & Mg DirectorBHARAT BIJLEE LTD


635

Central Marketing Office (Motor)P O Box 100Kalwe, Thane Belapur RoadMumbai 400 601Tel: +91-215-7691656Fax: +91-215-7691401 / 2:

Crompton Greaves LimitedCG Industrial SystemsETD Building, 2nd FloorKanjur Marg (E)Mumbai 400 042Tel: 022-5782451 Extn 8956/ 5795688Fax: 022-5789169

Energy efficient PumpsMr G RajendranManaging DirectorC.R.I. Pumps (PVT) LimitedAthipalayam Road,ChinnavedampattiCoimbatore 641 006Tel: (422) 867051 /2/6395

Mr N K RanganathChief ExecutiveGrundfos Pumps India Pvt LtdGround floorChamiers apartment119/121, Chamiers roadChennai 600028Tel: 044-4323487 / 4357065Fax: 044-4323489

Mr N C TiwariAssistant General Manager, ProductDevelopment & MangementKirloskar Brothers LimitedUjjain RoadDewas-455001Tel: 07272-27315Fax: 07272-27347Email: [email protected]

Energy management & Control systemsMr Lalit SethChief ExecutiveHPL-SOCOMEC PVT LTDAtma Ram Mansion, 2nd Floor1/21, Asaf Ali RoadNew Delhi 110 002Tel: +91-11-3236811 / 4811Fax: +91-11-3232639Email: [email protected] ENERGY Management systemsW 324, Rabale MIDCMumbai 400701Tel: 91-022-27696720,86Fax: 91-022-27694585

Energy metersMr Qimat Rai GuptaChairman & Mg DirectorHAVELL‘S INDIA LTD

1, Raj Narain MargCivil LinesDelhi 110 054Tel: +91-11-3935237 to 40, 2944469 to 72,3981101 to 05Fax: +91-11-3921500, 3981100Email: [email protected]

Mr Lalit SethChief ExecutiveHPL-SOCOMEC PVT LTDAtma Ram Mansion, 2nd Floor1/21, Asaf Ali RoadNew Delhi 110 002Tel: +91-11-3236811 / 4811Fax: +91-11-3232639Email: [email protected]

Energy Recovery Ventilator (ERV),Mr. Rajnish JoshiExe. Vice PresidentArctic India Engineering Pvt. Ltd.20, Rajpur Road,New Delhi 110054Tel: 011-2912800Fax: 011-2915127, 2521754Email: [email protected]

Energy saver for air conditionersDr V K KoshyChairman & Mg DirectorBHARAT ELECTRONICS LTDShankaranarayan Building, 2nd Floor25, M G RoadBangalore 560 001Tel: +91-80-5595729Fax: +91-80-5584911Email: [email protected]

Energy saver for LightingMr R SekarChairman & Managing DirectorES Electronics (India) Pvt Ltd438,4th Main RoadNagendra Block,B.S.K.I Stage,Bangalore 560050Tel: 080-6727836 / 8761

CLIPSAL Lighting India (P) LtdBajaj NiwasOpP. C.K.P. Club,712 , Linking Road, Khar (W)MumbaiTel: 022-6046483energy savers for AC Induction motorsSantronix india pvt ltdunit no 12Electronic sadan IIIMIDC, BhosariPune 411026Tel: 020-7122758Fax: 020-7129518Email: [email protected]

Energy Saving Lighting Systems.Mr. Praveen Kumar SoodManaging DirectorLinear Technologies India Pvt. Ltd.K-37, Green Park,Main Basement,New Delhi 110016Tel: 011-6854395, 6854946Fax: 011-6854057

Mr. Ajit R. ShahManaging DirectorEurolight Electricals Limited20,Sadashiv Peth, Rahi Chambers,L B S Road,Pune 411030Tel: 0212-531287, 534128Fax: 0212-532787Email: yantra @ bom3vsnl.net.in

Energy Services ConsultancyMr P S SankaranayaranDirectorAvant Garde Engineers & Consultants (p)Ltd.68A Porur Kundarathur High roadPorurChennai 600 116Tel: 044-4828717,18,19,22Fax: 91-44-4828531Email: [email protected]

ESCOMr B S PuniaJr Vice PresidentDCM Shriram Consolidated Ltd5th floor,Kanchenjunga Building18,Barakhamba RoadNew Delhi-110001Tel: 011-3316801Fax: 011-3318261Email: [email protected]

Mr Nalin KanshalBusiness DirectorElpro energy Dimensions Pvt ltd6,7,8 IV N BlockDr RajKumar Road, Rajaji Nagar entranceBangalore-560010Tel: 080-3122676,3123238,3132035,3132036Fax: 080-3487396Email: [email protected]

EVAPORATIVE CONDENSERSBaltimore Aircoil Company Inc.122, Hema Industrial EstateSarvodaya NagarJogeshwari (E)Mumbai 400 060Tel: 824 5714Fax: 824 5713Email: [email protected]



Systems & Components (India) PrivateLimited110, Gautam Udyog BhavanL.B.S Marg, Bhandup (West)Mumbai 400 078Tel: 022-564 0166-67Fax: 022-564 5896Email: [email protected]

Evaporative Cooling Pad (ECP) andControl Panel heat ExtractorMr. Rajnish JoshiExe. Vice PresidentArctic India Engineering Pvt. Ltd.20, Rajpur Road,New Delhi 110054Tel: 011-2912800Fax: 011-2915127, 2521754Email: [email protected]

FansMr Saroj PoddarChairmanALSTOM LTD14th Floor, Pragati Devika Tower6, Nehru PlaceNew Delhi 110 019Tel: +91-11-6449906, 6449907, 6449902 / 3Fax: +91-11-6449447

Mr A M NaikMg Director & CEOLARSEN & TOUBRO LTDL & T HouseBallard EstateMumbai 400 001Tel: +91-22-2618181Fax: +91-22-2620223, 2610396, 2622285Email: [email protected]

filters for Air CompressorsMr. Sanjay JoshiManaging DirectorDomnick Hunter India Pvt LimitedB-214, ANSAL CHAMBER-I3, BHIKAIJI CAMA PLACENEW DELHI 110066Tel: 11 61 92172Fax: 011-6185279

Flue Gas AnalysersMr T V KrishnamurthyChief ExecutiveMarvel Engineering company28,Deivasigamani roadRoypettahChennai-600014Tel: 044-8110582,2297Fax: 044-8117559Email: [email protected]

Fluid Bed DryerMr Subodh S NadkarniPresident & CEO

SULZER INDIA LTDSulzer HouseBaner Road, AundhPune 411 007Tel: +91-20-5888991 / 98Fax: +91-20-5886393Email:[email protected]

Aerotherm Systems Pvt LtdPlot no 1517 Phase IIIGIDC VatwaAheemedabad 382445Tel: 079-5890158Fax: 079-5834987Email: [email protected]

Mr K C PatelGeneral ManagerGujarat Perfect Engineering Ltd301, Shailja Complex II, Akota RoadVadodara 390 020Tel: +91-265-334861, 645786Fax: +91-265-646880Email: [email protected]

FRP BLADESAmalgamated Indl. Composites Pvt. Ltd.Unit No.111/112Ashok Service Industrial EstateL B S Marg, Bhandup (West)Mumbai 400 078Tel: 022-591 3591/04565, 534 6919Fax: 022-591 3611, 5346920

Encon (India)2 - B/17, ShivkripaN C Kelkar RoadDadar (West)Mumbai 400 028Tel: 022 - 437 2949, 4306578Fax: 022 - 431 0992, 4321929

FurnaceMr Saroj PoddarChairmanALSTOM LTD14th Floor, Pragati Devika Tower6, Nehru PlaceNew Delhi 110 019Tel: +91-11-6449906, 6449907, 6449902 / 3Fax: +91-11-6449447

Mr Mithu S MalaneyChairman & Mg DirectorVULCAN ENGINEERS LTD427, Unique Industrial EstateOff Veer Savarkar MargPrabhadeviMumbai 400 025Tel: +91-22-4304529 / 3671Fax: +91-22-4225814Email:[email protected]

Mr. Arun GandhiProprietorCrescent Engineering Corporation49, H-32, Sector - 3,Rohini,New Delhi 110085Tel: 011-7164109, 7276448Fax: 011-7274553, 7162490

Mr Vilas H PatilManaging DirectorDYNAMIC FURNACES PVT LTD65, Universal Industrial EstateI B Patel RoadGoregaon (E)Mumbai 400 063Tel: +91-22-8733516, 8746138Fax: +91-22-8733021Email: [email protected]

Mr R P SoodManaging DirectorENCON FURNANCES PVT LTD14/6, Mathura RoadFaridabad 121 003Tel: +91-129-274408, 275307 / 607Fax: +91-129-276448

Mr C P MaheshwariManaging DirectorHC GIDDINGS PVT LTD3, Chittaranjan AvenueKolkata 700 013Tel: +91-33-272820, 261740Fax: +91-33-2372820, 2361740

Mr M GopalManaging DirectorHIGHTEMP FURNACES LTDI - C, Phase IIP B No 5809Peenya Industrial AreaBangalore 560 058Tel: +91-80-8395917 / 4076 / 1446Fax: +91-80-8397798 / 2661Email: [email protected]

Mr M K SenManaging DirectorINCORPORATED ENGINEERS LTDD - 400, GayatriMIDC, Uran PhataNerulNavi Mumbai 400 706Tel: +91-22-7619352, 7619366Fax: +91-22-7619368Email: [email protected]

Mr N GopinathManaging DirectorFLUIDTHERM TECHNOLOGY PVT LTDSP - 132, III Main RoadAmbattur Industrial EstateChennai 600 058


637

Tel: +91-44-6357390, 6357391Fax: +91-44-6257632Email: [email protected]

generators and boilersMr K G RamachandranChairman & Mg DirectorBHARAT HEAVY ELECTRICALS LTDBHEL HouseSiri FortNew Delhi 110 049Tel: +91-11-6001010Fax: +91-11-6493021, 6492534

Mr Praveen SachdevMg Director & CEOGREAVES LTD1, Dr V B Gandhi MargP O Box 91Mumbai 400 001Tel: +91-22-2671524 / 4913Fax: +91-22-2677850, 2652853

Harmoic analyserNeptune India ltdNeptune houseC 270 SFS Sheikh saraiPhase INew delhi 110017Tel: 011-6013367-70Fax: 011-6013371Email: [email protected]

Mr Dilip DharmasthalManaging DirectorAlacrity Electronics Limited“Suresh Mahal”, 12 - BValmiki StreetT NagarChennai 600 017Tel: 044 - 823 6620Fax: 044 - 825 9406

Avante Global services225, Prakash MohallaEast of Kailash,New Delhi 110065Tel: 011-26233259,26443097Email: [email protected]

Mr. P Anil KumarManaging DirectorTOWLER ENTERPRISE SOLUTIONSPVT.LTDHARMAN HOUSE482, 80 FT ROAD, GANGANAGARBANGALORE 160032Tel: 080-3530033-36,3432289Fax: 080-3431548

Mr Lalit Kumar PahwaManaging DirectorHARMAN INNOVATIVETECHNOLOGIES LTD

Harman House482, 80 FT RoadGanganagarBangalore 560 032Tel: +91-80-3530036 / 37Fax: +91-80-3431548Email: [email protected]

harmonic filtersPower Linkers122,Nahar & seth estatechakalaMumbai 400099Tel: 022-28325565, 28371902Fax: 022-28386025Email: [email protected]

Mr. R. K. IyerVice PresidentSaha Sprague LimitedNo.805, North Rear Wing, 8th Floor, ManipalCentre47, Dickenson Road,Bangalore 560042Tel: 080-5595463, 5595266Fax: 080-5595463

Harmonic measurement and analysisPower Linkers122,Nahar & seth estatechakalaMumbai 400099Tel: 022-28325565, 28371902Fax: 022-28386025Email: [email protected]

Harmonic utility EquipmentsMr Parag J PandyaCEOAmtech Electronics India ltdE - 6 GIDC Electronics ZoneGandhi NagarGandhi Nagar 382 028Tel: 079 - 3225324/3227294/3227304Fax: 079 - 3224611Email: [email protected]

Heat exchangerMr M SreenivasanChief ExecutiveSUPER ENGINEERING COMPANYB - 1, Industrial EstateAriamangalamTrichy 620 010Tel: +91-431-441131Fax: +91-431-441366

Mr Mohammed MeeranProprietorAASIA RADIATORSP S C Bose RoadJawahar AutonagarVijayawada 520 007Tel: +91-0866-543881

Fax: +91-0866-545860

Mr Ajit SinghChief Executive OfficerAIRFRIGE INDUSTRIES10/65, Kirti Nagar Industrial AreaNew Delhi 110 015Tel: +91-11-5931909 / 72, 5162118 / 19Fax: +91-11-5436781Email: [email protected]

Mr B P DebooManaging PartnerALBAJ ENGINEERING CORPORATION340, Clover CentreMoledina RoadPune 411 001Tel: +91-20-6131511, 6133018, 6121542Fax: +91-20-6137255Email: [email protected]

Mr Deepak SinghExecutive DirectorBUILDWORTH PVT LTDG S RoadDispurGuwahati 781 005Tel: +91-361-560354Fax: +91-361-561411Email: [email protected]

Mr Sucha SinghManaging DirectorCOIL COMPANY PVT LTDA - 21/24, Naraina Industrial AreaNew Delhi 110 028Tel: +91-11-5701967 / 1968 / 9127Fax: +91-11-5709126Email: [email protected]

Er Ashok Kumar GuptaChairmanCRANE-BEL INTERNATIONALDev - Satya BhavanC - 23, Lohia NagarGhaziabad 201 001Tel: +91-120-4722994, 4716883, 4713281/82Fax: +91-120-4712709, 4722995Email: [email protected]

Mr. Dinesh HarjaiPartnerCrupp MetalsKh. No. 56/1, Mundka,Rohtak Road,New Delhi 110041Tel: 011-5189024, 5474133Fax: 011-5183085

Mr. A. Bhasker ReddyManaging PartnerEnfabC-2, Shanthi Nivas,Mettuguda,



Secunderabad 500017Tel: 040-823073, 830010Fax: 040-823073, 830010Email: enfabs @ hd1.vsnl.net.in

Mr B PattabhiramanManaging DirectorGB Engineering Enterprises Pvt LtdD - 99, Developed Plots EstateThuvakudiTrichy 620 015Tel: +91-431-501111 (8 lines)Fax: +91-431-500311Email: [email protected]

Mr K C PatelGeneral ManagerGUJARAT PERFECT ENGINEERINGLTD301, Shailja Complex IIAkota RoadVadodara 390 020Tel: +91-265-334861, 645786Fax: +91-265-646880Email: [email protected]

Mr C P MaheshwariManaging DirectorHC GIDDINGS PVT LTD3, Chittaranjan AvenueKolkata 700 013Tel: +91-33-272820, 261740Fax: +91-33-2372820, 2361740

Mr A D ParekhGeneral ManagerHDO PROCESS EQUIPMENT ANDSYSTEMS LTD5/1/2, GIDC Industrial EstateVatvaAhmedabad 382 445Tel: +91-79-5830591 to 94Fax: +91-79-5833286Email: [email protected]


Mr M K SenManaging DirectorINCORPORATED ENGINEERS LTDD - 400, GayatriMIDC, Uran PhataNerulNavi Mumbai 400 706Tel: +91-22-7619352, 7619366Fax: +91-22-7619368

Email: [email protected] Ranjit PuriChairman & Mg DirectorINDIAN SUGAR & GENERALENGINEERING CORPORATION (THE)A - 4, Sector 24Noida 201 301Tel: +91-118-4524071 / 72Fax: +91-118-4528630, 4529215, 4542072Email: [email protected]

Mr P V RaoManaging PartnerINDIRA INDUSTRIAL WORKS1 - 528, Lankalapalem P OVisakhapatnam 531 021Tel: +91-891-29461 / 53Fax: +91-891-29461Email:

Mr S V MehtaChairman & DirectorINDUSTRIAL MACHINERYMANUFACTURERS PVT LTD3607 - 3609, GIDC EstatePhase IVVatvaAhmedabad 382 445Tel: +91-79-5831152 / 1449Fax: +91-79-5832216Email:[email protected]

Mr L ChandrashekarManaging PartnerMYSORE ENGINEERINGENTERPRISESNo 169, Industrial SuburbII StageP B No 5859, Peenya PostBangalore 560 058Tel: +91-80-8394423Fax: +91-80-3349746Email: [email protected]

Mr V David SelvarajVice President (Operations)PARANI STEELS PVT LTDAL - 84, 4th Street11th Main RoadAnna NagarChennai 600 040Tel: +91-44-6286285 / 2246 / 2247Fax: +91-44-6211265

Mr Ramesh WadhwaniManaging DirectorUNITOP ENGINEERS PVT LTD78/1, GIDC Industrial EstateP O Box No 761MakarpuraVadodara 390 010Tel: +91-265-642161 / 62Fax: +91-265-644698

Email: [email protected] Chakor L DoshiChairmanWALCHANDNAGAR INDUSTRIES LTD3, Walchand TerracesOpp Air Conditioned MarketTardeoMumbai 400 034Tel: +91-22-4939498, 4934800Fax: +91-22-4936655

Mr Pashupati Nath KapoorPartnerKASHI INDUSTRIES16/80, B 1Civil LinesKanpur 208 001Tel: +91-512-311395, 319074Fax: +91-512-319074

Mr Roy EapenProprietorHEAT TRANSFER DEVELOPMENT84 - C, Jeevan Complex5th Cross, 100 Feet RoadGandhipuramCoimbatore 641 012Tel: +91-422-858271 / 2Fax: +91-422-447341

Mr J Peter ArokiamManaging DirectorMANIKAM RADIATORS PVT LTD11/275 - B, SubramaniapalayamK N G Pundur RoadG N Mills PostCoimbatore 641 029Tel: +91-422-843311 / 12Fax: +91-422-843311Email: [email protected]

Heat recovery boilersMr K G RamachandranChairman & Mg DirectorBHARAT HEAVY ELECTRICALS LTDBHEL HouseSiri FortNew Delhi 110 049Tel: +91-11-6001010Fax: +91-11-6493021, 6492534

Heat Recovery Wheel (HRW)Mr. Rajnish JoshiExe. Vice PresidentArctic India Engineering Pvt. Ltd.20, Rajpur Road,New Delhi 110054Tel: 011-2912800Fax: 011-2915127, 2521754Email: [email protected]


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Heat Treatment furnancesMr R N BakshiManaging DirectorUNITHERM ENGINEERS LTD101, Laxmi Market, 1st FloorVartak Nagar Junction, Pokhran Road No 1Mumbai 400 606Tel: +91-22-5406131, 5371654, 5371655Fax: +91-22-5406569Email: [email protected]

Mr. S. R. BabbarPartnerWellmake Engineering CompanyA-28,Mangolpuri Indl. Area,Phase-II,New Delhi 110034Tel: 011-7018199, 7025409Fax: 011-7019330

High alumina refractoriesMr V K GopalakrishnanDirectorVRW INDUSTRIES LTDNo 15, Reddy StreetVirugambakkamChennai 600 092Tel: +91-44-4838638 / 385Fax: +91-44-4833153

High Efficiency Electric MotorsMr. Liakat AliProprietorPremier Electric CompanyPlot No.7,12/2 Mathura Road,Faridabad 121002Tel: 0129-270858, 274311Fax: 0129-270858

High Efficiency Electric TransformersMr. Liakat AliProprietorPremier Electric CompanyPlot No.7,12/2 Mathura Road,Faridabad 121002Tel: 0129-270858, 274311Fax: 0129-270858

Mr. T. V. JosephGeneral ManagerTransformers and Electricals KerelaLtd.(TELK)Angamaly P.O. 683573,Angamaly 683573Tel: 04856-452251Fax: 04856-452873

High efficiency power distribution &special Transformers.Mr. Nitin NayakDirector

El -Tra Equipment Company (India) Pvt. Ltd.11th Mile, Old Madras Road,Avalahalli, P.O. Virgonagar,Bangalore 560049Tel: 080-8510652, 8472229Fax: 080-8510652Email: [email protected]

High Efficiency PumpsSulzer Pumps India LtdNo.9, MIDC, Thane Belapur RoadDingha,Navi Mumbai 400 708Tel: +91 22 790 4321Fax: +91 22 790 4306Email: [email protected] Andre Schmitz

HOC DriersManaging DirectorATLAS COPCO (INDIA) LTDMahatma Gandhi Memorial BuildingNetaji Subhas RoadMumbai 400 002Tel: +91-22-796416 / 17Fax: +91-22-797928Email: [email protected]

Mellcon Engineering Pvt LimitedB-297, Okhla Industrial AreaPhase-1New Delhi 110 020Tel: 011 – 6811727 / 6816103Fax: 011 – 6816573 / 6819151

MVS Engineering LimitedMVS House, E-24East of KailashNew Delhi 110 065Tel: 011 - 6431908, 6436869Fax: 011 - 6464994Email: E-mail: [email protected]

Puriflair India22, GIDC EstateP.B 790, MakarpuraVadora 390 010Tel: 0265 – 642487 / 645248Fax: 0265 – 644070

HT capacitors, Furnace duty capacitorsMr. M.D. KilledarManager (Works)Goa Capacitors Pvt. Ltd.14, Corlim Industrial Estate,Corlim, Ilhas,Panaji 403110Tel: 0832-286176/240Fax: 0832-286203

HumidifiersMr S V MehtaChairman & Director

INDUSTRIAL MACHINERYMANUFACTURERS PVT LTD3607 - 3609, GIDC EstatePhase IVVatvaAhmedabad 382 445Tel: +91-79-5831152 / 1449Fax: +91-79-5832216Email:[email protected]

HVACMr. Sandeep SaxenaManagerCapital Enterprise36 Industrial EstateMLN Regional Engineering CollegeAllahabad 211002Tel: 545362Fax: 461775Email: [email protected]

incineratorsMr S M JainVice PresidentADOR TECHNOLOGIES LTDPlot No 53, 54 & 55F - II Block, MIDC Area, pimpriPune 411 018Tel: +91-20-7470225, 7476009Fax: +91-20-7470224 / 7358Email: [email protected]

Mr U V RaoDirectorALLIED CONSULTING ENGINEERSPVT LTDAllied HouseRoad No 1, chemburMumbai 400 071Tel: +91-22-5284028Fax: +91-22-5283805Email: [email protected]

Mr M K SenManaging DirectorINCORPORATED ENGINEERS LTDD - 400, GayatriMIDC, Uran PhataNerulNavi Mumbai 400 706Tel: +91-22-7619352, 7619366Fax: +91-22-7619368Email: [email protected]

Induction heatersInventum engineering companyP O box 9435Andheri (E)Mumbai 400093Tel: 022-26730499/ 590Fax: 022-26730887Email: [email protected]



Industrial CeramicsMr N AnjiahManaging PartnerAnnapurna Annapurna Technical ceramics21-118Kakani NagarVaisag 534007Tel: code-507659:Email: [email protected]

Industrial fans& blowersMr Arindom MukherjeeChairman & Mg DirectorANDREW YULE & CO LTDYule House, 8, Dr Rajendra Prasad SaraniKolkata 700 001Tel: +91-33-2422796 / 8210Fax: +91-33-2434721Email: [email protected]

Industrial furnacesMr U V RaoDirectorAllied Consulting Engineers Pvt LtdAllied HouseRoad No 1, chemburMumbai 400 071Tel: +91-22-5284028Fax: +91-22-5283805Email: [email protected]

Mr Anup DasguptaDirectorFIRE GASES & KILN (INDIA) PVT LTD156, Jodhpur ParkKolkata 700 068Tel: +91-33-4730164 / 1289, 4728391 / 2Fax: +91-33-4731540

Mr S L MathurManaging DirectorSTEIN HEURTEY INDIA PROJECTSPVT LTD8/1, Middleton RowKolkata 700 071Tel: +91-33-2260194, 2457484 / 89Fax: +91-33-2443636, 2476655Email: [email protected]

Mr N M SudharshanChief Operating OfficerELECTROTECHNIK“B” Wing, 9th FloorParsn ComplexChennai 600 006Tel: +91-44-8259437Fax: +91-44-8269617

Mr R K AgrawalChief Executive OfficerEASTERN EQUIPMENT & ENGINEERSS - 14, Civil TownshipRourkela 769 004

Tel: +91-61-502508, 503898Fax: +91-61-503898Email: [email protected]

Aero therm systems pvt ltdPlot no 1517 Phase IIIGIDC VatwaAheemedabad 382445Tel: 079-5890158Fax: 079-5834987Email: [email protected]

Instrumentation control systemsMr P S KumarManaging DirectorABB INSTRUMENTATION LTD14, Delhi Mathura RoadP O AmarnagarFaridabad 121 003Tel: +91-0129-5275592 / 3 / 7, 5276350 / 54 /62 / 67Fax: +91-0129-5275019 / 466Email: [email protected]

Mr M L AnandChairmanANAND CONTROL SYSTEMS PVT LTDD - 67/68, Sector VINoida 201 301Tel: +91-118-4537395, 4554627Fax: +91-118-4533782Email: [email protected]

Fisher Rosemount (India) LimitedD Wing, 2nd FloorModern Mills CompoundMahalaxmiMumbai 400 011Tel: 91 22) 462 0462Fax: (91 22) 462 0500

Libratherm Instruments402, Diamond Industrial EstateKetki pada RoadDahisar EastMumbai 400068Tel: 022-28960659Fax: 022-28963823Email: [email protected]

Mr. Prem DuaDirectorPuneet Industrial Controls Pvt. Ltd.45 Community Centre,East of Kailash,New Delhi 110065Tel: 011-6423328, 6419479Fax: 011-6423328

Mr P S SridharanManaging DirectorMEGATECH CONTROL PVT LTDAlsha Complex51, 1st Main Road

Gandhi NagarChennai 600 020Tel: +91-44-4996733 / 5654Fax: +91-44-4341668, 4996215Email: [email protected]

Mr A N SenManaging DirectorAN INSTRUMENTS PVT LTD59 - B, Chowringhee Road5th FloorKolkata 700 020Tel: +91-33-2402222, 2472509Fax: +91-33-2806684Email: [email protected]

InsulationLloyds Insulation386, Veer Savarkar MargMumbai 400 025Tel: 022-4340876Fax: 022-4376858

intermediate controller for compressedairMr Kiran C pandeManager-Compressed air managementsolutionsGodrej & boyce manufacturing company ltdPirojshanagar, VikhroliMumbai-400079Tel: 022-55962251-56Fax: 022-55961525Email: [email protected]

Inverter weldingTejas EnterprisesC/5/72Sahyadri NagarCharakop, Kandivili WestMumbai 200067Tel: 022-28678692Fax:Email: [email protected]

Jet Tower-Induced draught without fanand FillsMr Bhagwan HaraniTechnical DirectorArmec groupArmec houseTiny Industrial estate,Kondhwa (B)Pune-411048Tel: 020-6930218Fax: 020-6930537Email: [email protected]

Kiln furniture systemsMr N G ManoharanManaging DirectorAbref Private ltdNO 32, Meeran Sahib streetAnna SalaiChennai-600002


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Tel: 044-28250074Fax: 044-28233486Email: [email protected]

kilnsMr M K SenManaging DirectorINCORPORATED ENGINEERS LTDD - 400, GayatriMIDC, Uran PhataNerulNavi Mumbai 400 706Tel: +91-22-7619352, 7619366Fax: +91-22-7619368Email: [email protected]

Mr Mithu S MalaneyChairman & Mg DirectorVULCAN ENGINEERS LTD427, Unique Industrial EstateOff Veer Savarkar MargPrabhadeviMumbai 400 025Tel: +91-22-4304529 / 3671Fax: +91-22-4225814Email:[email protected]

Mr Anup DasguptaDirectorFIRE GASES & KILN (INDIA) PVT LTD156, Jodhpur ParkKolkata 700 068Tel: +91-33-4730164 / 1289, 4728391 / 2Fax: +91-33-4731540Email:

LED based medium intensity aviationobstruction lightBinay opto electronics Private ltd44,Armenian streetCalcutta 700001Tel: 033-2429082,2103807Fax: 033-2421493Email: [email protected]

LED indicator modulesBinay opto electronics Private ltd44,Armenian streetCalcutta 700001Tel: 033-2429082,2103807Fax: 033-2421493Email: [email protected]

LIGHTING ENERGY SAVER / LIGHTINGTRANSFORMERMr S RaghavanManager - Sales & MarketignBeblec (India) Pvt. Ltd.,126, Sipcot Indl.ComplexHosur 635 126Tel: 91-4344-276358/278658/276958/276959

Fax: 91-4344-276358/59Email:

Electronics IndiaNo. 438, 4th Main RoadNagendra BlockBSK First StageBangalore 560 050Tel: 080 – 662 1836Fax: 080 – 662 1831Email:

Jindal Electric & Machinery CorpC-57, Focal Point,Ludhiana 141010Tel: 670250 / 670250 / 676968Fax: 0161 – 670252Email:

low energy consuming PortableGeneratorsMr. Wasim JavedBirla Yamaha LimitedA-7, Ring Road,N. D. S. E. Part - 1,New Delhi 110049Tel: 011-4690352 to 54, 4691852Fax: 011-4626188Email:

Low loss Power & DistributionTransformersMr. Adrian J D’SouzaDirectorSouthern Power Equipment Company42, Yumkur Road,Yeshwanthpur,Bangalore 560022Tel: 080-3372996, 3372741Fax: 080-3372997Email:

LT Power capacitorsMr. M.D. KilledarManager (Works)Goa Capacitors Pvt. Ltd.14, Corlim Industrial Estate,Corlim, Ilhas,Panaji 403110Tel: 0832-286176/240Fax: 0832-286203Email:

LUX METER AND HARMONICANALYSERMr Dilip DharmasthalManaging DirectorAlacrity Electronics Limited“Suresh Mahal”, 12 - BValmiki StreetT NagarChennai 600 017Tel: 044 - 823 6620Fax: 044 - 825 9406

M F induction melting/holding furnaceMr Mukesh B BhandariChairman & Mg DirectorELECTROTHERM (INDIA) LTDSurvey No 72Village - PalodiaVia ThaltejAhmedabad 382 115Tel: +91-2717-39953 to 57, 39613 to 15Fax: +91-2717-39616, 91-79-6740923Email: [email protected]

Maximum Demand ControllerCMS ENERGY Management systemsW 324, Rabale MIDCMumbai 400701Tel: 91-022-27696720,86Fax: 91-022-27694585

Medium frequency induction meltingand heating systemsMr D G SastryManaging DirectorPILLAR INDUCTION INDIA PVT LTDA/13, 2nd AvenueAnna NagarChennai 600 102Tel: +91-44-6261703 to 5Fax: +91-44-6260189Email: [email protected]

Most energy efficient tube light systems-T5 LampsMr . Suresh DhingraExecutive Vice PresidentAsian ElectronicsSurya plasaFirst follr, K 185/1 Sarai Julena, new friendscolonyNew Delhi-110025Tel: 011-26317232,26929073,26929075Fax: 011-26837406Email: [email protected]

MotorsMr Saroj PoddarChairmanALSTOM LTD14th Floor, Pragati Devika Tower6, Nehru PlaceNew Delhi 110 019Tel: +91-11-6449906, 6449907, 6449902 / 3Fax: +91-11-6449447Email:

Mr S M TrehanManaging Director



CROMPTON GREAVES LTD1, Dr V B Gandhi MargMumbai 400 001Tel: +91-22-2657937 (Direct)Fax: +91-22-2653740 (Direct), 2028025,2625814Email: [email protected]

Mr M V SrishaGeneral Manager - FAFanuc India LimitedNO. 41, Electronic CityKEONICSBangalore 561 229Tel: 080-8520057 / -0109Fax: 80-852-0051

Mr. R VijayraghavanManaging DirectorINTEGRATED ELECTRIC CO (P) LTD.66 A, GROUND FLOOR,ALSA REGENCY165,ELDAMS ROAD, ALWARPET,Chennai 600018Tel: 080-8362465 / 2047 / 2785 / 2793 / 2465

Multi effect evaporatorPraj IndustriesPraj houseBavdhanPune 411021Tel: 020-2951511/2214Fax: 020-2951718/2951515Email: [email protected]

NEUTRAL COMPENSATORStatic Transformers (P) LtdG-4, A/D, Industrial EstatePolo GroundIndore 452 015Tel: 0731 - 420 793, 420 859Fax: 0731 - 431 968, 420793Email: [email protected]

Oil coolersMr Mohammed MeeranProprietorAASIA RADIATORSP S C Bose RoadJawahar AutonagarVijayawada 520 007Tel: +91-0866-543881Fax: +91-0866-545860

OIL FIRED THERMOPAC/AQUATHERMSYSTEMThermax LimitedThermal Engg. DivisionChinchwadPune 411 019Tel: 020 - 775 941 to 49Fax: 020 - 775 907

oil/gas burners,Mr. Dinesh HarjaiPartnerCrupp MetalsKh. No. 56/1, Mundka,Rohtak Road,New Delhi 110041Tel: 011-5189024, 5474133Fax: 011-5183085

OvensMr N GopinathManaging DirectorFLUIDTHERM TECHNOLOGY PVT LTDSP - 132, III Main RoadAmbattur Industrial EstateChennai 600 058Tel: +91-44-6357390, 6357391Fax: +91-44-6257632Email: [email protected]

Mr M GopalManaging DirectorHIGHTEMP FURNACES LTDI - C, Phase II, P B No 5809Peenya Industrial AreaBangalore 560 058Tel: +91-80-8395917 / 4076 / 1446Fax: +91-80-8397798 / 2661Email: [email protected]

Mr Mithu S MalaneyChairman & Mg DirectorVULCAN ENGINEERS LTD427, Unique Industrial EstateOff Veer Savarkar MargPrabhadevi, Mumbai 400 025Tel: +91-22-4304529 / 3671Fax: +91-22-4225814Email:[email protected]

Plate & spiral heat exchangers,dryers &evaporatorsMr Satish TandonManaging DirectorALFA LAVAL (INDIA) LTDMumbai Pune RoadDapodiPune 411 012Tel: +91-0212-27127721Fax: +91-02121-2797711Email: [email protected]

PLCMr Madhav P. KamatManaging DirectorElectronic Automation Pvt. Ltd.No. 20, K.H.B Industrial Area,YelanhankaBanglore-560064Tel: 080-8567561-562,8567161Fax: 080-8567129

Email: [email protected]

Mr Balagopal KaratExecutive DirectorSPA ENGINEERING COMPANY LTD114, 3rd Floor, M G RoadBangalore 560 001Tel: +91-80-5267981Fax: +91-80-5260818

Pneumatic ToolsDr Jairam VaradarajManaging DirectorELGI EQUIPMENT LTDElgi Industrial Complex, Trichy RoadSinganallur P OCoimbatore 641 005Tel: +91-422-574691 to 5Fax: +91-422-573697Email: [email protected]

Portable Engines & Water Pumping SetsMr Sanjeev GovilGeneral Manager-marketingHonda Siel Power products ltd5th Floor, Kirthi Mahal Building19, Rajendra PalaceNew Delhi-110008Tel: 011-25739103-05Fax: 011-2572218, 25753652Email: [email protected] Gensets,Mr Sanjeev GovilGeneral Manager-marketingHonda Siel Power products ltd5th Floor, Kirthi Mahal Building19, Rajendra PalaceNew Delhi-110008Tel: 011-25739103-05Fax: 011-2572218, 25753652Email: [email protected]

Power & control cablesMr Y KameshManaging DirectorGEM CABLES & CONDUCTORS LTDNo 1, Badam Sohana ApartmentsRaj Bhavan RoadSomajigudaHyderabad 500 082Tel: +91-40-3310486, 3395970Fax: +91-40-3313486Email: [email protected]

Power & Distribution TransformersMr R R DhootChairmanIMP POWER LTDAdvent, 7th Floor12 - A, General J Bhosale MargNariman PointMumbai 400 021Tel: +91-22-2021890 / 886 / 697Fax: +91-22-2026775


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Email: [email protected]. S. DasguptaSr. Mktg. ManagerMarson’s Limited18, Palace Court,1, Kyd Streeet,Calcutta 700016Tel: 033-297346, 2264482Fax: 033-2263236

power & energy monitorMrs Hema HattangadyManaging DirectorEnercon Systems Pvt Ltd.23, KHB Light Industries AreaP B No.6418, YelahankaBangaloreHLTel: 080 – 8460666 / 8460555Fax: 080 – 8460667Email: [email protected]

Power and control cablesMr Hiten A KhatauChairman & Mg directorCABLE CORPORATION OF INDIA LTDLaxmi Building, 4th Floor6, Shoorji Vallabhdas MargBallard EstateMumbai 400 001Tel: +91-22-2666764Fax: +91-22-2632694

Power capacitorsMr. M.D. KilledarManager (Works)Goa Capacitors Pvt. Ltd.14, Corlim Industrial Estate,Corlim, Ilhas,Panaji 403110Tel: 0832-286176/240Fax: 0832-286203

Mr. Shantilal H. KaraniOwnerMalde Capacitors Manufacturing Company401,Madhav Apt, Jawahar Rd,Opp. Rly.St, Ghatkopar (E),Mumbai 400077Tel: 022-5168283/84Fax: 022-5160758

Power ConsultantsMr D B AroraManaging DirectorAcon Power consultants45, Satyanand ViharRampurJabalpur-482008Tel: 91-0761-2667261, 9826246688Fax: 91-0761-2664207Email: acon@sancharnetin

Power control equipments,Mr A SarkarVice PresidentSCHNEIDER ELECTRIC INDIA LTD58, MIDC Area, SatpurNashik 422 007Tel: +91-253-350394 / 95 / 96Fax: +91-253-350771Email: [email protected]

Power factor compensationNeptune India ltdNeptune houseC 270 SFS Sheikh sarai, Phase INew Delhi 110017Tel: 011-6013367-70Fax: 011-6013371Email: [email protected]

Power Factor controllerCMS ENERGY Management systemsW 324, Rabale MIDCMumbai 400701Tel: 91-022-27696720,86Fax: 91-022-27694585

Mr. R. K. IyerVice PresidentSaha Sprague LimitedNo.805, North Rear Wing, 8th Floor, ManipalCentre, 47, Dickenson Road,Bangalore 560042Tel: 080-5595463, 5595266Fax: 080-5595463

Power plant & industrial cooling towersMr. N. VenkatanarayananManaging DirectorEnviro Clean Systems Ltd.Hema Nagar, P.O.Box No.10,P.O. Uppal,Hyderabad 500039Tel: 040-7170876/879/881Fax: 040-7172717/4726

Power plant equipmentMr Pradeep MallickManaging DirectorWARTSILA INDIA LTD76, Free Press House, Nariman PointMumbai 400 021Tel: +91-22-2815601 / 5598, 28175995 / 5601Fax: +91-22-2842083Email: [email protected]

Process control instrumentsMr Sudhir JalanChairman & Mg DirectorBELLS CONTROLS LTDBells House, 21, Camac StreetKolkata 700 016Tel: +91-33-2475211 / 15Fax: +91-33-2471620

Email: [email protected] Amod GujralManaging DirectorEncardio-Rite Electronics Pvt LtdA - 7, Industrial Estate, Talkatora RoadLucknow 226 011Tel: +91-522-416460, 418855Fax: +91-522-418968Email: [email protected]

Mr P V KannanManaging DirectorMICROMAX SYSTEMS LTD104, Salai RoadSethu Rukmani ComplexTrichy 620 003Tel: +91-431-760704Fax: +91-431-762422Email: [email protected]

Mr K N BalajiChief Operating OfficerEurotherm Del India Ltd152, Developed Plots EstatePerungudiChennai - 600 096Tel: 044-4961129Fax: 044-4961831Email: [email protected]

Mr N C AgrawalManaging DirectorMEDITRONSIRTDO Industrial EstateP O BIT, MesraRanchi 835 215Tel: +91-651-275875 / 628Fax: +91-651-275841Email: [email protected],[email protected]

Program logic control (PLC)Mr Laxman R KatratMg Director & CEOKATLAX ENTERPRISES PVT LTD507, Golden TriangleStadium RoadAhmedabad 380 014Tel: +91-79-6461991 / 646, 6854693,6851521Fax: +91-79-6464719 (W), 6853978

Programmable controllersMr Ranjan Kumar DeCountry ManagerALLEN BRADLEY INDIA LTDC - 11, Industrial AreaSite IV,shahiabadGhaziabad 201 010Tel: +91-120-471112 / 0103 / 0105 / 0164Fax: +91-120-4770822Email: [email protected],[email protected]



PumpsMr D K HohensteinChief Executive OfficerKSB PUMPS LTDMumbai Pune RoadP O PimpriPune 411 018Tel: +91-20-7472006, 7473684Fax: +91-20-7476120Email: [email protected]

Mr K C DhingraManaging DirectorWESTERN INDIA MACHINERY CO PVTLTDPark PlazaNorth Block, 6E, 6th Floor71, Park StreetKolkata 700 016Tel: +91-33-2468913 / 9674Fax: +91-33-2468914

radiant heaterMr. Ashok TannaManaging DirectorVinosha Boilers Pvt. Ltd. And Taurus HeatSystemsBaarat House, Ist Floor,104, Apollo Street, Fort,Mumbai 400001Tel: 022-2674590, 2676447Fax: 022-2611515

RADIANT TUBE RECUPERATIVEHEATERMr U V RaoDirectorALLIED CONSULTING ENGINEERSPVT LTDAllied HouseRoad No 1, chemburMumbai 400 071Tel: +91-22-5284028Fax: +91-22-5283805Email: [email protected]

Thermax LimitedThermal Engg. DivisionChinchwadPune 411 019Tel: 020 - 775 941 to 49Fax: 020 - 775 907

Reactive compensatorEmco Electronics106, Industrial areaSion (East)Mumbai 400022Tel: 022-24096731/782Fax: 022-24096039

Reactive power compensationequipment and systemsMr. S. M. Subba RaoAdviserMeher Capacitors (P) Ltd.52/1, Basappa Road,Shantinagar,Bangalore 560027Tel: 080-2236879, 2241272Fax: 080-2225325

ReactorsMr Ranjit PuriChairman & Mg DirectorINDIAN SUGAR & GENERALENGINEERING CORPORATION (THE)A - 4, Sector 24Noida 201 301Tel: +91-118-4524071 / 72Fax: +91-118-4528630, 4529215, 4542072Email: [email protected]

Reciprocating & centrifugal pumpsMr Hemant DidwaniaDirectorINDIAN COMPRESSORS LTD33, Okhla Industrial EstateNew Delhi 110 020Tel: +91-11-6839440 / 9, 635030Fax: +91-11-6840020

RecuperatorsMr R K AgrawalChief Executive OfficerEASTERN EQUIPMENT & ENGINEERSS - 14, Civil TownshipRourkela 769 004Tel: +91-61-502508, 503898Fax: +91-61-503898Email: [email protected]

RefractoreisMr.R.RajagopalanDy.General ManagerCarborundum Universal Limited-SuperRefractoriesPlot Nos.102&103,Sipcot Industrial ComplexPhase IIRanipet-632403Tel: 04172-244197,244951,244582Fax: 04172-244982Email: [email protected]

Mr N anjiahManaging PartnerAnnapurna Annapurna Technical ceramics21-118Kakani NagarVaisag 534007Email: [email protected]

Mr I C SinhaManaging DirectorBURN STANDARD CO LTD10 - C, Hungerford StreetKolkata 700 017Tel: +91-33-2471772 / 067 / 762Fax: +91-33-2471788Email: [email protected]

Mr Kantilal GugaliaChief ExecutiveKATNI TILE WORKSP B No 62Katni 483 501Tel: +91-7622-52682, 53212, 50894Fax: +91-7622-52733

Mr M L ChandExecutive DirectorOCL INDIA LTDRajgangpur,Dist. Sundergarh 770 017Tel: +91-6624-220121 (4 lines)Fax: +91-6624-220933 / 133 / 733Email: [email protected]

Mr Arun BhalotiaManaging DirectorTATANAGAR REFRACTORIES &MINERALS CO LTDChamber BhawanBistupurJamshedpur 831 001Tel: +91-657-427187, 435039, 428044Fax: +91-657-428044

Mr K S SwaminathanMg Director & Vice ChairmanTATA REFRACTORIES LTDP O BelapurJharsuguda 768 218Tel: +91-6645-50260Fax: +91-6645-50243

Daka Monolitics Pvt. Ltd.32-B, Samachar MargOpp. Allahabad BankMumbai 400 023Tel: 044 - 265 4837

Refrigeration Dryers.Mr. Rajnish JoshiExe. Vice PresidentDelair India Pvt. Ltd.20, Rajpur Road,New Delhi 110054Tel: 011-2912800Fax: 011-2915127, 2521754Email: [email protected]


645

Rotary kilnsMr Madhukar SinhaManaging DirectorAssociated Plates & Vessels Pvt Ltd 1/A -14, 15 & C - 17, Industrial AreaBokaro Steel City, Bokaro 827 104Tel: +91-6542-51034, 51434Fax: +91-6542-51334Email: [email protected],[email protected]

RotometersAQUAMEAS (Danfoss)Commerce avenue, 3rd floor,Mahaganesh SOC., Paud RoadPune 411 038Tel: +020 544 9767, 544 9757Fax: +020 542 0401Email: [email protected]

EUREKA INDUSTRIAL EQUIPMENTSPVT. LTD.Royal Chambers, Paud Road,Pune 411038Tel: 91 20 5443079 / 4004535/ 4004554Fax: 91 20 5441323

Fitzer Instruments (India) Pvt. Ltd.Near Ambivli Station (W)P.O. MohoneThane 421 102Tel: 0251 – 2271321Fax: 0251 – 2271336Email: [email protected]

SCADA System for Energy managementMr. Shashank KalkarDirector MarketingRMS Automation Systems Pvt. Ltd.W-218, M.I.D.C.,Ambad,Nasik 422010Tel: 0253-383261, 384604Fax: 0253-383261, 384604

Screw compressorsMr Jasmohan SinghManaging DirectorFRICK INDIA LTD21.5 KM, Main Mathura RoadFaridabad 121 003Tel: +91-129-5275691 (4 lines), 5270546Fax: +91-129-5275695Email: [email protected]

Sections & blocks for thermal insulationMr Shreyas C ShethManaging DirectorAMOL DICALITE LTD301, Akshay53, Shrimali Society,’NavrangpuraAhmedabad 380 009Tel: +91-79-6443331, 6560458Fax: +91-79-6569103

Separator and other oil & gasprocessing equipmentsMr A D ParekhGeneral ManagerHDO PROCESS EQUIPMENT ANDSYSTEMS LTD5/1/2, GIDC Industrial EstateVatvaAhmedabad 382 445Tel: +91-79-5830591 to 94Fax: +91-79-5833286Email: [email protected]

Servo voltage stabiliserGreen Dot electric corporationG 9, Hem Kunt Tower98, Nehru Place,New delhi 100019Tel: 011-26416395Fax: 011-26222088Email: [email protected]

Slip Power Recovery SystemsMr A M NaikMg Director & CEOLARSEN & TOUBRO LTDL & T HouseBallard EstateMumbai 400 001Tel: +91-22-2618181Fax: +91-22-2620223, 2610396, 2622285Email: [email protected]

Mr J SchubertManaging DirectorSIEMENS LTD130, Padurang Budhkar MargWorliMumbai 400 018Tel: +91-22-4931350 / 60Fax: +91-22-4950552Email:

Smart demand controllerMrs Hema HattangadyManaging DirectorEnercon Systems Pvt Ltd.23, KHB Light Industries AreaP B No.6418, YelahankaBangaloreHLTel: 080 – 8460666 / 8460555Fax: 080 – 8460667Email: [email protected]

Soft starterExcellent Industrial Instruments1/63, Type ESidco NagarVillivakkamChennai 600049Tel: 044-6172977Fax: 044-6172531

Mr. K. W. KekaneDirector SalesMinilec Marketing Services Pvt. Ltd.S.No. 1073/1-2-3, At. Post. Pirancoot,Tal. Mulshi,Pune 412111Tel: 02139-22162, 22354 to 57Fax: 02139-22134, 22180

Mr Ranjan Kumar DeCountry ManagerALLEN BRADLEY INDIA LTDC - 11, Industrial AreaSite IV,shahiabadGhaziabad 201 010Tel: +91-120-471112 / 0103 / 0105 / 0164Fax: +91-120-4770822Email: [email protected],[email protected]

Crompton Greaves LimitedElectronics Technology Div.71 / 72, MIDC, SatpurNashik 422 007Tel: 0253 - 351 069Fax: 0253 - 351 492Email:

Mr. Sudhir NaikVice President - Corporate Mktg.Hi-Rel Electronics LimitedB -117 & 118, GIDC,Electronics Zone, Sector-25Gandhi Nagar 382044Tel: 02712-21636, 22531Fax: 02712-24698

Project & SupplyA - 605, Sunsweptokhandawala ComplexSwami Samarth Nagar, 4, Bungalow,Andheri (West)Mumbai 400 050Tel: 022 - 626 6584

Vrushali Services5, Swapna Nagar, Hanuman Nagar,NearDNC High SchoolNandivli Road, Dombivli (East)-Mumbai- 421 201Tel: 0251 – 472 426Fax: 0251 – 431 151

Software for promoting energyconservationMr. Rahul S. WalawalkarProduct Manager - Eco Lumen & ManagerTata Infotech Ltd.Manish Commercial Centre,216-A, Dr. Annie Besant Rd., Worli,Mumbai 400025Tel: 91 22 8291261Fax: 91 22 8290214



Software to measure the efficiency ofmotorsMr Narayana SharmaDirectorV B India# 1032, 14th main, 7th crossBTM lay out1st stage, 1st crossBangalore 560029Tel: +91 (80) 6781315Fax: 91-080-6687798Email: [email protected]

Soot Blower with Industrial BoilersMr. R. RajshekharManaging DirectorR R Techno Mechanicals (P) Ltd.94, Thiru Vi Ka Industrial Estate,Guindy,Chennai 600032Tel: 044-2346693Fax: 044-4918183, 2333204Email:

Sound proof gensetsMr R N KhannaManaging DirectorCONTROLS & SWITCHGEAR CO LTD222, Okhla Industtrial EstateNew Delhi 110 020Tel: +91-11-6918834 to 37, 6836170 / 020Fax: +91-11-6848241 / 7342 / 8245Email: [email protected]

Speciality Refrigerants/PropellantsK.GaneshMarketing Manager(South Asia)RegionalSegment ManagerDupont Flurochemicals E.I.DuPont India LtdArihant Nitco Park,^th Floor90,Dr.Radha Krishnan RoadMylaporechennai 600004Tel: 044-8472800,8473752(D)Fax: 044-8473800Email: [email protected]

split air conditionerMr Brij Raj PunjChairmanLLOYD ELECTRIC & ENGINEERINGLTDM - 13A, Punj HouseConnaught PlaceNew Delhi 110 001Tel: +91-11-3329091 to 98Fax: +91-11-3326107Email: [email protected]

star -delta-star converterMr M VijayasarathyManaging DirectorVIJAY ENERGY PRODUCTS PVT LTDS P - 75, Ambattur Industrial EstateChennai 600 058Tel: +91-44-6254326, 6256883Fax: +91-44-8282906, 6255185Email: [email protected]

Ambetronics4B PushotamGirgaonNear Dream Land CinemaMumbai 400004Tel: 022-28371143

Excellent Industrial Instruments1/63, Type E, Sidco NagarVillivakkamChennai 600049Tel: 044-6172977Fax: 044-6172531

Steam jet ejectorsForbes MarshallPB No 29, Mumbai-Pune roadKasarwadiPune 411034Tel: 91-0212-21279445Fax: 91-0212-797413

MAZDA CONTROLS LTDMAZDA HOUSEANCHWATI 2ND LANE, AMBAWADIAHMEDABAD 380006Tel: 79 6431151Fax: 79 6565605

STEAM TRAP MONITORSpirax Marshall LimitedP B No.29, Mumbai-Pune RoadKasarwadi,Pune 411 034Tel: 020 - 794 495Fax: 020 - 797 593/ 413

Steel tubes for boilersTube Products of IndiaPost Box No. 4, AvadiChennai 600 054Tel: 91 44 6384040Fax: 91 44 6384051Email: [email protected]

Superheater & EconomiserMr Ranjit PuriChairman & Mg DirectorINDIAN SUGAR & GENERALENGINEERING CORPORATION (THE)A - 4, Sector 24Noida 201 301Tel: +91-118-4524071 / 72Fax: +91-118-4528630, 4529215, 4542072Email: [email protected]

SYNTHETIC FLAT BELTSElgi Ultra Industries Ltd.‘Elgi House’, Trichy RoadRamanathapuramCoimbatore 641 045Tel: 0422 – 304141Fax: 0422 - 311 740

Habasit Iakoka Pvt. Ltd.C - 207, Kailas EsplanadeOpp. Shreyas CinemaL B S Marg, GhatkoparMumbai 400 086Tel: 022 - 500 2464Fax: 022 - 500 2466

NTB groupNTB House, A-302Road No.32, Wagle Estate,Thane 400 604Tel: (091)-22-5822118,5821582Fax: 58100565823778

NTB International ltdA 302, Road no 32Wagle estateThane 400604Tel: 022-25821582, 25822118Fax: 022-25810056Email: [email protected]

Systems engineering for captive powergenerationMr D R DhingraManaging DirectorCONTINENTAL GENERATORS PVT LTD3869, Behind Primary School, G B RoadDelhi 110 006Tel: +91-11-7535566 to 68, 525632, 522983,528510Fax: +91-11-7516598, 528510

TEMPERATURE INDICATORCONTROLLER (TIC)Ensave Systems Private Limited3, Anand Shopping CenterSecond Floor, Bhattha, PaldiAhmedabad 380 007Tel: . 079 – 662 1116Fax: 079 – 663 7907

Thermal power equipment includingsteam turbinesMr K G RamachandranChairman & Mg DirectorBHARAT HEAVY ELECTRICALS LTDBHEL HouseSiri FortNew Delhi 110 049Tel: +91-11-6001010Fax: +91-11-6493021, 6492534


647

Thermic filud heatersAero therm systems pvt ltdPlot no 1517 Phase IIIGIDC VatwaAheemedabad 382445Tel: 079-5890158Fax: 079-5834987Email: [email protected]

Thyristorised Power factor ControllerMr. Shashank KalkarDirector MarketingRMS Automation Systems Pvt. Ltd.W-218, M.I.D.C., Ambad,Nasik 422010Tel: 0253-383261, 384604Fax: 0253-383261, 384604

TransformerMr Saroj PoddarChairmanALSTOM LTD14th Floor, Pragati Devika Tower6, Nehru PlaceNew Delhi 110 019Tel: +91-11-6449906, 6449907, 6449902Fax: +91-11-6449447

Mr G V RaoCMDRowsons Marketing Pvt Ltd4, 7 th Street GopalapuramMadras 600 086Tel: 044 - 28110196/28112958Fax: 044 - 2815741/28114021Email: [email protected]

Mr N J DananiVice Chairman & Mg DirectorBHARAT BIJLEE LTDCentral Marketing Office (Motor)P O Box 100, Kalwe, Thane Belapur RoadMumbai 400 601Tel: +91-215-7691656Fax: +91-215-7691401 / 2

Mr Rahul N AminChairman & Mg DirectorJYOTI LTDIndustrial Area, P O Chemical IndustriesVadodara 390 003Tel: +91-265-380633, 380627Fax: +91-265-380671, 381871Email: [email protected]

Mr Sylvester P MoorthyGeneral ManagerMEASUREMENT SYSTEMS PVT LTD66, 4th Main RoadIndustrial TownRajajinagarBangalore 560 044Tel: +91-80-3300347 / 494 / 522Fax: +91-80-3303141

TRANSVECTOR NOZZLESGeneral Imsubs Pvt. Ltd.3711/A, GIDCPhase IV, VatvaAhmedabad 382 445Tel: 079 - 584 0845/ 2503Fax: 079 - 584 1846Email: [email protected]

S J United300/ 1-B, 16th CrossUpper Palace OrchardsBangalore 560 080

Trivector monitorMrs Hema HattangadyManaging DirectorEnercon Systems Pvt Ltd.23, KHB Light Industries AreaP B No.6418, YelahankaBangaloreHLTel: 080 – 8460666 / 8460555Fax: 080 – 8460667Email: [email protected]

universal power & energy meterMrs Hema HattangadyManaging DirectorEnercon Systems Pvt Ltd.23, KHB Light Industries AreaP B No.6418, YelahankaBangaloreHLTel: 080 – 8460666 / 8460555Fax: 080 – 8460667Email: [email protected]

Vaccum PumpsKakati Karshak Industries Pvt. LtdNacharam Industrial AreaHyderabad 500 076Tel: 91-40-7153104/05Fax: 91-040-7171980Email: [email protected]

Nash vaccum pumps67 UPS, Kaggadaspura ExtensionGuru LayoutBangaloreTel: (+91) 80 - 521 49 38Fax: (+91) 80 - 528 43 37Email: [email protected]

PPI PUMPS PVT LTD4/2 PHASE 1 G I D C VATWAAHMEDABAD 382445Tel: 079-5832273/4 / 5835698Fax: 079-5830578

Variable Drives,Mr. Liakat AliProprietorPremier Electric CompanyPlot No.7,12/2 Mathura Road,Faridabad 121002Tel: 0129-270858, 274311Fax: 0129-270858

Variable fluid couplingsMr Praveen SachdevMg Director & CEOGREAVES LTD1, Dr V B Gandhi MargP O Box 91Mumbai 400 001Tel: +91-22-2671524 / 4913Fax: +91-22-2677850, 2652853Email:

Variable Frequency DriveMr Ramnath S ManiManaging DirectorCONTROL TECHNIQUES INDIALIMITED117/B, Developed PlotIndustrial EstatePerungudiChennai 600 096Tel: 044-4961123 / 1130 / 1083

Mr. BalagopalManaging DirectorDynaspede Integrated Systems (P) Limited136-A Sipcot Industrial ComplexHosur 635126Tel: 91-4344 - 276915, 276813Fax: 91-4344 - 276841

Dr M T SantPresidentTB Wood’s (India) Pvt Ltd27A, II Cross, Electronics CityHosur RoadBanglore 561229Tel: 080 8520123Fax: 080 8520124Email: [email protected]



Mr Ranjan Kumar DeCountry ManagerALLEN BRADLEY INDIA LTDC - 11, Industrial AreaSite IV,shahiabadGhaziabad 201 010Tel: +91-120-471112 / 0103 / 0105 / 0164Fax: +91-120-4770822Email: [email protected],[email protected]

Asea Brown Boveri ltdPlot No 5 & 6, II PhasePeenya Industrial AreaP B no 5806, PeenyaBangalore 560058Tel: 080-8370416 / 8394734 extn 2322 /6691375Fax: 080-8399178 / 8396537

Mr S M TrehanManaging DirectorCROMPTON GREAVES LTD1, Dr V B Gandhi MargMumbai 400 001Tel: +91-22-2657937 (Direct)Fax: +91-22-2653740 (Direct), 2028025,2625814Email: [email protected]

Mr. Sudhir NaikVice President - Corporate Mktg.Hi-Rel Electronics LimitedB -117 & 118, GIDC,Electronics Zone, Sector-25Gandhi Nagar 382044Tel: 02712-21636, 22531Fax: 02712-24698Email:[email protected]

Mr. K. W. KekaneDirector SalesMinilec Marketing Services Pvt. Ltd.S.No. 1073/1-2-3, At. Post. Pirancoot,Tal. Mulshi,Pune 412111Tel: 02139-22162, 22354 to 57Fax: 02139-22134, 22180

Mr Debashish GhoshManager -commercial marketing productsRockwell AutomationC II, Site IV,Sahibabad Industrial AreaGhaziabad dist-201010

Tel: code-4895247-252Fax: 4895225-227Email: [email protected]

Mr J SchubertManaging DirectorSIEMENS LTD130, Padurang Budhkar MargWorliMumbai 400 018Tel: +91-22-4931350 / 60Fax: +91-22-4950552Email:

Waste Heat RecoveryMr U V RaoDirectorALLIED CONSULTING ENGINEERSPVT LTDAllied HouseRoad No 1, chemburMumbai 400 071Tel: +91-22-5284028Fax: +91-22-5283805Email: [email protected]

Mr Robert A ChildsManaging DirectorDEUTSCHE BABCOCK POWERSYSTEMS LTD18 / 2A, SennerkuppamBy - Pass RoadPoonamalleeChennai 600 056Tel: +91-44-4985949 / 1250Fax: +91-44-4992221Email: [email protected]

Kuppuraju KPresident-TechnicalCetharVessels Pvt ltd4,Dindigul road,tiruchirappillyTel: 0431-482452/53Fax: 0431-481079Email: [email protected]

Waste Heat Recovery RecuperatorsMr R P SoodManaging DirectorENCON FURNANCES PVT LTD14/6, Mathura RoadFaridabad 121 003Tel: +91-129-274408, 275307 / 607Fax: +91-129-276448:

Waste Heat Recovery systemMr K C RanaManaging DirectorAVU ENGINEERING PVT LTDA - 15, APIE

BalanagarHyderabad 500 037Tel: +91-40-3773235 / 2343Fax: +91-40-3772343 / 3235Email: [email protected]

Cristopia Energy systems303, Kothari ManorNO 10, Diamon colonyNew PalasiaIndore 452001Tel: 91-0731-2433644, 2536624Fax: 91-0731-2533766Email:

Ensys Technologies (I) Pvt. Ltd.B/69-A, Seventh AvenueAshok NagarChennai 600 083Tel: 044 - 3711259/ 297Fax: 044 – 4897752

Mr C E FernandesChairman & Mg DirectorGEI HAMON INDUSTRIES LTD26 - A, Industrial AreaGovindpuraBhopal 462 023Tel: +91-755-586692, 586922, 587147Fax: +91-755-587678, 586619Email: [email protected]


Megatherm Engineers & Consultants Pvt.Ltd.10, Kodambakkam High RoadChennai 600 034Tel: 044 - 823 3528/ 3707Fax: 044 - 825 8559

Mr. M. M. NarangProprietorMembrane India347, Udyog Vihar, Ph.-II,Gurgaon 122016Tel: 0124-341159Fax: 0124-342717


649

WHR boilersMr P V RajuManaging DirectorThermal Systems (Hyd) Pvt. Ltd.Plot No.1, Apuroopa TownshipIDA, JeedimetlaHyderabad 500 055Tel: 040 - 309 8272/ 8273Fax: 040 - 309 7433Email: [email protected]



1 Confederation of Indian Industry ALL TYPESEnergy Management Cell35/1, Abhiramapuram 3rd StreetAlwarpetChennai - 600018

2 National Productivity Council ALL TYPES5/6, Institutional AreaUtpadaka Bhawan, Lodi RoadNew Delhi-110003

3 The Energy & Resources Institute All typesDarbari Seth BlockHabibat Place, Lodi RoadNew Delhi-110003

4 National Council for Cement and CementBuilding materials p-121,South Extension Part II Ring Road, New Delhi-110019

5 Cement Corporation of India Cement Plants59, Nehru Place, New Delhi-110019

6 National Sugar Institute SugarMinistry of Food & Civil SuppliesDepartment of FoodKanpur

7 Engineers India Ltd. Chemical & ProcessEngineers India Bhawan1, Bhikaji Cama PlaceR.K.Puram, New Delhi-110066

8 M/s, North India Technical Consultancy Thermal Audits in Paper &Organisation Ltd. S.C.O 131-132(1st Floor) Sector 17-C, Chandigarh-160017

9 Dy. National Project Director Process Industries All typesPHD chamber of Commerce & industryRamakrishna Dalmia Wing, PHD House, Thaper Floor,Opp. Asian GamesVillage New Delhi-110020

List of Energy Auditors


651

10 M/s. SGS India limited Electrical & Thermal210,Netaji Subhash RoadNew Delhi-110020

11 Balmer Lawrie & Company Ltd. All types21,Netaji Subhash RoadCalcutta-700001

12 Project & Development India Ltd. FertilizerP.O.Sindri, Distt. DhandbanBihar-828122

13 FACT Engineering & Design (p) Organisation FertilizerP.O.Sindri, Distt. DhanbanBihar-828122

14 Industrial and Business Management Textile,jute,Tea,EngineeringConsultants Limited & Chemical27, Weston Street, Room-226Calcutta-700012

15 M/s. National Small Industries Corpn. Ltd Thermal & Electrical AuditIndustrial Estate BamunimaidanGuwahati-21

16 M/s. Maharashtra Industrial & Tech. All typesConsultancy Organisation Ltd.(MITCON)Kubera Chambers, 1ST FloorDr. Rajendra Prasad Path, Shivaji NagarPune-411005

17 Ahmedabad Textile Industry’s Assn. TextileP.O.Polytechnic, Ahmedabad-380015

18 The Bombay Textile Research Association TextileLal Bahadur Shastri Marg, Ghatkopar (west)Bombay-400086

19 M/s. Associated Energy Consultants, Thermal & Electrical Energy Audit3rd Floor, 44 Cawasji Patel, FortBombay-400023

20 Dalal Consultants Thermal & Electrical Energy404, H.K.House, Ashram Road AuditAhmedabad-380009



21 M/s. Mecon Services Thermal & Electrical118.New RmdaspethNagpur-440010

22 M/s. Kirloskar Consultants Ltd. All types 917/19-A, A Shivaji NagarFergusson College Road Pune-411004

23 M/s. Electrical Research and Thermal & ElectricalDevelopment AssociationP.B.No 760 Mkarapura Ind. EstateOpp. Makarpur VillageVadodar-390010

24 M/s NSIC Technical Services Centre Thermal & Electrical(Formerly Prototype Development &Training Centre), Aji Industrial AreaBhavnagar RoadRjkot-360003

25 Fichtner Consulting Engineers India All typesPvt.Ltd. “Ganesh Chambers”143,Eldams RoadChannai-600018

26 M.K.Raju Consultants Pvt.Ltd. All typesEnergy Management Division16, Srinagar Colony, Temple AvenueChannai-600015

27 Industrial & Technical Consultancy All typesOrganisation of Tamil Nadu Ltd.50-A, Graemes RoadChennai-600008

28 M/s. Andhra Pradesh Productivity Council Thermal & Electrical Audit3-6-69/4/3, Basheer BaghHyderabad-500029

29 M/s Andhra Pradesh Industrial and All typesTechnical Consultancy Organisation Ltd.Parisharma Bhavanam, 8th Floor, Eastern Wing, 5-9-58/B, BasheerbaghHyderabad-500029

List of Energy Auditors


653

30 M/s.Central Power Research Institute All typesEnergy Research Centre, P.B.No.3506Srikrishna Nagar, SreekariyamThiruvananthapuram-695017(Kerala)

31 The school of Energy Bharathidasan Electrical & ThermalUniversity, Khajamalai CampusTiruchirappalli-620023 Tamil Nadu

32 M/s. Separation Engineers Pvt.Ltd. Electrical & Thermal5,Masilamani Colony, Sir P.S.Sivasamy SalaiPalur Kannaippa St., MylaporeChannai-600004 (India)

33 M/s. Crompton Greaves Ltd. Electrical & Thermal3A, Kodambakkam High RoadNungambakkam Channai-600034

34 M/s.Energy Economy & Environmental Cosultants Thermal & Electrical264,6th Cross, 1st Stage IndiranagarBangalore-560038

35 M/s. S.SM.Shakthi Consultants Thermal & Electrical17/1, Nehru Nagar, 1st Main Road AdyarChennai-600020



DCM Shriram Consolidated Ltd.5th flr. Kanchenjunga Bldg.,18 Barakhamba

RoadNew Delhi - 110 001Telephone : (011) 331-6801Fax : (011) 331-8072Email : [email protected] Contact Person : Dr. G.C. Datta Roy, Chief

Executive Officer

INTESCO Asia Ltd.Oakland,114 Ulsoor Road CrossBangalore - 560 042Telephone : (080) 558-3726Fax : (080) 559-6036Email : [email protected] Contact Person : Mr. R. Vasu, President & CEO

Saha Sprague Limited266,Dr. Annie Besant Road,1st flr.Opp. Passport Office,WorliMumbai - 400 025Telephone :(022) 421-0234Fax : (022) 430-1969Email : [email protected] Person : Mr. Manoj Saha, Director

Saket Projects Ltd.Saket House,Pancheel,UsmanpuraAhmedabad - 380 013Telephone : (079) 755-1817Fax : (079) 755-0452Email : [email protected] Person : Mr. Kamal Khokhani, Director

See Tech solutions Pvt.Ltd.H-001,Sanchayani Prestige,Swavalambi NagarNagpur - 440 022Telephone : (071) 226-4433Fax : (071) 226-5816Email : [email protected] Person : Mr. Millind Chittawar, Chief

Consultant

Thermax Energy Performance Services LimitedSai Chambers,15,Mumbai Pune Road

WakadewadiPune - 411 003Telephone : (020) 551-1010Fax : (020) 551-1144Contact Person : Mr. Shishir Joshipura, Chief

Executive Officer

Sudnya Industrial Services Pvt. Ltd.5 Raj Apartments,28 Pushpak Park,AundhPune - 411 007Telephone : (020) 5888-5601Fax : (020) 5898-6290Email : [email protected] Person : Mr. Shishir Athale, Director

Shri Shakti Alternative Energy LimitedVenus Plaza BegumpetHyderabad - 500 016Telephone : (040) 790-7979Fax : (040) 790-8989Contact Person : Mr. D.V. Satya Kumar, Managing

Director

Basera Environmental & Energy ManagementGroupKewra Dam RoadBhopalTelephone : (075) 523-4731Fax : (075) 586-8382Email : [email protected] Person : Mr. Rahul Saxena, CEO

Agni Energy Services Pvt. Ltd.1-A/1 kautilya 6-3-652 SomajigudaHyderabad - 500 082Telephone : (040) 606-2172Fax : (040) 339-4529Email : [email protected] Person : Mr. G.S. Varma, President

Asian Electronics LimitedD-11 Road No.28 Wagle Industrial AreaThane - 400 064Telephone : (022) 583-5504Fax : (022) 582-7636Email : [email protected] Person : Mr. Suresh Shah, Chairman &

Managing Director

List of Indian Energy Service Companies (ESCOs)

List of Energy Service Companies


655

Financial Mechanism


656Financial Mechanism

ENERGY CONSERVATION AND COMMERCIALISATIONPROGRAMME (USAID FUNDED)

The Energy Conservation and Commercialisation Programme ( ECO) project is a joint projectbetween USAID and the Government of India. The project aims to promote widespreadcommercialisation of end-use energy efficiency technologies and services in India, therebyreducing greenhouse gas emissions per unit of electricity generated.

The project grant agreement for the project between the Government of India and USAID wassigned on January 28, 2000.(USAID Project No: 386-0542)

Project Assistance Completion Date: September 30, 2004

Objective To promote commercialisation of energy efficiency technologies andservices

Sectors Energy efficiency projects, non-sugar cogeneration, demand sidemanagement with utilities and energy service companies (ESCO’s)

Beneficiary Public / private companies

Eligibility Project should be innovative, demonstrative and replicable. Shouldachieve significant energy saving and be impact making. Assistancefor a specific project and would cover civil works, plant and machinery,miscellaneous fixed assets, preoperative expenses etc.

Terms

Amount 50% eligible project cost or Rs 50 million whichever is lower

Repayment 6-8 years (including moratorium)

Type Rupee loan and Conditional Loans

Rate of interest 8% - 9%

ContactMr.Anil Malhotra,Chief ManagerICICI Bank LtdICICI Tower, 2nd Floor, North Tower,Bandra-Kurla Complex,Mumbai - 400 051Tel: 022 26536813e-mail: [email protected]


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State Bank of India - Project Uptech to Finance EnergyEfficiency

SBI has launched an Uptech Project to promote Energy Efficiency measures in small andmedium enterprises. The project will be implemented in the following Circles where there isgood scope for energy saving in respect of SME sector. (i) Ahmedabad (ii) Bangalore (iii)Chennai (iv) Hyderabad (v) New Delhi (vi) Mumbai (viii) Patna. The project will be of 3 yearsduration, which may be extended if required. The Circle will identify 10 units enjoying financeunder sole banking arrangement which satisfy following criteria and are interested in adoptingEE measures.

i) Investments in plant and machinery are less than Rs 10 crore as at the date of last BalanceSheet.

ii) Credit Rating ranging SB-1 to SB-4.

These 10 units will be assisted in the following manner to implement EE projects.

i) The consultant will be selected jointly by the unit and CCO of the Circle from the list ofconsultants available with petroleum Conservation Research association (PCRA), IndianRenewable Energy Development Agency (IREDA), ICICI, state-level energy developmentagencies. The services of Institutes like National Productivity Council (NPC), Tata EnergyResearch Institute (TERI) can be used.

ii) The consultants will conduct energy audit and prepare detailed project report (DPR).

iii) The DPR will be appraised by Consultancy Services Cell for techno-economic aspects.

iv) The bank will finance the project as per financial package detailed below.

Financial PackageEnergy efficiency project have following cost components

i. Energy audit charges

ii. Consultancy fees for detailed project report (DPR)

iii. Consultancy charges for implementation of project

iv. Cost of plant and machinery including the cost of retrofitting /renovating / modification ofexisting items, miscellaneous assets for establishing a monitoring system.

v. Charges for monitoring the energy efficiency on long-term basis.

The EE projects result in additional cash flow due to savings of energy and this is the crucialparameter for the success of the project rather than additional assets generated. Hence thenorms for adequacy of security available in EE project needs to be liberal. The appraisal ofsecurity aspects of financial package of the project should be done after taking this intoconsideration.

The project has three distinct stages of implementation. The finance will be sanctioned in twostages.

Stage I: Energy Audit and Preparation of Detailed Project Report



In the first stage the unit is studied to explore the scope of energy saving and improvingenergy efficiency and a detailed plan is drawn up outlining various steps to be undertaken,investments required and likely benefits. The cost involved is the Consultant’s charges forthese studies namely Energy Audit and Detailed Project Report (DPR). SBI proposes toextend grant under scheme for financing energy efficiency projects as detailed below:

PurposeTo finance cost of energy audit and detailed project report.

Financing patterna. Grant from TDISCF# 50% of the cost subject to a maximum of Rs. 50,000/-b. Borrower’s contribution Balance amount#Technology Data and Information Services Centre Fund

Scheme of Grant for Energy Efficiency ProjectsIn case of energy efficiency projects the units will need incentives to encourage to take initialsteps of i) energy audit which will lead to in-depth study of units operations and processesfor saving the energy and ii) detailed project report (DPR) giving Action Plan. The Bankproposes to provide a grant of 50 percent of cost of energy audit and DPR subject tomaximum of RS. 50,000/-, to each unit selected under the Project Uptech.Sanctioning Authority : CCC of the circleDocumentation : Letter of agreement from borrower

The Consultancy Cell will scrutinise the DPR and if the venture is found acceptable, theproject will be financed as per details given below:

Stage II: Acquisition/ Modification/ Rrenovation of Plant and Machinery,and Establishment of Monitoring System

PurposeTo finance cost of plant and machinery including cost of renovating /modification of existingitems, miscellaneous assets, for establishing monitoring system, fees of consultant or contractorfor implementation and monitoring of the project.

Financing Pattern MTL

Quantum 90 percent of cost subject to maximum ofRs.100 lakh and minimum of Rs.2 lakh

Interest SBIMTLR

Tenure 5-7 years including maximum moratorium period of 1 year

Security i) Primary -Assets proposed to be acquired

ii) Collateral – Extension of charge on the assets provided as securityfor the existing advance including extension of guarantee coverwhere available


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Sanctioning Authority As per scheme for delegation of financial powers

Documentation As applicable for SSI and C&I units depending upon the marketsegment

If the MTL exceeds Rs. 100 lakh the balance portion of the projectcost of stage 2 will be financed under Banks usual scheme on thenormal terms and conditions.

Other Support ActivitiesIn order to strengthen the process within the Bank as well as build awareness among potentialSME clients, the Bank has proposed a slew of activities under Project Uptech for promotionof energy efficiency financing. These are:

i) Conduct of seminars / workshops on ‘Energy Efficiency’ projects for borrowers of the Bank.

ii) Conduct of training programme for Bank staff in appraising and financing of ‘EnergyEfficiency’ project.

iii) Support to Research Institutes, consultants, equipment manufacturers, engineering colleges,technical institutes for development of Energy Efficient technologies, equipment, processesand practices.

iv) Development of panel of engineers, auditors, consultants for EE projects on all-India basis,based on Bank’s experience with consultants selected by CCOs of LHOs Circle.

Registration fees – It is proposed to charge a nominal registration fee of Rs.10,000 per unitas a token of their commitment to project.

Parameters for Success of the Project

The project is expected to achieve the following basic benchmark within a period of 3 years.

1) Each Circle should have financed at least 10 EE projects. Thus 60 such projects wouldhave been funded.

2) The EE projects are immensely useful to SME sector to survive in the liberalised economyopen to global competition. The benefits will be visible in a short period. The additionaladvances to the 60 projects will be around 20 crore in a span of 2 years.

Once the benefits of such projects in from of saving in energy costs are established, moresuch projects are expected to come resulting in a spurt in advances to SME sector.

Contact for further information:Mr ES BalasubramanianDy General ManagerState Bank of India, Development Banking Department9th Floor Corporate CentreState Bank BhawanMadam Cama Road Mumbai 400 021Tel: 022-22817462, 22022426 (ext: 3503)E-mail: [email protected]; [email protected]



Mr Sonalal DattaAGM (CS), Credit Appraisal CellState Bank of India,Consultancy Services CellLocal Head Office, 7th Floor11, Sansad Marg New Delhi 110 001Tel: 011-23368481, 233629422336 2908 (ext 453)Email:[email protected]; [email protected]


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Petroleum Conservation Research Association (PCRA)(a) Energy Audit Subsidy

PCRA is an organization under the Ministry of Petroleum & Natural Gas. It offers subsidiesup to 50% of the cost of conducting an audit at an industrial premises limited to amaximum of Rs.50,000/-. The subsidy is payable after the satisfactory conduct of theaudit and upon its acceptance by both PCRA and the concerned party. A writtencommitment from the party for the recommendation of the recommendations amountingto 50% or more of the identified energy saving potential.

This subsidy can be availed by industries who consume more than 1000 tonnes of oilequivalent per annum and where in majority of fuel consumption is constituted by petroleumproducts.

The energy auditor has to be already empanelled by PCRA.

(b) Scheme for setting up of Energy Audit Centre / upgrading energy auditing facilities

Soft loans are available for procuring energy audit equipments and for upgrading energyauditing facilities

A loan of 50% of the cost or Rs. 1 million, whichever is lower, is given. An interest rateof 8 % is charged on a reduced principle basis. The repayment of loans begins 1 yearafter it is disbursed in six equal annual installments.



Industrial Development Bank of India (IDBI) SchemeThe scheme is available for financially sound industrial undertakings, which are in operation,at least for the last five years. There are basically two schemes, which are operational.

(a) Energy Audit subsidy scheme

IDBI bears 50 % charges of an approved consultancy for detailed energy audits. For abasic energy audit the subsidy is Rs. 10000/- or 0.1 % of the gross value of the fixedassets, whichever is less.

IDBI will assess the whole process.

(b) Equipment finance

Assistance is available for improving energy efficiency only. An energy audit has toprecede the application. The assistance is limited to 50 % of the gross value of fixedassets (excluding revenue reserves) or Rs. 40 million whichever is less. An interest @Rs. 14 % per annum is charged. Interest can be funded for a period of up to 2 years froma period of first disbursement on simple interest basis.

Repayment will commence after two years from the date of first disbursement to berepaid in full within three years thereafter. The borrower can claim a rebate in interestsubject to actual energy saving.


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IREDA’s Schemes for Financing of Energy Efficiency/Conservation Projects

General Eligibility: All types of applicants, who have borrowing powers and powers to takeup energy efficiency projects as per their Charter, are eligible to avail financial assistance fromIREDA except the following:

• Government Departments and State Electricity Boards/ utilities unless they are restructuredor in the process of restructuring and are also eligible to borrow from REC/PFC.

• a) Individual, Proprietary concerns and Partnership firms; b) Loss making applicants; c)Applicants with accumulated losses (without taking into account effect of revaluation ofassets, if any); and d) having erosion of paid up equity share capital as per audited AnnualAccounts of the immediate preceding financial year unless security of Bank Guarantee/Pledge of FDR from scheduled commercial bank is provided.

• Applicants whose existing Debt Equity Ratio {total borrowings (other than unsecured loansand working capital loans) to net worth} exceeds 3:1 after taking into account the proposedborrowings from IREDA unless security of Bank Guarantee/ Pledge of FDR from scheduledcommercial bank is provided.

• Trust/Societies with accumulated revenue deficit or revenue deficit immediately during thepast year unless Bank Guarantee is provided unless security of Bank Guarantee/ Pledgeof FDR from scheduled commercial bank is provided.

• Applicants who are in default in payment of dues to Financial Institutions, Banks NBFCsand/or IREDA at the time of submission of application.

• Applicants/Group Companies and/or main promoters of the applicants company which arein default in payment of IREDA dues at the time of submission of application.

• Applicants/Group Companies classified as willful defaulters as defined by RBI/classified byother FIs.

• Refinancing

• Projects Commissioned prior to the date of registration of application by IREDA.

• Second-hand project, equipment and machinery. Cost overrun financing.

• Applicants/Group companies who had availed OTS from IREDA.

• Applicants requesting financial assistance of less than Rs. 10 Lakhs

• Applicants/Group Companies and/or main promoters of the applicant Company convictedby court for criminal/economic offences or under national security laws.

• Applicants registered outside India.

• Companies which do not have minimum paid up capital of Rs. 1.00 Lakh/Rs. 5.00 Lakhsor such higher paid up capital as may be prescribed for private and public companiesrespectively.

Terms: IREDA provides loan for Energy Efficiency/Conservation sector under followingcategories:



SCHEME Rate of Maximum Max. Minimum MaximumInterest(%) repayment Moratorium Promoters IREDA

p.a. period (Years) Contribution(%) loan(%)including

moratorium(Years)

A. PROJECT FINANCING: (INCLUDING POWER PROJECTS BASED ON WASTE HEATRECOVERY, DSM AND ESCO)

Commercial and Upto 70% ofIndustrial 13.00 10 2 30 total project cost

Domestic sector 12.00 5 1 30 - do -

Agricultural sector 12.00 10 2 30 - do -

B. MANUFACTURING OF ENERGY EFFICIENT EQUIPMENT/SYSTEMS:

All sectors 13.50 8 2 30 Upto 70% oftotal project cost

C. EQUIPMENT FINANCING: ENERGY CONSERVATION/EFFICIENCY SYSTEMS &EQUIPMENTS (INCLUDING DSM)

Commercial and 13.50 10 2 25 Upto 75% ofIndustrial sector total eligible

equipment cost

Domestic Sector 12.50 5 1 25 - do -

Agricultural Sector 12.50 10 2 25 - do -

Concessions/Rebates and Special Provisions from IREDA• Project financed by IREDA from the World Bank line of credit are likely to qualify for

excise/ custom duty exemptions as per notification issued by the Government of India

• Interest Rebate of 1.00% for furnishing security of Bank Guarantee/Pledge of FDR Orunconditional and irrevocable guarantee of All India Public Financial Institution with “AAA”or equivalent rating.

• Rebate of 0.5% in interest rate for timely payment of interest & repayment of loan instalment.

• Special Concessions for entrepreneurs belonging to SC/ST, Women, Physically Handicappedand Ex-servicemen Categories and those setting up projects in North Eastern States,Sikkim, Jammu & Kashmir, newly created states, Islands and Estuaries.

Other Charges Payable to IREDA after the Loan is Sanctioned (please check IREDA’sFinancing Guidelines for further Details):

• Front End Fee (@1.00% for loan upto Rs.1 Crores; @1.25% for Rs.1-10 Crores; @1.50%for Rs.10-20 Crores; @1.75% for Rs.20-30 Crores and @2% for loan above Rs.30 Crores)


665

• Legal Charges (if incurred by IREDA) and Expenditure on Nominee Director (if incurred byIREDA)

• Inspection and Monitoring Charges incurred by IREDA for the Project

IREDA also offers following Grant Assistance to the project financed by it:

Category of Project Purpose of Grant Eligible Amount Remarks End User Energy Efficiency & Energy Conservation projects

Cost of carrying out Energy Audit and for Preparation of Bankable Detailed Project Report for availing Term Loan

Rs.10.00 Lakhs per project or 2% of the loan directly availed from IREDA, whichever is less

Fund Utilisation certificate in the format prescribed by IREDA shall be required to be submitted

Cost of carrying out Energy Audit and for Preparation of Bankable Detailed Project Report for availing Term Loan

Rs.10.00 Lakhs per project or 2% of the loan directly availed from IREDA, whichever is less

--do-- Utility DSM Projects

For Setting up a DSM Cell in the utility

Rs.10.00 Lakhs (provided loan of minimum 100 Lakhs is availed.

--do--

Cost of carrying out Energy Audit by ESCO and Preparation of Bankable Detailed Project Report

Rs.10.00 Lakhs per project or 2% of the loan availed from IREDA, whichever is less

--do--

Cost of preparation of Performance Contract for the Project


--do--

Cost of Collaboration/ Experience Sharing/ Technology Transfer


--do--

ESCO Promoted Projects (with performance guarantee/ shared saving)

Cost of Promotional/ Outreach Efforts by the ESCO

Rs.2.00 Lakhs per project or ½% of the loan availed from IREDA, whichever is less

--do--

ecurity for IREDA’s Loan :

OPTION PROJECT FINANCING EQUIPMENT FINANCING SET 1 Bank Guarantee/Pledge of FDR

from Scheduled Commercial Bank

Bank Guarantee/Pledge of FDR from Scheduled Commercial Bank

SET 2 State Government Guarantee State Government Guarantee SET 3 Unconditional and irrevocable

guarantee of All India Public Financial Institution with “AAA” or equivalent rating.

Unconditional and irrevocable guarantee of All India Public Financial Institution with “AAA” or equivalent rating.

SET 4 Equitable Mortgage (Mortgage by deposit of title deeds) of all immovable properties

Hypothecation of movable

Demand Promissory Note for the amount of loan

Exclusive charge by way of hypothecation of all movable assets acquired/ to be acquired out of



Note:

1) All equipment financing loans (where mortgage of immovable properties either on exclusiveor pari-passu or second charge basis is not stipulated) will have to be secured by additionalsecurity in the form of equitable mortgage of immovable non-agricultural properties locatedeither in urban or rural areas (excluding waste/barren lands) belonging to promoters/directorsof the borrower company and/or close relatives and friends of the promoters having marketvalue equivalent to at least 33% of IREDA’s Loan. The valuation of the property shall bearranged from any of the approved and registered valuers/architects at the cost of theborrowers to the satisfaction of IREDA and the borrower shall establish the title of suchproperty to the satisfaction of IREDA. Alternatively, Bank Guarantee from a scheduled bankor pledge of Fixed Deposit Receipt (FDR) can be submitted.

assets, both existing and future, subject to prior charge of Banks on specified current assets

Guarantees by promoters/ promoter directors and promoter companies

Deposit of post dated cheques in accordance with repayment schedule of principal loan amount and interest.

IREDA’s loan and Borrowers’ own funds under the project, both existing and future

Guarantees by promoters/ promoter directors and promoter companies

Deposit of post dated cheques in accordance with repayment schedule of principal loan amount and interest.

MINISTRY OF LAW, JUSTICE AND COMPANY AFFAIRS (Legislative Department)

New Delhi, the 1st October, 2001/ Asvina 9, 1923 (Saka)

The following Act of Parliament received the assent of the President on the 29th September, 2001, and is hereby published for general information:--

THE ENERGY CONSERVATION ACT, 2001

No 52 OF 2001 [29th September 2001]

An Act to provide for efficient use of energy and its conservation and for

matters connected therewith or incidental thereto.

BE it enacted by Parliament in the Fifty second Year of the Republic of India as follows:—

CHAPTER I

PRELIMINARY

1. (1) This Act may be called the Energy Conservation Act, 2001. (2) It extends to the whole of India except the state of Jammu and Kashmir (3) It shall come into force on such dates as the Central Government may, by notification

in the Official Gazette, appoint; and different dates may be appointed for different provisions of this Act and any reference in any such provision to the commencement of this Act shall be construed as a reference to the coming into force of that provision.

Short title, extent and commencement

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Definitions 2. In this Act, unless the context otherwise requires: —

(a) “accredited energy auditor” means an auditor possessing qualifications specified under clause (p) of sub-section (2) of section 13;

(b) “ Appellate Tribunal” means Appellate Tribunal for Energy Conservation established under section 30;

(c) “building” means any structure or erection or part of a structure or erection, after the rules relating to energy conservation building codes have been notified under clause (a) of section 15 of clause (l) of sub-section (2) of section 56, which is having a connected load of 500kW or contract demand of 600 kVA and above and is intended to be used for commercial purposes;

(d) “Bureau” means the Bureau of Energy Efficiency established under subsection (l) of section 3;

(e) “Chairperson” means the Chairperson of the Governing council;

(f) “designated agency” means any agency designated under clause (d) of section 15;

(g) “designated consumer” means any consumer specified under clause (e) of section 14;

(h) “energy” means any form of energy derived from fossil fuels, nuclear substances or materials, hydro-electricity and includes electrical energy or electricity generated from renewable sources of energy or bio-mass connected to the grid;

(i) “energy audit” means the verification, monitoring and analysis of use of energy including submission of technical report containing recommendations for improving energy efficiency with cost benefit analysis and an action plan to reduce energy consumption;

(j) “energy conservation building codes” means the norms and standards of energy consumption expressed in terms of per square meter of the area wherein energy is used and includes the location of the building;

(k) “energy consumption standards” means the norms for process and energy consumption standards specified under clause (a) of section 14;

(l) “Energy Management Centre” means the Energy Management Centre set up under the Resolution of the Government of India in the erstwhile Ministry of Energy, Department of Power No. 7(2)/87-EP (Vol. IV), dated the 5th July, 1989 and registered under the Societies Registration Act, 1860;

21 of 1860

(m) “energy manager” means any individual possessing the qualifications prescribed under clause (m) of section 14;

(n) “ Governing Council” means the Governing Council referred to in section 4;

(o) “member” means the member of the Governing Council and includes the Chairperson;

(p) “notification” means a notification in the Gazette of India or, as the case may be, the Official Gazette of a State;

(q) “prescribed” means prescribed by rules made under this Act;

(r) “regulations” means regulations made by the Bureau under this Act;

(s) “schedule” means the Schedule of this Act;

(t) “State Commission” means the State Electricity Regulatory Commission established under sub-section (l) of section 17 of the Electricity Regulatory Commissions Act, 1998;

14 of 1998

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9 of 1940 54 of 1948 14 of 1998

(u) words and expression used and not defined in this Act but defined in the Indian Electricity Act, 1910 or the Electricity (Supply) Act, 1948 or the Electricity Regulatory Commissions Act, 1998 shall have meanings respectively assigned to them in those Acts.

CHAPTER II

BUREAU OF ENERGY EFFICIENCY

3. (1) With effect from such date as the Central Government may, by notification, appoint, there shall be established, for the purposes of this Act, a Bureau to be called the Bureau of Energy Efficiency

Establishment and incorporation of Bureau of Energy Efficiency

(2) The Bureau shall be a body corporate by the name aforesaid having perpetual succession and a common seal, with power subject to the provisions of this Act, to acquire, hold and dispose of property, both movable and immovable, and to contract, and shall, by the said name, sue or be sued.

(3) The head office of the Bureau shall be at Delhi.

(4) The Bureau may establish offices at other places in India.

4. (1) The general superintendence, direction and management of the affairs of the Bureau shall vest in the Governing Council which shall consists of not less than twenty, but not exceeding twenty-six members to be appointed by the Central Government.

Management of Bureau

(2) The Governing Council shall consist of the following members, namely:-

(a) the Minister in charge of the Ministry or Department of the Central Government dealing with the Power

ex officio Chairperson;

(b) the Secretary to the Government of India, in charge of the Ministry or Department of the Central Government dealing with the Power

ex officio member;

(c) the Secretary to the Government of India, in charge of the Ministry or Department of the Central Government dealing with the Petroleum and Natural Gas

ex officio member;

(d) the Secretary to the Government of India, in charge of the Ministry or Department of the Central Government dealing with the Coal

ex officio member;

(e) the Secretary to the Government of India, in charge of the Ministry or Department of the Central Government dealing with the Non-conventional Energy Sources

ex officio member;

(f) the Secretary to the Government of India, in charge of the Ministry or Department of the Central Government dealing with the Atomic Energy

ex officio member;

(g) the Secretary to the Government of India, in charge of the Ministry or Department of the Central Government dealing with the Consumer Affairs

ex officio member;

54 of 1948

(h) Chairman of the Central Electricity Authority established under the Electricity (Supply) Act, 1948

ex officio member;

Karnataka Act 17 of 1960

(i) Director-General of the Central Power Research Institute registered under the Karnataka Societies Act, 1960

ex officio member;

XXI of 1860

(j) Executive Director of the Petroleum Conservation Research Association, a society registered under the Societies Registration Act, 1860

ex officio member;

1 of 1956

(k) Chairman-cum-Managing Director of the Central Mine Planning and Design Institute Limited, a company incorporated under the Companies Act, 1956

ex officio member;

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(l) Director-General of the Bureau of Indian Standards established under the Bureau of Indian Standards Act, 1986

ex officio member; 63 of 1986

(m) Director-General of the National Test House, Department of Supply, Ministry of Commerce and Industry, Kolkata

ex officio member;

(n) Managing Director of the Indian Renewable Energy Development Agency Limited, a company incorporated under the Companies act, 1956

ex officio member; 1 of 1956

(o) one member each from five power regions representing the States of the region to be appointed by the Central Government

members;

(p) such number of persons, not exceeding four as may be prescribed, to be appointed by the Central Government as members from amongst persons who are in the opinion of the Central Government capable of representing industry, equipment and appliance manufacturers, architects and consumers

members;

(q) such number of persons, not exceeding two as may be nominated by the Governing Council as members

members;

(r) Director-General of Bureau ex officio member – secretary;

(3) The Governing Council may exercise all powers and do all acts and things which may be exercised or done by the Bureau.

(4) Every member referred to in clause (o), (p) and (q) of sub-section (2) shall hold office for a term of three years from the date on which he enters upon his office.

(5) The fee and allowances to be paid to the members referred to in clauses (o), (p) and (q) of sub-section (2) and the manner of filling up of vacancies and the procedure to be followed in the discharge of their functions shall be such as may be prescribed.

Meetings of Governing Council

5. (1) The Governing Council shall meet at such times and places, and shall observe such rules of procedure in regard to the transaction of business as its meetings (including quorum of such meetings) as may be provided by regulations.

Meetings of Governing Council

(2) The Chairperson or, if for any reason, he is unable to attend a meeting of the Governing Council, any other member chosen by the members present from amongst themselves at the meeting shall preside at the meeting.

(3) All questions which come up before any meeting of the Governing Council shall be decided by a majority vote of the members present and voting, and in the event of an equality of votes, the Chairperson or his absence, the person presiding, shall have second or casting vote.

6. No act or proceeding of the Bureau or the Governing Council or any Committee shall be invalid merely by reason of -

Vacancies etc., not to invalidate proceedings of Bureau, Governing Council or Committee

(a) any vacancy in, or any defect in the constitution of, the Bureau or the Governing Council or the Committee; or

(b) any defect in the appointment of a person acting as a Director -General or Secretary of the Bureau or a member of the Governing Council or the Committee; or

(c) any irregularity in the procedure of the Bureau or the Governing Council or the Committee not affecting the merits of the case.

Removal of member from office

7. The Central Government shall remove a member referred to in clause (o), (p) and (q) of sub-section (2) of section 4 from office if he —

(a) is, or at any time has been, adjudicated as insolvent;

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(b) is of unsound mind and stands so declared by a competent court;

(c) has been convicted of an offence which, in the opinion of the Central Government, involves a moral turpitude;

(d) has, in the opinion of the Central Government, so abused his position as to render his continuation in office detrimental to the public interest: Provided that no member shall be removed under this clause unless he has been given a reasonable opportunity of being heard in the matter.

8. (1) Subject to any regulations made in this behalf, the Bureau shall, within six months from the date of commencement of this Act, constitute Advisory Committees for the efficient discharge of its functions.

Constitution of Advisory Committees and other committees

(2) Each Advisory Committee shall consist of a Chairperson and such other members as may be determined by regulations.

(3) Without prejudice to the powers contained in sub-section (1), the Bureau may constitute, such number of technical committees of experts for the formulation of energy consumption standards or norms in respect of equipment or processes, as it considers necessary.

9. (1) The Central Government shall, by notification, appoint a Director -General from amongst persons of ability and standing, having adequate knowledge and experience in dealing with the matters relating to energy production, supply and energy management standarisation and efficient use of energy and its conservation

Director-General of Bureau

(2) The Central Government shall, by notification appoint any person not below the rank of Deputy Secretary to the Government of India as Secretary of the Bureau

(3) The Director-General shall hold office for a term of three years from the date on which he enters upon his office or until he attains the age of sixty years, whichever is earlier

(4) The salary and allowances payable to the Director-General and other terms and conditions of his service and other terms and conditions of service of the Secretary of the Bureau shall be such as may be prescribed

(5) Subject to general superintendence, direction and management of the affairs by the Governing Council, the Director-General of the Bureau shall be the Chief Executive Authority of the Bureau

(6) The Director-General of the Bureau shall exercise and discharge such powers and duties of the Bureau as may be determined by regulations

10. (1) The Central Government may appoint such other officers and employees in the Bureau as it considers necessary for the efficient discharge of its functions under this Act.

Officers and employees of Bureau

(2) The terms and conditions of service of officers and other employees of the Bureau appointed under sub-section (1) shall be such as may be prescribed.

11. All orders and decisions of the Bureau shall be authenticated by the signature of the Director-General or any other officer of the Bureau authorised by the Director-General in this behalf.

Authentication of orders and decisions of Bureau

CHAPTER III TRANSFER OF ASSETS, LIABILITIES ETC, OF ENERGY MANAGEMENT CENTRE TO BUREAU

12. (1) On and from the date of establishment of the Bureau - (a) any reference to the Energy Management Centre in any law other than this Act or

in any contract or other instrument shall be deemed as a reference to the Bureau;

(b) all properties and assets, movable and immovable of, or belonging to, the Energy Management Centre shall vest in the Bureau;

Transfer of assets, liabilities and employees of Energy Management Centre

(c) all the rights and liabilities of the Energy Management Centre shall be transferred to, and be the right and liabilities of, the Bureau;

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(d) without prejudice to the provisions of clause (c), all debts, obligations and liabilities incurred, all contracts entered into and all matters and things engaged to be done by, with or for the Energy Management Centre immediately before that date for or in connection with the purposes of the said Centre shall be deemed to have been incurred, entered into, or engaged to be done by, with or for, the Bureau;

(e) all sums of money due to the Energy Management Centre immediately before that date shall be deemed to be due to the Bureau;

(f) all suits and other legal proceedings instituted or which could have been instituted by or against the Energy Management Centre immediately before that date may be continued or may be instituted by or against the Bureau; and

(g) every employee holding any office under the Energy Management Centre immediately before that date shall hold his office in the Bureau by the same tenure and upon the same terms and conditions of service as respects remuneration, leave, provident fund, reti rement or other terminal benefits as he would have held such office if the Bureau had not been established and shall continue to do so as an employee of the Bureau or until the expiry of six months from the date if such employee opts not to be the employee of the Bureau within such period.

(2) Not withstanding anything contained in the Industrial Disputes Act, 1947 or in any other law for the time being in force, the absorption of any employees by the Bureau in its regular service under this section s hall not entitle such employees to any compensation under that Act or other law and no such claim shall be entertained by any court, tribunal or other authority.

14 of 1947

CHAPTER IV

POWERS AND FUNCTIONS OF BUREAU

Powers and functions of Bureau

13. (1) The Bureau shall, effectively co-ordinate with designated consumers, designated agencies and other agencies, recognise and utilise the existing resources and infrastructure, in performing the functions assigned to it by or under this Act

(2) The Bureau may perform such functions and exercise such powers as may be assigned to it by or under this Act and in particular, such functions and powers include the function and power to -

(a) recommend to the Central Government the norms for pro cesses and energy consumption standards required to be notified under clause (a) of section 14 ;

(b) recommend to the Central Government the particulars required tobe displayed on label on equipment or on appliances and manner of their display under clause (d) of section 14;

(c) recommend to the Central Government for notifying any user or class of users of energy as a designated consumer under clause (e) of section 14;

(d) take suitable steps to prescribe guidelines for energy conservation building codes under clause (p) of section 14;

(e) take all measures necessary to create awareness and disseminate information for efficient use of energy and its conservation;

(f) arrange and organize training of personnel and specialists in the techniques for efficient use of energy and its conservation;

(g) strengthen consultancy services in the field of energy conservation; (h) promote research and development in the field of energy conservation; (i) develop testing and certification procedure and promote testing facilities for

certification and testing for energy consumption of equipment and appliances;

(j) formulate and facilitate implementation of pilot projects and demonstration projects for promotion of efficient use of energy and its conservation;

(k) promote use of energy efficient processes, equipment, devices and systems; (l) promote innovative financing of energy efficiency projects;

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(m) give financial assistance to institutions for promoting efficient use of energy and its conservation;

(n) levy fee, as may be determined by regulations, for services provided for promoting efficient use of energy and its conservation;

(o) maintain a list of accredited energy auditors as may be specified by regulations; (p) specify, by regulations, qualifications for the accredited energy auditors; (q) specify, by regulations, the manner and intervals of time in which the energy

audit shall be conducted ;

(r) specify, by regulations, certification procedures for energy managers to be designated or appointed by designated consumers;

(s) prepare educational curriculum on efficient use of energy and its conservation for educational institutions, boards, universities or autonomous bodies and coordinate with them for inclusion of such curriculum in their syllabus;

(t) implement internat ional co-operation programmes relating to efficient use of energy and its conservation as may be assigned to it by the Central Government;

(u) perform such other functions as may be prescribed.

CHAPTER V POWER OF CENTRAL GOVERNMENT TO FACILITATE AND ENFORCE EFFICIENT

USE OF ENERGY AND ITS CONSERVATION

14. The Central Government may, by notification, in consultation with the Bureau, — (a) specify the norms for processes and energy consumption standards for any equipment,

appliances which consumes, generates, transmits or supplies energy; (b) specify equipment or appliance or class of equipments or appliances, as the case may

be, for the purposes of this Act; (c) prohibit manufacture or sale or purchase or import of equipment or appliance specified

under clause (b) unless such equipment or appliances conforms to energy consumption standards;

Power of Central Government to enforce efficient use of energy and its conservation

Provided that no notification prohibiting manufacture or sale or purchase or import or equipment or appliance shall be issued within two years from the date of notification issued under clause (a) of this section;

(d) direct display of such particulars on label on equipment or on appliance specified under clause (b) and in such manner as may be specified by regulations;

(e) specify, having regarding to the intensity or quantity of energy consumed and the amount of investment required for switching over to energy efficient equipments and capacity or industry to invest in it and availability of the energy efficient machinery and equipment required by the industry, any user or class of users of energy as a designated consumer for the purposes of this Act;

(f) alter the list of Energy Intensive Industries specified in the Schedule; (g) establish and prescribe such energy consumption norms and standards for designated

consumers as it may consider necessary: Provided that the Central Government may prescribe different norms and standards for different designated consumers having regard to such factors as may be prescribed;

(h) direct, having regard to quantity of energy consumed or the norms and standards of energy consumption specified under clause (a) the energy intensive industries specified in the Schedule to get energy audit conducted by an accredited energy auditor in such manner and intervals of time as may be specified by regulations;

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(i) direct, if considered necessary for efficient use of energy and its conservation, any designated consumer to get energy audit conducted by an accredited energy auditor;

(j) specify the matters to be included for the purposes of inspection under sub-section (2) of section 17;

(k) direct any designated consumer to furnish to the designated agency, in such form and manner and within such period, as may be prescribed, the information with regard to the energy consumed and action taken on the recommendation of the accredited energy auditor;

(l) direct any designated consumer to designate or appoint energy manger in charge of activities for efficient use of energy and its conservation and submit a report, in the form and manner as may be prescribed, on the status of energy consumption at the end of the every financial year to designated agency;

(m) prescribe minimum qualification for energy managers to be designated or appointed under clause (l);

(n) direct every designated consumer to comply with energy consumption norms and standards;

(o) direct any designated consumer, who does not fulfil the energy consumption norms and standards prescribed under clause (g), to prepare a scheme for efficient use of energy and its conservation and implement such scheme keeping in view of the economic viability of the investment in such form and manner a s may be prescribed;

(p) prescribe energy conservation building codes for efficient use of energy and its conservation in the building or building complex;

(q) amend the energy conservation building codes to suit the regional and local climatic conditions;

(r) direct every owner or occupier of the building or building complex, being a designated consumer to comply with the provisions of energy conservation building codes for efficient use of energy and its conservation;

(s) direct, any designated consumer referred to in clause (r), if considered necessary, for efficient use of energy and its conservation in his building to get energy audit conducted in respect of such building by an accredited energy auditor in such manner and intervals of time as may be specified by regulations;

(t) take all measures necessary to create awareness and disseminate information for efficient use of energy and its conservation;

(u) arrange and organise training of personnel and specialists in the techniques for efficient use of energy and its conservation;

(v) take steps to encourage preferential treatment for use of energy efficient equipment or appliances: Provided that the powers under clauses (p) and (s) shall be exercised in consultation with the concerned State.

CHAPTER VI

POWER OF STATE GOVERNMENT TO FACILITATE AND ENFORCE EFFICIENT USE OF ENERGY AND ITS CONSERVATION

15. The State Government may, by notification, in consultation with the Bureau - Power of State Government to enforce certain provisions for efficient use of energy and its conservation

(a) amend the energy conservation building codes to suit the regional and local climatic conditions and may, by rules made by it, specify and notify energy conservation building codes with respect to use of energy in the buildings;

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(b) direct every owner or occupier of a building or building complex being a designated

consumer to comply with the provisions of the energy conservation building codes;

(c) direct, if considered necessary for efficient use of energy and its conservation, any designated consumer referred to in clause (b) to get energy audit conducted by an accredited energy auditor in such manner and at such intervals of time as may be specified by regulations;

(d) designate any agency as designated agency to coordinate, regulate and enforce provisions of this Act within the State;

(e) take all measures necessary to create awareness and disseminate information for efficient use of energy and its conservation;

(f) arrange and organise training of personnel and specialists in the techniques for efficient use of energy and its conservation;

(g) take steps to encourage preferential treatment for use of energy efficient equipment or appliances;

(h) direct, any designated consumer to furnish to the designated agency, in such form and manner and within such period as may be specified by rules made by it, information with regard to the energy consumed by such consumer;

(i) specify the matters to be included for the purposes of inspection under sub-section (2) of section 17;

16. (1) The State Government shall constitute a Fund to be called the State Energy Conservation Fund for the purposes of promotion of efficient use of energy and its conservation within the State.

(2) To the Fund shall be credited all grants and loans that may be made by the State Government or, Central Government or any other organization or individual for the purposes of this Act.

Establishment of Fund by State Government

(3) The Fund shall be applied for meeting the expenses incurred for implementing the provisions of this Act.

(4) The Fund created under sub-section (l) shall be administered by such persons or any authority and in such manner as may be spe cified in the rules made by the State Government.

17. (1) The designated agency may appoint, after the expiry of five years from the date of commencement of this Act, as many inspecting officers as may be necessary for the purpose of ensuring compliance with energy consumption standard specified under clause (a) of section 14 or ensure display of particulars on label on equipment or appliances specified under clause (b) of section 14 or for the purpose of performing such other functions as may be assigned to them.

Power of inspection

(2) Subject to any rules made under this Act, an inspecting officer shall have power to - (a) inspect any operation carried on or in connection with the equipment or appliance

specified under clause (b) of section 14 or in respect of which energy standards under clause (a) of section 14 have been specified;

(b) enter any place of designated consumer at which the energy is used for any activity and may require any proprietor, employee, director, manager or secretary or any other person who may be attending in any manner to or helping in, carrying on any activity with the help of energy -

(i) to afford him necessary facility to inspect - (A) any equipment or appliance as he may require and which may be available

at such place;

(B) any production process to ascertain the energy consumption norms and

standards;

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(ii) to make an inventory of stock of any equipment or appliance checked or verified by him;

(iii) to record the statement of any person which may be useful for, or relevant to, for efficient use of energy and its conservation under this Act.

(3) An inspecting officer may enter any place of designated consumer - (a) where any activity with the help of energy is carried on; and (b) where any equipment or appliance notified under clause (b) of section 14 has been

kept,

during the hours at which such places is open for production or conduct of business connected therewith.

(4) An inspecting officer acting under this section shall, on no account, remove or cause to be removed from the place wherein he has entered, any equipment or appliance or books of accounts or other documents.

18. The Central Government or the State Government may, in the exercise of its powers and performance of its functions under this Act and for efficient use of energy and its conservation, issue such directions in writing as it deems fit for the purposes of thi s Act to any person, officer, authority or any designated consumer and such person, officer or authority or any designated consumer shall be bound to comply with such directions.

Explanation – For the avoidance of doubts, it is hereby declared that the power to issue directions under this section includes the power to direct –

Power of Central Government or State Government to issue directions

(a) regulation of norms for process and energy consumption standards in any industry or building or building complex; or

(b) regulation of the energy consumption standards for equipment and appliances.

CHAPTER VII FINANCE, ACCOUNT S AND AUDIT OF BUREAU

Grants and loans by Central Government

19. The Central Government may, after due appropriation made by Parliament by law in this behalf, make to the Bureau or to the State Government grants and loans of such sums or money as the Central Government may consider necessary.

20. (1) There shall be constituted a Fund to be called as the Central Energy Conservation Fund and there shall be credited thereto -

Establishment of Fund by Central Government

(a) any grants and loans made to the Bureau by the Central Government under section 19;

(b) all fees received by the Bureau under this Act;

(c) all sums received by the Bureau from such other sources as may be decided upon by the Central Government.

(2) The Fund shall be applied for meeting -

(a) the salary, allowances and other remuneration of Director-General, Secretary officers and other employees of the Bureau,

(b) expenses of the Bureau in the discharge of its functions under section 13;

(c) fee and allowances to be paid to the members of the Governing Council under sub-section (5) or section 4;

(d) expenses on objects and for purposes authorised by this Act

Borrowing powers of Bureau

21. (1) The Bureau may, with the consent of the Central Government or in accordance with the terms of any general or special authority given to it by the Central Government borrow money from any source as it may deem fit for discharging all or any of its functions under this Act.

(2) The Central Government may guarantee, in such manner as it thinks fit, the repayment of the principle and the payment of interest thereon with respect to the loans borrowed by the Bureau under sub-section (l).

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22. The Bureau shall prepare, in such form and at such time in each financial year as may be prescribed, its budget for the next financial year, showing the estimated receipts and expenditure of the Bureau and forward the same to the Central Government.

Budget

23. The Bureau shall prepare, in such form and at such time in each financial year as may be prescribed, its annual report, giving full account of its activities during the previous financial year, and submit a copy thereof to the Central Government.

Annual report

24. The Central Government shall cause the annual report referred to in section 23 to be laid, as soon as may be after it is received, before each House of Parliament.

Annual report tobe laid before Parliament

25. (1) The Bureau shall maintain proper accounts and other relevant records and prepare an annual statement of accounts in such form as may be prescribed by the Central Government in consultation with the Comptroller and Auditor -General of India.

Accounts and Audit

(2) The accounts of the Bureau shall be audited by the Comptroller and Auditor-General of India at such intervals as may be specified by him and any expenditure incurred in connection with such audit shall be payable by the Bureau to the Comptroller and Auditor-General.

(3) The Comptroller and Auditor-General of India and any other person appointed by him in connection with the audit of the accounts of the Bureau shall have the same rights and privileges and authority in connection with such audit as the Comptroller and Auditor-General generally has in connection with the audit of the Government accounts and in particular, shall have the right to demand the production of books, accounts, connected vouchers and other documents and papers and to inspect any of the offices of the Bureau.

(4) The accounts of the Bureau as certified by the Comptroller and Auditor-General of India or any other person appointed by him in this behalf together with the audit report thereon shall forward annually to the Central Government and that Government shall cause the same to be laid before each House of Parliament.

CHAPTER VIII

PENALTIES AND ADJUDICATION

26. (1) If any person fails to comply with the provision of clause (c) or the clause (d) or clause (h) or clause (i) or clause (k) or clause (l) or clause (n) or clause (r) or clause (s) of section 14 or clause (b) or clause (c) or clause (h) of section 15, he shall be liable to a penalty which shall not exceed ten thousand rupees for each such failures and, in the case of continuing failures, with an additional penalty which may extend t o one thousand rupees for every day during which such failures continues:

Penalty

Provided that no person shall be liable to pay penalty within five years from the date of commencement of this Act.

(2) Any amount payable under this section, if not paid, may be recovered as if it were an arrear of land revenue.

27. (1) For the purpose of adjudging section 26, the State Commission shall appoint any of its members to be an adjudicating officer for holding an inquiry in such manner as may be prescribed by the Central Government, after giving any person concerned a reasonable opportunity of being heard for the purpose of imposing any penalty.

(2) While holding an inquiry the adjudicating officer shal l have power to summon and enforce the attendance of any person acquainted with the facts and circumstances of the case of give evidence or produce any document which in the opinion of the adjudicating officer, may be useful for or relevant to the subject-matter of the inquiry, and if, on such inquiry, he is satisfied that the person has failed to comply with the provisions of any of the clauses of the sections specified in section 26, he may impose such penalty as he thinks fit in accordance with the provi sions of any of those clauses of that section:

Power to adjudicate

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Provided that where a State Commission has not been established in a State, the Government of that State shall appoint any of its officer not below the rank equivalent to a Secretary dealing with legal affairs in that State to be an adjudicating officer for the purposes of this section and such officer shall cease to be an adjudicating officer immediately on the appointment of an adjudicating officer by the State Commission on its establishment in that State:

Provided further that where an adjudicating officer appointed by a State Government ceased to be an adjudicating officer, he shall transfer to the adjudicating officer appointed by the State Commission all matters being adjudicated by him and thereafter the adjudicating officer appointed by the State Commission shall adjudicate the penalties on such matters.

28. While adjudicating the quantum of penalty under section 26, the adjudicating officer shall have due regard to the following factors, namely:-

Factors to be taken into account by adjudicating officer

(a) the amount of disproportionate gain or unfair advantage, wherever quantifiable, made as a result of the default;

(b) the repetitive nature of the default.

Civil court not to have jurisdiction

29. No civil court shall have jurisdiction to entertain any suit or proceeding in respect of any matter which an adjudicating officer appointed under this Act or the Appellate Tribunal is empowered by or under this Act to determine and no injunction shall be granted by any court or other authority in respect of any action taken or to be taken in pursuance of any power conferred by or under this Act.

CHAPTER IX

APPELLATE TRIBUNAL FOR ENERGY CONSERVATION

Establishment of Appellate Tribunal

30. The Central Government shall, by notification, establish an Appellate Tribunal to be known as the Appellate Tribunal for Energy Conservation to hear appeals against the orders of the adjudicating officer or the Central Government or the State Government or any other authority under this Act.

Appeal to Appellate Tribunal

31. (1) Any person aggrieved, by an order made by an adjudicating officer or the Central Government or the State Government or any other authority under this Act, may prefer an appeal to the Appellate Tribunal for Energy Conservation: Provided that any person appealing against the order of the adjudicating officer levying any penalty, shall while filing the appeal, deposit the amount of such penalty: Provided further that where in any particular case, the Appellate Tribunal is of the opinion that the deposit of such penalty would cause undue hardship to such person, the Appellate Tribunal may dispense with such deposit subject to such conditions as it may deem fit to impose so as to safeguard the realisation of penalty.

(2) Every appeal under sub-section (1) shall be filed within a period of forty-five days from the date on which a copy of the order made by the adjudicating officer or the Central Government or the State Government or any other authority is received by the aggrieved person and it shall be in such form, verified in such manner and be accompanies by such fee as may be prescribed:

Provided that the Appellate Tribunal may entertain an appeal after the expiry of the said period of forty-five days if it is satisfied that there was sufficient cause for not filing it within that period.

(3) On receipt of an appeal under sub-section (1), the Appellate Tribunal may, after giving the parties to the appeal an opportunity of being heard, pass such orders thereo n as it thinks fit, confirming, modifying or setting aside the order appealed against

(4) The Appellate Tribunal shall send a copy of every order made by it to the parties to the appeal and to the concerned adjudicating officer or the Central Governm ent or the State Government or any other authority.

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(5) The appeal filed before the Appellate Tribunal under sub-section (l) shall be dealt with by it as expeditiously as possible and endeavour shall be made by it to dispose of the appeal finally within one hundred and eighty days from the date of receipt of the appeal: Provided that where an appeal could not be disposed of within the said period of one hundred and eighty days, the Appellate Tribunal shall record its reasons in writing for not disposing of the appeal within the said period.

(6) The Appellate Tribunal may, for the purpose of examining the legality, propriety or correctness of any order made by the adjudicating officer or the Central Government or the State Government or any other authority under this Act, as the case may be in relation to any proceeding, on its own motion or otherwise, call for the records of such proceedings and make such order in the case as it thinks fit.

32. (1) The Appellate Tribunal shall consist of a Chairperson and such number of Members not exceeding four, as the Central Government may deem fit.

(2) Subject to the provisions of this Act, -

Composition of Appellate Tribunal

(a) the jurisdiction of the Appellate Tribunal maybe exercised by Benches thereof;

(b) a Bench may be constituted by the Chairperson of the Appellate Tribunal with two or more Members of the Appellate Tribunal as the Chairperson of the Appellate Tribunal may deem fit: Provided that every Bench constituted under this clause shall include at least one Judicial Member and one Technical Member;

(c) The Benches of the Appellate Tribunal shall ordinarily sit a t Delhi and such other places as the Central Government may, in consultation with the Chairperson of the Appellate Tribunal, notify;

(d) The Central Government shall notify the areas in relation to which each Bench of the Appellate Tribunal may exercise jurisdiction,

(3) Notwithstanding anything contained in sub -section (2), the Chairperson of the Appellate Tribunal may transfer a Member of the Appellate Tribunal from one Bench to another Bench Explanation – For the purposes of this Chapter, –

(i) “Judicial Member” means a Member of the Appellate Tribunal appointed as such under item (i) or item (ii) or clause (b) of sub-section (1) of section 33, and includes the Chairperson of the Appellate Tribunal;

(ii) “Technical Member” means a Member of the Appellate Tribunal appointed as such under item (iii) or item (iv) or item (v) or item (vi) of clause (b) of sub-section (l) of section 33

33. (1) A person shall not be qualified for appointment as the Chairperson of the Appellate Tribunal or a Member of the Appellate Tribunal unless he -

(a) in the case of Chairperson of the Appellate Tribunal, is or has been, a judge of the Supreme Court or the Chief Justice of a High Court; and

(b) in the case of a Member of the Appellate Tribunal,- (i) is, or has been, or is qualified to be, a Judge of a High Court; or

Qualifications for appointment of Chairperson and Members of Appellate Tribunal

(ii) is, or has been, a Member of the Indian Legal Service and has held a post in Grade I in that service for atleast three years; or

(iii) is, or has been, a Secretary for at least one year in Ministry or Department or the Central Government dealing with the Power, or Coal, or Petroleum and Natural Gas, or Atomic Energy; or

(iv) is, or has been Chairman of the Central Electricity Autho rity for at least one year; or

(v) is, or has been, Director-General of Bureau or Director-General of the Central Power Research Institute or Bureau of Indian Standards for atleast three years or has held any equivalent post for atleast three years; or

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(vi) is, or has been, a qualified technical person of ability and standing having adequate knowledge and experience in dealing with the matters relating to energy production and supply, energy management, standardisation and efficient use of energy and its conservation, and has shown capacity in dealing with problems relating to engineering, finance, commerce, economics, law or management

Term of office 34. The Chairperson of the Appellate Tribunal and every Member of the Appellate Tribunal shall hold office as such for a term of five years from the date on which he enters upon his office:

Provided that no Chairperson of the Appellate Tribunal or Mem ber of the Appellate Tribunal shall hold office as such after he has attained, – (a) in the case of the Chairperson of the Appellate Tribunal, the age of seventy

years; (b) in the case of any Member of the Appellate Tribunal, the age of sixty-five

years.

Terms and conditions of service

35. The salary and allowances payable to and the other terms and conditions of service of the Chairperson of the Appellate Tribunal, Members of the Appellate Tribunal shall be such as may be prescribed: Provided that neither the salary and allowances nor the other terms and conditions of service of the Chairperson of the Appellate Tribunal or a Member of the Appellate Tribunal shall be varied to his disadvantage after appointment.

Vacancies 36. If for reason other than temporary absence any vacancy occurs in the office of the Chairperson of the Appellate Tribunal or the Member of the Appellate Tribunal, the Central Government shall appoint another person in accordance with the provisions of this Act to fill the vacancy and the proceedings may be continued before the Appellate Tribunal from the stage at which the vacancy is filled.

Registration and removal

37. (1) The Chairperson or a Member of the Appellate Tribunal may, by notice in writing under his hand addressed to the Central Government, resign his office: Provided that the Chairperson of the Appellate Tribunal or a Member of the Appellate Tribunal shall, unless he is per mitted by the Central Government to relinquish his office sooner, continue to hold office until the expiry of three months from the date of receipt of such notice or until a person duly appointed as his successor enters upon his office or until the expiry of term of office, whichever is the earliest.

(2) The Chairperson of the Appellate Tribunal or a Member of the Appellate Tribunal shall not be removed from his office except by an order by the Central Government on the ground of proved misbehaviour or incapacity after an inquiry made by such persons as the President may appoint for this purpose in which the Chairperson or a Member of the Appellate Tribunal concerned has been informed of the charges against him and given a reasonable opportunity of being heard in respect of such charges.

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38. (1) In the event of the occurrence of vacancy in the office of the Chairperson of the

Appellate Tribunal by reason of his death, resignation or otherwise, the senior-most member of the Appellate Tribunal shall act as the Chairperson of the Appellate Tribunal until the date on which a new Chairperson appointed in accordance with the provisions of this Act to fill such vacancy enters upon his office.

Member to act as Chairperson in certain circumstances

(2) When the Chairperson of the Appellate Tribunal is unable to discharge his functions owing to his absence, illness or any other cause, the senior most Member of the Appellate Tribunal shall discharge the functions of the Chairperson of the Appellate Tribunal until the date on which the Chairperson of the Appellate Tribunal resumes his duties.

39. (1) The Central Government shall provide the Appellate Tribunal with such officers and employees as it may deem fit.

(2) The officers and employees of the Appellate Tribunal shall discharge their functions under the general superintendence of the Chairperson of the Appellate Tribunal as the case may be.

Staff of Appellate Tribunal

(3) The salaries and allowances and other conditions of service of the officers and employees of the Appellate Tribunal shall be such as may be prescribed.

5 of 1908

40. (1) The Appellate Tribunal shall not be bound by the procedure laid down by the Code of civil Procedure, 1908 but shall be guided by the principles of natural justice and subject to the other provisions of this Act, the Appellate Tribunal shall have powers to regulate it own procedure.

Procedure and powers of Appellate Tribunal

5 of 1908

(2) The Appellate Tribunal shall have, for the purposes of discharging its functions under this Act, the same powers as are vested in the civil court under the Code of C ivil Procedure 1908, while trying to suit in respect of the following matters, namely:-

(a) summoning and enforcing the attendance of any person and examining him on oath;

(b) requiring the discovery and production of documents;

(c) receiving evidence of affidavits;

1 of 1872

(d) subject to the provisions of section 123 and 124 of the Indian Evidence Act, 1872, requisitioning any public record or document or copy of such record or document from any office

(e) issuing commissions for the examination of witnesses or documents;

(f) reviewing its decisions;

(g) dismissing a representation of default or deciding it, ex parte;

(h) setting aside any order of dismissal or any representation for default or any order passed by it, ex parte;

(i) any other matter which may be prescribed by the Central Government.

(3) An order made by the Appellate Tribunal under this Act sha ll be executable by the Appellate Tribunal as a decree of civil court and, for this purpose, the Appellate Tribunal shall have all the powers of a civil court.

(4) Not withstanding anything contained in sub -section (3), the Appellate Tribunal may transmit any order made by it to a civil court having local jurisdiction and such civil court shall execute the order as if it were a decree made by the that court.

45 of 1860 2 of 1974

(5) All proceedings before the Appellate Tribunal shall be deemed to be judicial proceedings within the meaning of sections 193 and 228 of the Indian Penal Code and the Appellate Tribunal shall be deemed to be civil court for the purposes of section 345 and 346 of the Code of Criminal Procedure, 1973.

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Distribution of business amongst Benches.

41. Where Benches are constituted, the Chairperson of the Appellate Tribunal may, from time to time, by notification, make provisions as to the distribution of the business of the Appellate Tribunal amongst the Benches and also provide for the matters which ma y be dealt with by each Bench.

Power of Chairpersont to transfer cases

42. On the application of any of the parties and after notice to the parties, and after hearing such of them as he may desire to be heard, or on his own motion without such notice, the Chairperson of the Appellate Tribunal may transfer any case pending before one Bench for disposal, to any other Bench.

Decision to be by majority

43. If the Members of the Appellate Tribunal of a Bench consisting of two Members differ in opinion on any point, they shall state the point or points on which they differ, and make a reference to the Chairperson of the Appellate Tribunal who shall either hear the point or points himself or refer the case for hearing on such point or points b y one or more of the other Members of the Appellate Tribunal and such point or points shall be decided according to the opinion of the majority of the Members of the Appellate Tribunal who have heard the case, including those who first heard it.

Right to appellant to take assistance of legal practitioner or accredited auditor and of Government to appoint presenting officers

44. (1) A person preferring an appeal to the Appellate Tribunal under this Act may either appear in person or take assistance of a legal practitioner or an accredited energy auditor of his choice to present his case before the Appellate Tribunal, as the case may be.

(2) The Central Government or the State Government may authorise one or more legal practitioners or any of its officers to act as presenting officers and every person so authorised may present the case with respect to any appeal before the Appellate Tribunal as the case may be.

Appeal to Supreme Court

45. Any person aggrieved by any decision or order of the Appellate Tribunal may, file an appeal to the Supreme court within sixty days from the date of communication of the decision or order of the Appellate Tribunal to him, on any one or more of the ground specified in section 100 of the Code of Civil Procedure, 1908: Provided that the Supreme Court may, if it is satisfied that the appellant was prevented by the sufficient cause from the filing the appeal within the said period, allow it to be filed within a further period of not exceeding sixty days.

5 of 1908

CHAPTER X

MISCELLANEOUS

46. (1) Without prejudice to the foregoing provisions of this Act, the Bureau shall, in exercise of its powers or the performance of its functions under this Act, be bound by such directions on questions of policy as the Central Government may give in writing to it from time to time: Provided that the Bureau shall, as far as practicable, be given an opportunity to express his views before any direction is given under this sub-section.

Power of Central Government to issue directions to Bureau

(2) The decision of the Central Government, whether a question is one of policy or not, shall be final.

47. (1) If at any time the Central Government is of opinion - Power of Central Government to supersede Bureau

(a) that on account of grave emergency, the Bureau is unable to discharge the functions and duties imposed on it by or under the provisions of this Act; or

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(b) that the Bureau has persistently made default in complying with any direction issued by the Central Government under this Act or in discharge of the functions and duties imposed on it by or under the provisions of this Act and as a result of such default, the financial position of the Bureau had deteriorated or the administration of the Bureau had deteriorated; or

(c) that circumstances exist which render it necessary in the public interest so to do, the Central Government may, by notification, supersede the Bureau for such period, not exceeding six months, as may be specified in the notification.

(2) Upon the publication of a notification under sub-section (1) superseding the Bureau -

(a) all the members referred to in clauses (o), (p) and (q) of sub-section (2) of section 4 shall, as from the date of supersession, vacate their offices as such;

(b) all the powers, functions and duties which may, by or under the provisions of this Act, be exercised or discharged by or on behalf of the Bureau, shall until the Bureau is reconstituted under sub-section (3), be exercised and discharged by such person or persons as the Central Government may direct; and

(c) all property owned or controlled by the Bureau shall, until the Bureau is reconstituted under sub-section (3), vest in the Central Government.

(3) On the expiration of the period of supersession specified in the notification issued under sub-section (1), the Central Government may reconstitute the Bureau by a fresh appointment and in such case any person or persons who vacated their offices under clause (a) of sub-section (2), shall not be deemed disqualified for appointment:

Provided that the Central Government may, at any time, before the expiration of the period of supersession, take action under this sub-section

(d) the Central Government shall cause a notification issued under sub -section (1) and full report of any action taken under this section and the circumstances leading to such action to be laid before each House of Parliament at the earliest.

48. (1) Where a company makes a default in complying with the provisions of clause (c) or clause (d) or clause (h) or clause (i) or clause (k) or clause (l) or clause (n) or clause (r) or clause (s) of section 14 or clause (b) or clause (c) or clause (h) of section 15, every person who at the time of such contravention was incharge of, and was responsible to the company for the conduct of the business of the company, as well as the company, shall be deemed to have acted in contravention of the said provisions and shall be liable to be proceeded against and imposed penalty under section 26 accordingly: Provided that nothing contained in this sub -section shall render any such person liable for penalty provided in this Act if he proves that the contravention of the aforesaid provisions was committed without his knowledge or that he exercised all due diligence to prevent the contravention of the aforesaid provision.

Default by companies

(2) Notwithstanding anything contained in sub -section (l), where any contravention of the provisions of clause (c) or clause (d) or clause (h) or clause (i) or clause (k) or clause (l) or clause (n) or clause (r) or clause (s) of section 14 or clause (b) or clause (c) or clause (h) of section 15 has been committed with the consent or connivance of, or in attributable to, any neglect on the part of , any director, manager, secretary or other officer of the company, such director, manager, secretary or other officer shall also be deemed to have contravened the said provisions and shall be liable to be proceeded for imposition of penalty accordingly. Explanation – For the purposes of this section, “company” means a body corporate and includes a firm or other association of individuals.

43 of 1961 49. Notwithstanding anything contained in the Income -tax Act, 1961 or any other enactment for the time being in force relating to tax on income, profits or gains -

(a) the Bureau;

Exemption from tax on income

(b) the existing Energy Management Centre from the date of its constitution to the date of establishment of the Bureau,

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shall not be liable to pay any income tax or any tax in respect of their income, profits or gains derived.

Protection of action taken in good faith

50. No suit, prosecution or other legal proceedings shall lie against the Central Government or Director-General or Secretary or State Government or any officer of those Governments or State Commission or its members or any member or officer or other employee of the Bureau for anything which is in good faith done or intended to be done under this Act or the rules or regulations made thereunder.

Delegation 51. The Bureau may, by general or special order in writing, delegate to any member, member of the committee, officer of the Bureau or any other person subject to such conditions, if any, as may be specified in the order, such of its powers and functions under this Act (except the powers under section (58) as it may deem necessary

Power to obtain information

52. Every designated consumer or manufacturer of equipment or appliances specified under clause (b) of section 14 shall supply the Bureau with such information, and with such samples of any material or substance used in relation to any equipment or appliance, as the Bureau may require.

Power to exempt

53. If the Central Government or the Stat e Government is of the opinion that it is necessary or expedient so to do in the public interest, it may, by notification and subject to such conditions as may be specified in the notification, exempt any designated consumer or class of designated consumers from application of all or any of the provisions of this Act: Provided that the Central Government or the State Government, as the case may be, shall not grant exemption to any designated consumer or class of designated consumers for the period exceeding five years: Provided further that the Central Government or State Government, as the case may be shall consult the Bureau of Energy Efficiency before granting such exemption.

Chairperson, Members, officers and employees of the Appellate Tribunal, Members of State Commission, Director-General, Secretary, members, officers and employees to be public servants.

54. The Chairperson of the Appellate Tribunal or the Members of the Appellate Tribunal or officers or employees of the Appellate Tribunal or the members of the State Commission or the members, Director-General, Secretary, officers and other employees of the Bureau shall be deemed, when acting or purporting to act in pursuance of any of the provisions of the Act, to be public servants within the meaning of section 21 of the Indian Penal Code.

45 0f 1860

Power of Central Government to issue directions.

55. The Central Government may give directions to a State Government or the Bureau as to carrying out into execution of this Act in the State

Power of Central Government to make rules.

56. (1) The Central Government may, by notification, make rules for carrying out the provisions of this Act.

(2) In particular, and without prejudice to the generality of the foregoing power, such rules may provide for all or any of the following matters, namely:-

(a) such number of persons to be appointed as members by the Central Government under clauses (o), (p) and (q) of sub-section (2) of section 4;

(b) the fee and allowances to be paid to the members under sub-section (5) of section 4;

(c) the salary and allowances payable to the Director-General and other terms and conditions of his service and other terms and conditions of service of the Secretary of the Bureau under sub-section (4) of section 9;

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(d) the terms and conditions of service of officer and other employees of the Bureau under sub-section (2) of section 10;

(e) performing such other functions by the Bureau, as may be prescribed, under clause(u) of sub-section (2) or section 13;

(f) the energy consumption norms and standards for designated consumers under clause (g) of section 14;

(g) prescribing the different norms and standards for different designated consumers under the proviso to clause (g) of section 14;

(h) the form and manner and the time within which information with regard to energy consumed and the action taken on the r ecommendations of the accredited energy auditor be furnished under clause (k) of section 14;

(i) the form and manner in which the status of energy consumption be submitted under clause (l) of section 14;

(j) the minimum qualification for energy managers under clause (m) of section 14;

(k) the form and manner for preparation of scheme and its implementation under clause (o) of section 14;

(l) the energy conservation building codes under clause (p) of section 14;

(m) the matters relating to inspection under sub -section (2) of section 17;

(n) the form in which, and the time at which, the Bureau shall prepare its budget under section 22;

(o) the form in which, and the time at which, the Bureau shall prepare its annual report under section 23;

(p) the form in which the accounts of the Bureau shall be maintained under section 25;

(q) the manner of holding inquiry under sub -section (l) of section 27;

(r) the form of and fee for filing such appeal under sub-section (2) of section 31;

(s) the salary and allowances payable to and other terms and conditions of service of the Chairperson of the Appellate Tribunal and Member of the Appellate Tribunal under section 35;

(t) the salary and allowances and other conditions of service of the officers and other employees of the Appellate Tribunal under sub-section (3) of section 39;

(u) the additional matters in respect of which the Appellate Tribunal may exercise the powers of a civil court under clause (i) of sub-section (2) of section 40;

(v) any other matters which is to be, or may be, prescribed, or in respect of which provision is to be made, or may be made by rules.

57. (1) The State Government may, by notification, makes rules for carrying out the provisions of this Act and not inconsistent with the rules, if any, made by the Central Government.

Power of State Government to make rules

(2) In particular, and without prej udice to the generality of the foregoing power, such rules may provide for all or any of the following matters, namely: -

(a) energy conservation building codes under clause (a) of section 15;

(b) the form, the manner and the period within which information with regard to energy consumption shall be furnished under clause (h) of section 15;

(c) the person or any authority who shall administer the Fund and the manner in which the Fund shall be administered under sub-section (4) of section 16;

(d) the matters to be included for the purposes of inspection under sub-section (2) of section 17

(e) any other matter which is to be, or may be, prescribed, or in respect of which provision is to be made, or may be made, by rules.

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Power of Bureau to make regulations

58. (1) The Bureau may, with the previous approval of the Central Government and subject to the condition of previous publication, by notification, make regulations not inconsistent with the provisions of this Act and the rules made thereunder to carry out the pur poses of this Act.

(2) In particular, and without prejudice to the generality of the foregoing power, such regulations may provide for all or any of the following matters, namely:-

(a) the times and places of the meetings of the Governing Council and the procedure to be followed at such meetings under sub-section (1) of section 5;

(b) the members of advisory committees constituted under sub-section (2) of section 8;

(c) the powers and duties that maybe exercised and discharged by the Director-General of the Bureau under sub-section (6) of section 9;

(d) the levy of fee for services provided for promoting efficient use of energy and its conservation under clause (n) of sub-section (2) of section 13;

(e) the list of accredited energy auditors under clause (o) of sub-section (2) of section 13;

(f) the qualifications for accredited energy auditors under clause (p) of sub-section (2) of section 13;

(g) the manner and the intervals or time in which the energy audit shall be conducted under clause (q) of sub-section (2) of section 13;

(h) certification procedure for energy managers under clause (r) of sub-section (2) of section (13);

(i) particulars required to be displayed on label and the manner of their display under clause (d) of section 14;

(j) the manner and the intervals of time for conduct of energy audit under clause (h) or clause (s) of section 14;

(k) the manner and the intervals of time for conducting energy audit by an accredited energy auditor under clause (c) of section 15;

(l) any other matter which is required to be, or may be, specified.

Rules and regulations to be laid before Parliament and State Legislature

59. (1) Every rule made by the Central Government and every regulation made under this Act shall be laid, as soon as may be after it is made, before each House of Parliament while it is in session, for a total period of thirty days which may be comprised in one session or in two or more successive session, and if, before the expiry of the session immediately following the session or the successive sessions aforesaid, both Houses agree in making any modification in the rule or regulation, or both Houses agree that the rule or regulation should not be made, the rule or regulation shall thereafter have effect only in such modified form or be of no effect, as the case may be; so however that any such modification or annulment shall be without prejudice to the validity of anything previously done under that rule or regulation.

(2) Every rule made by the State Government shall be laid, as soon as may be after it is made, before each House of the State Legislature where it consists of two Houses, or where such Legislature consists of one House, before that House.

Application of other laws not barred.

60. The provisions of this Act shall be in addition to, and not in derogation of, the provisions of any other law for the time being in force.

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61. The provisions of this Act shall not apply to the Ministry or Department of the Central

Government dealing with Defence, Atomic Energy or such other similar Ministries or Departments undertakings or Boards or institutions under the control of such Ministries or Departments as may be notified by the Central Government.

Provisions of Act not to apply in certain cases

62. (1) If any difficulty arises in giving effect to the provisions of this Act, the Central Government may, by order, published in the Official Gazette, make such provisions not inconsistent with the provisions of this Act as may appear to be necessary for removing the difficulty: Provided that no such order shall be made under this section after the expiry of two

years from the date of commencement of this Act. (2) Every order made under this section shall be laid, as soon as may be after it is made, before each House of Parliament.

Power to remove difficulty.

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THE SCHEDULE

[See section 2 (s)]

List of Energy Intensive Industries and other establishments specified as designated consumers

1. Aluminium;

2. Fertilizers;

3. Iron and Steel;

4. Cement;

5. Pulp and paper;

6. Chlor Akali;

7. Sugar;

8. Textile;

9. Chemicals;

10. Railways;

11. Port Trust;

12. Transport Sector (industries and services);

13. Petrochemicals, Gas Crackers, Naphtha Crackers and Petroleum Refineries;

14. Thermal Power Stations, hydel power stations, electricity transmission companies

and distribution companies;

15. Commercial buildings or establishments;

SUBHASH C.JAIN,

Secy. to the Govt. of India.

MGIP(PLU)MRND— 2995GI— 19-10-2001

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References


690References

REFERENCES

• Detailed Energy Audit reports

CII – Energy management cell has carried out detailed energy audits in over 360 Industriesin India, comprising of various sectors such as cement, paper, sugar, fertilizer, ceramics,engineering, power plants, commercial buildings, synthetic fibre, caustic chlor, etc.

The feedback from the audited units indicated a saving of Rs 850 million based on theimplementation of proposals suggested in the detailed energy audit.

The energy consumption details and savings possible in each of these sectors have beencompiled from these detailed energy audit reports.

• Energy Efficiency at design stage Manual prepared by CII

This unique manual, the first of its kind was developed by CII – EMC under the ADB –Energy Efficiency support project. This manual includes all the energy saving aspects thatcan be incorporated at design stage for achieving energy efficiency.

• Case Study booklets on energy efficiency prepared by CII on Cement Paper, Sugar, Fertilizer,Ceramic & Textile

Six case study booklets in six energy intensive sectors covering actual implemented casestudies were brought out under the project.

This project involved extensive travel by CII team to over 30 industries to study the energysaving project implemented.

• Seminar material – various presentation of energy efficiency in equipment & process

• IDEAS – Report prepared by CII for power sector reforms

• Clean Development Mechanism (CDM) handbook – prepared by CII


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Internet

Data & StatisticsMinistry of power - www.powermin.nic.in

Central Electricity Authority (CEA), India - www.cea.org

CMIE – www.cmie.com

Indian Statistics – www.indiastat.com

India info line – www.indiainfoline.com

Cement Manufacturers Association (CMA) – www.cma.com

Sugar – www.sugaronline.com

Paper - www.Kakaz.com

Fertilizer

Database - www.Eco-web.com

Petroleum Conservation & Research Association - www.pcra.org

Alkali Manufacturers Association - www.amaionline.org

Ministry of Chemicals - www.chemicals.nic.in

Chemical Manufacturers Association - www.icmaindia.com

Chemical Technology - www.chemicals-technology.com

Gujarat Alkalies - www.gujaratalkalies.com

Equipment SuppliersBharat Heavy Electricals Limited – www.bhel.com

Thermax – www.thermax.com

Asea Brown Boveri – www.abb.com

Siemens www.siemens.com

Financial InstitutionsIndian Renewable Energy Development Agency www.iredaltd.com

World Bank – www.worldbank.org

The Energy & Resources Institute – www.teriin.org

USAID – www.usaid.gov


692References

Resource person consulted /organisation visitedThe Associated Cement CompaniesPetroleum Conservation Research AssociationMr C V Chalam, Director, C V Chalam Consultants Pvt LtdIndian Institute of Technology, ChennaiMr N Srinivasan, President, Thiru Arooran Sugars LimitedSIEL – Caustic Chlor companyMr C Sitaram, Manager – Technical, Coromandel Fertilisers LimitedBombay Dyeing Manufacturing Co LtdITC – Bhadrachalam Paper Boards Ltd, Bhadrachalam and SecunderabadFuller India Limited, ChennaiMr K S Kasi Viswanathan, President (Operations), Seshasayee Paper Boards Ltd, Erode

Visits madeFinancial InstitutionsIndustrial Credit and Investment Corporation of India (ICICI), Bandra Kurla Complex, MumbaiIndustrial Development Bank of India (IDBI), MumbaiIndian Renewable Energy Development Agency (IREDA), New DelhiState Bank of India (SBI) – Energy Business Division, Chennai

Visit to companiesArunachalam Sugar Mills Ltd, MallappambadyLanco Power, KondappalliJK Pharmaceuticals Ltd, CuddaloreEID Parry Ltd (Sugar Division), NellikuppamTata Power Ltd, TrombayBirla Tyres Ltd, BalasoreGujarat Ambuja Cements Ltd, KodinarApollo Tyres Ltd, PerambaraShriram Fibres Ltd, ChennaiIndian Aluminium Ltd (INDAL), KalwaLarsen & Toubro Ltd – AP Cement Works, TadpatriEnnore Foundries Ltd, ChennaiLarsen & Toubro Ltd, Rajula Cement worksGrasim Industries Limited (Staple Fibre Division), NagdaJindal Vijayanagar Steel Ltd, BellaryMotor Industries Company Limited (MICO), Adugodi, BangaloreSundaram Clayton Ltd, ChennaiCoromandel Fertilisers Ltd, VizagSterlite Industries Ltd, TuticorinCentury Pulp & Paper Ltd, LalkuaSPIC Pharmaceuticals Ltd, CuddaloreRieter LMW Ltd, Coimbatore


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ConclusionIndian Renewable Energy Development Agency (IREDA) has received a line of credit from theInternational Bank for Reconstruction and Development (IBRD) / Global environmental facility(GEF) towards the cost of India: second renewable energy project.

As a part of this line of credit, technical assistance plan (TAP) is envisaged for institutionaldevelopment and technical support to IREDA. Preparation of this investors’ manual forenergy efficiency sector – industrial sub sector, as a guide to intending entrepreneurs, is oneof these TAP activities.

The objective is to prepare an Investors’ Manual covering the topics like energy savingpotential for various industries, technologies available to improve energy efficiency, equipmentsuppliers, government policies / incentives available for the sector, terms of IREDA and otherfinancial institutions extending support to such projects etc.

The end objective of the activity is market development for energy efficiency / conservationproducts & services. The whole effort is to prepare a simplified and user-friendly manualbased on inputs from various stakeholders in energy efficiency sector.

Confederation of Indian Industry (CII) – Energy Management Cell (EMC) was awarded thetask of preparing this manual by IREDA.

CII – EMC adopted the following methodology in preparing this manual:

1. Analyze the existing data available with CII and develop a detailed action plan for execution

2. Identify industries under energy intensive and non-intensive categories

3. Review the detailed energy audits carried out by CII in various sectors and estimateenergy saving potential possible in identified energy intensive and non-intensive sectors

4. Analyze literature available with CII

5. Discuss with industry experts / Consultants

6. Identify list of energy saving measures to be undertaken in each industry

7. Evaluate technical details for each of the proposed energy saving measures in variousindustries

8. Prepare / identify the list of equipment suppliers (National & International), EPS Contractors,Energy Service Companies, etc., who can take up these energy saving measures


10. Prepare / identify the list of consultants / energy auditors etc., who can be approachedfor conducting energy audit, preparation of DPR, etc.

11. Interacting with IREDA and other financial institutions

12. Preparation of a brief note of finance mechanism available for taking up energy efficiencyprojects from IREDA and other financial institutions

Conclusion


694Conclusion

13. Preparation of a brief description of government policy / incentives / concessions availablefor identified energy saving projects / equipment identified in various energy intensive andnon-intensive sectors


The various sectors identified under this project, and the share of energy in the manufacturingcost, is as under:

Sector Power & Fuel cost as % of Production cost

1 Cement 43.72 Caustic Chlor 40.73 Aluminium 33.44 Glass 30.95 Ceramic 25.36 Copper 24.07 Paper 23.78 Fertiliser 18.49 Foundry 13.710 Steel 13.311 Sponge Iron 12.812 Synthetic Textiles 11.313 Textile 10.314 Engineering 6.015 Tyre 7.716 Drugs & Pharma 4.617 Dairy 4.218 Sugar 2.019 Petro Chemical 2.020 Refinery 2.0

The list of sectors identified under this project comprises of about 68% of India’s totalindustrial energy consumption.

Energy saving – Case StudiesThe objective of highlighting these projects & case studies is to facilitate the potential investors,in having a quick reference of the various energy saving measures and also enable themmake decisions on investment.


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These projects are all proven projects, which have been implemented successfully in Indianindustry.

Majority of the plants have still not implemented these projects, due to lack of suitable incentivesand financing.

The projects have been described in detail, highlighting the earlier & current practice, benefitsachieved, financial analysis and also its replication potential, wherever applicable.

Some of these projects / case studies are sector specific. But, majority of these projects havepotential to find an application in different sectors. These projects are not limiting to thesector under which they are described. The idea can be replicated in other sectors also.

Summary of this reportThe various sectors highlighted in this report offer an annual saving potential ofRs 37510 million (USD 750 million). This, in turn, creates an investment opportunity ofRs 82575 million (USD 1650 million), to achieve the projected energy savings.

S.No Sector Annual saving Investment opportunityPotential Rs. Million, Rs. Million,

(US $, Million) (US $, Million)

1 Cement 3500 (70) 7000 (140)2 Caustic Chlor 8600 (172) 30000 (600)3 Aluminium 500 (10) 1000 (20)4 Glass 550 (11) 800 (16)5 Ceramic 350 (7) 725 (14.5)6 Paper 3000 (60) 5000 (100)7 Fertiliser 2000 (40) 6000 (120)8 Foundry 1800 (36) 3500 (70)9 Sythetic Fibre 1300 (26) 2500 (50)10 Textile11 Tyre 860 (17) 1750 (35)12 Drugs & Pharma 1100 (22) 1800 (36)13 Sugar 4200 (84) 6000 (120)14 Engineering 5000 (100) 10.000 (200)15 Copper 750 (15) 1500 (30)16 Power Plants 3000 (60) 5000 (100)

Total 37,510 (750) 82,575 (1650)

This report will serve the objective of its preparation, in promoting / development of market forenergy efficient equipment & suppliers in Indian industry.

Conclusion

Confederation of Indian IndustryEnergy Management Cell

#35/1 Abhiramapuram 3rd Street, Alwarpet, Chennai 600 018.Tel: 2466 1311 / 0570 / 0291 / 0430 (D) Fax: 24660312

E-Mail : [email protected] Website : www.greenbusinesscentre.com

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