Journal of Cleaner Production xxx (2016) 1e11

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Journal of Cleaner Production

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Potential of solar industrial process heating in dairy industry in India

and consequent carbon mitigation
Ashish K. Sharma*, Chandan Sharma, Subhash C. Mullick, Tara C. Kandpal
Center for Energy Studies, Indian Institute of Technology Delhi, Hauz Khas, New Delhi 110016, India

a r t i c l e i n f o a b s t r a c t

Article history: An attempt to estimate the potential of solar industrial process heating (SIPH) and corresponding
Received 8 September 2015 mitigation of greenhouse gas emissions in dairy industry in India is presented. An assessment of avail-
Received in revised form ability of solar radiation as well as of the ambient conditions at various locations with milk processing
17 May 2016
plants has been made. The effect of the choice of design value of direct normal irradiance on the annual
Accepted 25 July 2016
performance of solar process heating systems has been studied using model developed for hourly
Available online xxx
simulation of the performance of solar process heating system. Further, state wise estimates for useful
thermal energy delivery and corresponding solar fraction have also been obtained.
Keywords:
Potential of solar industrial process heating
The total process heating potential in term of useful energy requirement in dairy sector in India has
Dairy industry in India been estimated at 6.40 PJ/annum which reduces to 4.50 PJ per annum if the process heating requirement
Energy delivery of SIPH systems is restricted to only pasteurization stage of milk processing. The corresponding solar collector area
Carbon mitigation potential requirement for process heating in dairy industry in India is estimated in the range of 1.54
e1.83 million m2 with the average solar fraction estimated in the range 0.18e0.32. The use of solar
energy for meeting milk processing related thermal energy demand is expected to mitigate (32
e144 thousand tonnes) of CO2 emissions annually.
© 2016 Elsevier Ltd. All rights reserved.

1. Introduction
To promote the use of solar energy in industrial process heating,
government of India has implemented a UNDP-GEF supported
project (UNDP-GEF, 2011). The project is aimed to promote and
commercialize Concentrating Solar Technologies for industrial
process heat applications. The dairy industry in India is also
included in the scope of the project.
In the past, several studies those were primarily focused on the
potential of process heating in industrial sector of a country and
region invariably include the dairy industry in the scope (ABPS,
2011; BEE, 2010; Claudia et al., 2008; Lauterbach et al., 2012;
Schnitzer et al., 2007; Schweiger et al., 2001). Potential assess-
ment of solar process heating in the industrial sector of Greece has
been carried out by (Karagiorgas, 2008). The scope of this study was
only limited to use of solar energy for boiler feed water heating.
Case studies presenting the actual performance of solar process
heating systems using concentrating solar collectors (Parabolic
* Corresponding author.
E-mail address: aksharmanith@gmail.com (A.K. Sharma).
trough and Arun 160) in the dairy industry have also been reported
in the literature (Bhosale at al., 2008, Ramirez et al., 2006; Quijera
and Labidi, 2013).
In the context of Indian dairy industry, solar process heating
potential of 1.88 PJ per annum was estimated (GIZ, 2011). However,
the study was only limited to low temperature process heat ap-
plications such as hot water generation and boiler feed water
heating. It did not consider (i) the use of solar energy to meet
process heating demand (through steam generation) at higher
temperatures, (ii) solar resource availability at different locations
having dairy plants and (iii) expected performance of solar indus-
trial process heating (SIPH) systems in dairy industry in terms of
useful energy delivery and solar fraction.
In order to develop and implement effective policies and pro-
motional measures, policy makers and regulators in a government
would require reliable information about (a) The overall potential
of SIPH in the country (b) niche locations that are suitable for the
interventions in the initial phase, (c) expected performance of SIPH
systems in these locations and (d) expected fuel saving and emis-
sions mitigation likely to be offered by SIPH systems.
In view of the above an attempt to estimate the potential of
SIPH in dairy industry and corresponding carbon mitigation

http://dx.doi.org/10.1016/j.jclepro.2016.07.157
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Please cite this article in press as: Sharma, A.K., et al., Potential of solar industrial process heating in dairy industry in India and consequent
carbon mitigation, Journal of Cleaner Production (2016), http://dx.doi.org/10.1016/j.jclepro.2016.07.157
2 A.K. Sharma et al. / Journal of Cleaner Production xxx (2016) 1e11

Table 1
Time trend of milk production in the states of India and installed capacity of milk processing plants as on (2011e12).

State Milk production (million tonnes per annum) No of milk processing plants Installed capacity (tonnes per day)

2008e09 2009e10 2010e11 2011e12 2012e13

Andhra Pradesh 9.57 10.42 11.20 12.08 12.76 48 7843

Gujarat 8.38 8.84 9.32 9.81 10.31 33 14,477
Haryana 5.74 5.74 6.00 6.66 7.40 37 2947
Karnataka 4.53 4.82 5.11 5.44 5.78 24 4808
Madhya Pradesh 6.85 7.16 7.51 8.14 8.83 25 5012
Maharashtra 7.45 7.67 8.04 8.46 8.74 395 26,592
Punjab 9.38 9.38 9.42 9.55 9.71 77 8349
Rajasthan 11.93 12.33 13.23 13.51 13.9 38 5841
Tamil Nadu 6.54 6.65 6.78 6.96 7.00 37 9319
Uttar Pradesh 19,35 20.20 21.03 22.55 23.33 253 35,045
Others 41.93 23.19 24.16 24.74 23.19 98 10,380

Total 112.20 116.41 121.28 127.90 132.42 1065 130,613

potential in India has been presented in this paper. The potential
of solar industrial process heating (SIPH) in dairy industry essen-
tially refers to the amount of useful energy that can be saved (or
substitute) in dairy industry by providing the process heat
required. In other words the potential represents the useful energy
supplied with solar energy system. Moreover, often the potential
of solar industrial process heating (SIPH) is also expressed in terms
of the solar collector area that can be installed to meet the part of
process heating requirement. Finally, the greenhouse gas emis-
sions (GHG) CO2, CH4 and N2O etc. mitigation potential essentially
represents the net amount of GHG gases those are likely to be
mitigated due to replacement of fossil fuels used in dairy industry
by solar energy.
2. Overview of dairy industry in India
Dairy industry in India is considered as one of the most suc-
cessful development programs in post-Independence period. In the
year 2012e13, with a total production of 132.5 million tonnes of
milk, dairy industry in India accounted for 13% of global milk
production. The time trend of milk production in some of the states
of India is presented in Table 1. States mentioned in the table are
contributing for more than 80% of overall milk production of the
country (NDDB, 2014). In India milk from mainly three animals is
consumed. These are cows, buffaloes and goats with approximately
44.5%, 51.5% and 4% contribution respectively (DAHD&F, 2012).
In India the milk is consumed both in the raw (un-processed) as
well as processed forms with the raw milk being consumed locally
(Fig. 1) (MOA, 2012). The use of processed milk is prevalent through
both the organized as well as un-organized sectors. The milk pro-
cessing in the organized sector (20% of the total milk processed) is
undertaken to produce the pasteurized liquid milk as well as other
value added products Table 2.
Organized sector consists of the milk processing plants are those
registered with state or central authorities and having installed
capacities of handling up to one million liters of milk per day. In
India, 1065 milk processing plants with installed capacity of
37 million tonnes per annum are reportedly registered in the
organized sector (MOA, 2012; CII, 2013). State wise installed ca-
pacity of such plants in the country is presented in Table 1.

Fig. 1. A schematic of the structure of dairy industry in India.

Please cite this article in press as: Sharma, A.K., et al., Potential of solar industrial process heating in dairy industry in India and consequent
carbon mitigation, Journal of Cleaner Production (2016), http://dx.doi.org/10.1016/j.jclepro.2016.07.157
 A.K. Sharma et al. / Journal of Cleaner Production xxx (2016) 1e11 3

Table 2 Table 3
Estimates for percentage of milk processed in the organized sector in India. Specific thermal energy requirement in a typical milk processing plant in India.

S. no. Year Share of milk Remarks Reference Process Pressure Temperature Thermal energy
processed in (bar) (
C) requirement
organized sector (MJ/tonne)

1 2009e10 20% Liquid Milk (15%) CII, 2013 Up to milk 1e3 85e110 180
Value added products (5%) pasteurization
2 2009e10 20% Liquid Milk (15%) HS&SL, 2009 (STERp)
Value added products (5%) Value added products 2e5 130e140 230
3 2009e10 20% Liquid Milk (15%) RIFL, 2010 (excluding milk powder)
Value added products (5%) average value of the specific 10e15 180e200 250
4 2012e13 20% Liquid milk (13.5%) NDDB, 2014 thermal energy requirement
Value added products (6.5%) for milk processing plants
in India (STERA)

In these plants, pasteurization of milk (packed liquid milk) and

manufacturing of value added products from milk, such as clarified
butter, butter, yogurt, skimmed milk powder and ice creams etc. is
carried out.
Milk processing in unorganized sector comprises of numerous
small and/or seasonal milk producers/traders (popularly known as
halwais) those are not registered under states and central dairy
authorities. They are involved in selling raw milk, boiled milk and
many other traditional Indian milk products at local levels. Milk
processing in un-organized sector has a major share (80%) in total
milk consumption but due to the huge diversity at the local level
there is no official record of such units (HS&SL, 2009).
2.1. Typical processes involved and energy use in dairy industry
Processes involved in the dairy industry vary as per the final
product(s) being produced. These processes can be divided into two
categories: (a) processes involved in pasteurization of milk and (b)
manufacturing of value added products such as butter, clarified
butter, skimmed milk powder, cheese etc.
Raw milk is collected from the farms and domestic suppliers and
stored at lower temperatures. The collected milk is then pasteur-
ized to kill harmful bacteria after which the cream is separated in a
separator and skimmed milk is stored for further use or processing.
A schematic diagram of a typical milk processing unit representing
some of the processes involved in manufacturing of different
products of milk is presented in Fig. 2 (NRCOEE, 2001).
Processes such as pasteurization, sterilization, spray drying,
evaporation and hot water generation etc. require thermal energy
at different temperature levels (Table 3). In a typical milk pro-
cessing plant, a major fraction (70%) of energy use is essentially for
process heating (50e200
C) (FOE, 2006; Kalogirou, 2003; NMCC,
2007). Steam and pressurized hot water at different temperatures
and pressures are commonly used as the heat transfer media.
Steam is produced in a captive boiler and as per the requirement of
processes extracted at desired pressures.
Energy consumption of milk processing plants varies widely,
depending on annual capacity utilization, seasonal variation in
the availability of milk, current technology being used for milk
processing, and the product mix (CII, 2013). The data for the
product wise specific energy consumption in the in the milk
processing plants in India is not available with sufficient detail.
Moreover, presently there are no benchmark values defined for
specific energy consumption of different products. An average
thermal energy requirement of 250 MJ/tonne of milk processed
has been reported by the Bureau of Energy Efficiency (CII, 2013).
However, as per the international standards (IDF, 2005) data
regarding specific energy requirements in dairies for different
products being manufactured is presented in Table 3 (FAO, 2014;
IDF, 2005).
In the year of 2007e08 approximately 210 kilo tonnes of oil
equivalent (ktoe) of primary energy was consumed in the orga-
nized dairy sector (GIZ, 2011). Most of the energy demand

Fig. 2. A schematic showing the flow chart of a milk processing unit.

Please cite this article in press as: Sharma, A.K., et al., Potential of solar industrial process heating in dairy industry in India and consequent
carbon mitigation, Journal of Cleaner Production (2016), http://dx.doi.org/10.1016/j.jclepro.2016.07.157
4 A.K. Sharma et al. / Journal of Cleaner Production xxx (2016) 1e11
(electricity as well as process heat) in dairy industry in India is met
with the use of fossil fuels. Though petroleum products (furnace oil,
and high speed diesel (HSD)) have a significant share but other
fuels, such as coal, agro-residues (rice husk, bagasse etc.) are also
used in the boilers. In addition, grid electricity is used for running
motors and refrigeration units (BEE, 2010).
2.1.1. Methodology adopted for potential estimation
The methodology used (Fig. 3) for estimating the potential (SIPH
and consequent GHG emissions mitigation) involves the (a) Esti-
mation of the useful thermal energy requirement for milk pro-
cessing, (b) Checking for solar resource availability at
representative locations of milk processing plants in the country (c)
Performance assessment of SIPH systems at representative loca-
tions of milk processing plants and (d) Estimation of GHG emissions
mitigation potential. A brief description on each one of the above
mentioned steps is presented in the following paragraphs.
2.2. Estimation of the useful thermal energy requirement for milk
processing
Since a certain fraction (Fmlc,i) of the total milk produced is
consumed locally without processing, the total annual amount of
milk that is processed in the country (TAMp) in million tonnes per
annum is
X
n   from 1600 kWh/m2 to 2100 kWh/m2. As an example, data for few
TAMp ¼ 1  Fmlc;i Tmp;i
i¼1
where Tmp,i representing the total milk production (millions tonnes
per annum) of the ith state of the country. The summation has been
made for all states in the country (varying from i ¼ 1 to n) with the
subscript i denoting the ith state.
Only a certain fraction (FMPos,i) of the total milk processed is
routed through the organized sector. Thus the total annual amount
of milk (TAMp,os) that is processed in organized sector (million
tonnes) can be estimated as
X
n     location of use.
TAMp;os ¼ 1  Fmlc;i FMPos;i Tmp;i
i1
The useful thermal energy requirement for milk processing
(ATER) in PJ/annum can therefore be estimated as
X
n     
ATER ¼ 1  Fmlc;i FMPos;i Tmp;i ðSTERa Þ
i¼1
where STERa denotes the average value of the specific thermal
energy requirement for milk processing (MJ/kg) in Indian milk
processing plants (Table 3). Also in order to estimate the useful
thermal energy requirement for milk processing up to pasteuriza-
tion stage (ATERp) in PJ/annum same expression is used, however
value of specific thermal energy requirement of pasteurization
(Table 3) has been considered.
As per the available data, about 58% of the milk produced in the
country is consumed without processing (CII, 2013). Since such an
information is not available at state level, as a first approximation
the country level average has been used in this study (i.e.
Fmlc,i ¼ 0.58 for all values of i). The value of the fraction of milk
processed in organized sector has been estimated from the re-
ported values of installed capacity of the milk processing plants and
their annual average capacity utilization factor. For example, for the
ith state the fraction of milk processed in organized sector (FMPos,i)
can be estimated as
Please cite this article in press as: Sharma, A.K., et al., Potential of solar industrial process heating in dairy industry in India and consequent
carbon mitigation, Journal of Cleaner Production (2016), http://dx.doi.org/10.1016/j.jclepro.2016.07.157
ð365ÞðICi  ACUFÞ
FMPos;i ¼   (4)
1  Fmlc;i  Tmp;i
with ICi representing the total installed capacity of milk processing
plants (tonnes per day) in the ith state, ACUF the average value of
the annual capacity utilization of milk processing plants in the
country.
2.3. Assessment of solar resource availability at some representative
locations with milk processing plants
Milk processing plants are widely distributed across the country
with almost each district having at least one plant. Therefore, in
each state few representative locations with milk processing plants
have been identified and the corresponding data regarding the
annual cumulative value of Direct Normal Irradiance (DNI), annual
average ambient temperature (Ta) and annual average wind speed
at these locations has been obtained from the weather data source
of the software Meteonorm 7.1 (2014). It is worth mentioning that,
DNI refers to the intensity of direct (beam) component of solar
radiation incident normally on the aperture of the solar collector.
Though, DNI is expressed in the units of W/m2, its annual cumu-
lative at a location is expressed in kWh/m2 so as to facilitate
comparison between different locations. The values of available
annual DNI in the niche locations with dairy plants in India varies
(1) representative locations in the state of Maharashtra is presented in
Table A (Appendix).
2.4. Performance assessment of SIPH systems at selected locations
with milk processing plants
Performance of any solar process heating system mainly de-
pends on (a) Required temperatures of process, (b) performance
characteristics of solar collector being used and (c) Availability of
solar radiation (DNI in case of concentrators based systems) and
climatic conditions (e.g. ambient temperatures, wind speeds) at the
(2) Details of some of the existing milk processing plants in India
are presented in Table 4 (Solar Power, 2006; PCRA, 2015). Based on
the process heating requirements of a typical dairy plant (Table 4), a
solar processing heating system that can provide outlet tempera-
ture of 184
C and pressure of 10.55 bar has been considered. Two
solar concentrator technologies (Arun 160 parabolic dish, and
(3) parabolic trough) have been considered to supply the required
process heat.
The area (in m2) of solar collector field (ASCf) required to meet
the process heating demand at a given location for pre-defined
operating conditioning (temperature and pressure) can be esti-
mated as
PHRh
ASCf ¼   (5)
hsiph ðDNId Þ
where, PHRh represents the hourly value of process heating
requirement (GJ/hour), hsiph the overall thermal efficiency of solar
energy utilization of SIPH system at chosen value of design DNI as
well as operating conditions and DNId the chosen value of design
DNI incident on the aperture of the solar concentrator (W/m2).
Design DNI is the intensity of direct component of solar radia-
tion at which a solar concentrator based SIPH system would pro-
duce its nominal (rated) thermal output. As may be noted from
equation (5), the higher the chosen value of design DNI for the SIPH
 A.K. Sharma et al. / Journal of Cleaner Production xxx (2016) 1e11 5

Fig. 3. Methodology used for estimation of GHG emissions mitigation potential of SIPH in dairy industry.

Please cite this article in press as: Sharma, A.K., et al., Potential of solar industrial process heating in dairy industry in India and consequent
carbon mitigation, Journal of Cleaner Production (2016), http://dx.doi.org/10.1016/j.jclepro.2016.07.157
6 A.K. Sharma et al. / Journal of Cleaner Production xxx (2016) 1e11

Table 4
Details of some existing milk processing plants in India.

Location State Process requirements Products Heat transfer medium

Pressure (bar) Temperature (
C)

Barmati Maharashtra 10.55 184 Milk, Flavoured milk, UHT milk, Cheese, Butter. Other Indian Products Steam
Sangali Maharashtra 5 152 Milk, butter milk Cheese, Butter. Steam
Latur Maharashtra 18 180 Pasteurized liquid milk Pressurized Hot water
Surat Gujarat 8.5 170 Pasteurized liquid milk, butter milk, UHT milk Steam
Anand Gujarat 5 152 Pasteurized liquid milk Steam
Surat Gujarat 15.55 200 Milk, Flavoured milk, UHT milk, Ice cream, Skimmed milk powder Steam
Himatnagar Gujarat 10 180 Pasteurized liquid milk, butter milk, UHT milk Steam
Rajkot Gujarat 9 170 Milk, Flavoured milk, UHT milk, Cheese, Butter. Other Indian Products Steam
Chittoor Tamilnadu 4 140 Pasteurized liquid milk, Butter, Cheese Steam
Bellary Karnataka 8.5 170 Milk, Flavoured milk, UHT milk, Cheese, Butter. Other Indian Products Steam

system lower would be the collector area required for producing its
nominal output and vice versa. In actual operation of an SIPH sys-
tem, usually the value of available DNI varies during the day e the
values being relatively much smaller during early forenoons and
late afternoons. As a consequence, during a day whenever the value
of available DNI is lower than the chosen value of design DNI for the
SIPH system, its output will be less than the nominal value. Thus, in
this case, an auxiliary backup or storage would be required to meet
the process heating demand.
On the other hand, if the available DNI is more than the design
DNI, the SIPH system will produce more output than its nominal
capacity and thus the extra amount of thermal energy collected will
have to be dumped or stored in a thermal storage system. An SIPH
system designed for a DNI value of 900 W/m2 would have much
smaller collector area as compared to a system designed for a DNI of
600 W/m2. Therefore, the system designed for a DNI value of
900 W/m2 would not be able to produce the nominal thermal
output during all the time of the day when the available DNI is less
than its design value leading to a smaller solar fraction. On the
other hand, a system designed for a DNI value of 600 W/m2
(implying larger solar collector area) is likely to produce its nominal
output for longer time during the day as compared to the system
designed for 900 W/m2 and thus having a higher solar fraction.
Determining the solar collector area from equation (5), using
hourly DNI values the useful thermal energy delivered by the SIPH
system has been estimated. Hourly values of the DNI at the selected
locations were obtained using the weather software Meteonorm
7.1. This exercise is repeated for all representative locations of milk
processing plants in the country. Schematic of the procedure fol-
lowed has also been presented in the (Fig. 4).
Also the fraction of useful energy requirement for process
heating that is met by the solar industrial process heating system
(i.e. Solar Fraction) can then be estimated as the ratio of the annual
value of the useful energy delivered by the SIPH system to the total
useful energy requirement for process heating in the milk pro-
cessing plant. To analyze the effect of design DNI on the useful
energy delivery of SIPH systems different values of design DNI
(600 W/m2 and 900 W/m2) have been considered.

Fig. 4. Approach used for estimation of solar collector area and performance of SIPH systems.

Please cite this article in press as: Sharma, A.K., et al., Potential of solar industrial process heating in dairy industry in India and consequent
carbon mitigation, Journal of Cleaner Production (2016), http://dx.doi.org/10.1016/j.jclepro.2016.07.157
 A.K. Sharma et al. / Journal of Cleaner Production xxx (2016) 1e11
Table 5
Scenarios of fuel mix use in dairy industry in India.
Scenario Fuel use (%)
Biomass High speed diesel
I 15 15
II 15 70
III 33 33
IV 70 15
V e 100
VI e e
It is assumed that the SIPH system does not store heat and is
equipped with an auxiliary backup system to supplement the
thermal energy requirement in off sunshine hours. In such a case
only a certain fraction of gross potential (total useful energy
requirement of process heating) of SIPH would be partially realized.
In order to estimate the potential of SIPH (without thermal storage)
an average value of solar fraction for each state has been taken.
2.5. Carbon mitigation potential of SIPH in dairy industry in India
Emissions from fossil fuel combustion depend on the grade and
composition of the fuel, the type and size of the boiler, the firing
and loading practices used, and the level of equipment mainte-
nance (Herold, 2003). Often CO2 emissions make up most of GHG
emissions besides carbon monoxide (CO), methane (CH4) and non-
methane volatile organic compounds (Reilly et al., 2003).
Milk processing plants in India use a variety of fuels also a large
number of milk processing still use biomass feedstock (such as fuel
wood, agricultural residuals etc.) Moreover, due to sessional avail-
ability of biomass same plants also use fossil fuels (HSD and furnace
oil). Also in context of dairy industry in India, data regarding the
actual figures of different fuels use has not been available in the
literature. Therefore, in the present study based on the data
regarding the breakup of fuel use in few milk processing in India
has been analyzed (ABPS, 2011). Based on these breakup different
combinations of fuel mix use have been considered (Table 5).
Further, for each scenario, amount of CO2 and other GHG emissions
(CH4, N2O) that are likely to be mitigated with the replacement of
solar energy have been estimated.
The annual gross amount of CO2 emissions mitigated (ACM)
with the use of SIPH is estimated using the following expression
44 X   ðCF Þ ðF Þ design DNI value of 600 W/m2, the average solar fraction of SIPH
i co
ACM ¼ Fphd;i  Tphd
12 hi CVi
i 900 W/m2 solar fraction is found to be in between 0.20 and 0.24. As
where 44/12 represents the ratio of molecular weight of CO2 (44) to
the molecular weight of Carbon (12), Tphd, the total annual process
heating demand of the industry met with SIPH, (GJ/annum) Fphd,i,
the fraction of process heating demand met by ith fuel, CVi the
Calorific Value of ith fuel (MJ/kg), CFi the carbon fraction in ith fuel,
Fco,i the fraction of carbon oxidized in the combustion of ith fuel
and, hi the efficiency of ith fuel utilization in the boiler.
The other GHG emissions (CH4 and N2O) associated with the fuel
use mix of dairy industry in India are also estimated using the
following expression
 ðCV Þ  EF !
X   
i ijoxec
Eij ¼ Fphd;i  Tphd
1000
i
where Eij (tonnes) is the emissions of gas type (j), (methane or
nitrous oxide, from fuel type (i), EFij, oxec the emission factor for
each gas type (j) (which includes the effect of an oxidation factor)
for fuel type (i). The values of these factors are listed in Table 5.
Please cite this article in press as: Sharma, A.K., et al., Potential of solar industrial process heating in dairy industry in India and consequent
carbon mitigation, Journal of Cleaner Production (2016), http://dx.doi.org/10.1016/j.jclepro.2016.07.157
7
Also direct Global Warming Potential (GWP) of these gases
relative to CO2 based on the characterization factors adopted by the
Intergovernmental Panel on Climate Change (IPCC, 2007) has also
Furnace oil
been estimated in the present analysis. It is worth mentioning that,
the net annual amount of GHG emissions mitigated would depend
70
upon the annual equivalent of the GHG emissions embodied in the
15
34 manufacturing of SIPH system. In the present study the same has
15 not been taken into account.
e
100
3. Results
Using the methodology outlined in Section 3, calculations have
been made to estimate the potential of using solar energy for
meeting process heating demand in dairy industry and also its GHG
mitigation potential. The values of various input parameters used in
the estimation of potential of SIPH and of corresponding GHG
mitigation in dairy industry in India are listed in Table 5. It is worth
mentioning that owing to unavailability of data required for
detailed modeling of SIPH potential, several simplifying assump-
tions have been made for estimating the potential. In particular, the
values of the following parameters may have some uncertainty
associated with their values (a) Fraction of milk locally consumed in
the country (b) fraction of milk processed in organized dairy sector
in India, (c) the value of specific thermal energy requirement of
process heating in typical milk processing plant and (d) the fuel mix
and associated efficiency of fuel utilization for process heating in
dairy industry. The efficiency equations of the two solar collector
technologies used in this study are also presented in Table 5.
State-wise estimates for the annual amount of milk processed in
the organized dairy sector as obtained using equation (2) are pre-
sented in Table 6. Also using equation (3), the estimates for corre-
sponding annual useful thermal energy requirements (ATERP) for
pasteurization as well as overall milk processing (ATERo) have been
presented in this table. Thus, in principle, a total of 6.40 PJ of
thermal energy can be supplied with the use of solar energy for
meeting the process heating demand of dairy industry in India. Also
if process heating demand is restricted to pasteurization stage of
milk processing than 4.50 PJ of useful energy could be supplied
with SIPH. These numbers signify the gross potential of SIPH in
dairy industry in India.
Locations wise estimates of the collector area requirement cor-
responding to two values of design DNI at representative locations
of dairy plants in the state of Gujarat are presented in Table 7. At
(6) systems are higher (0.26e0.32) whereas, at design DNI values of
expected, the chosen value of design DNI has a direct effect on the
collector area requirement and solar fraction. Also it signifies that a
solar industrial process heating system without storage will be able
to meet a maximum of about 32% of the process heating demand of
a milk processing plant in the state of Gujarat. It may be noted that
between two collectors technologies considered (Arun 160 and
parabolic trough) the Arun 160 based process heating system is
expected to operate with marginally higher solar fraction. Esti-
mates for other 8 states in India are also listed in Appendix B.
Results for collector area requirement of SIPH in dairy sector in
India at two values of design DNI chosen are estimated in the range
of 1.54e1.83 million m2 (Table 8). State wise estimates for collector
(7) area requirement based on Arun 160 solar collector are presented in
Appendix C. Table 9 presents the estimates of GHG emissions likely
to be mitigated with the use of solar industrial process heating
systems in 9 major milk producing states of India. In all the scenario
of fuel mix use considered, the maximum value of annual CO2
emissions mitigation potential is estimated at 144 thousand tonnes
per annum) when design DNI is 600 W/m2 and HSD is replaced as a
8 A.K. Sharma et al. / Journal of Cleaner Production xxx (2016) 1e11

Table 6
Values of input parameters used in the analysis.

Parameter Symbol Unit Value Reference(s)

(A) Parameters for estimating the useful thermal energy requirement of milk pasteurization
Total annual milk production in the state Tmp Million tonnes e e
Fraction of milk locally consumed Fmlc Fraction 0.58 MOA, 2012
Installed capacity of dairy plant in each state IC Tonnes per day e e
Annual average capacity utilization factor ACUF Fraction 0.70 CII, 2013
Specific useful thermal energy requirement of milk pasteurization STERp MJ/tonne 180 FAO, 2014
Average thermal energy requirement of milk processing units in India STERA MJ/tonne 250 CII, 2013
(B) Parameters for assessing the performance of SIPH system
Design DNI DNId W/m2 600e900 e


Intel Temperature Ti C 60 PCRA, 2015


Outlet Temperature To C 184 e


Mean fluid temperature Tm C 122 e
Pressure P bar 5 e
Efficiency Equations (Arun 160) h ¼ 0.65  0.40  (Tm  Ta)/I Bhosale et al., 2008
Parabolic trough h ¼ 0.635  0.6431  (Tm  Ta/I SRCC (2014)
(C) Parameters for estimating the CO2 emissions mitigation potential
Calorific value of Furnace oil CV MJ/kg 38.6 (DOE, 2014)
Calorific value of furnace oil CV MJ/kg 39.7 e
Carbon fraction in furnace oil CF Fraction 0.84 CEA 2005 and UNEP, 2006
Carbon fraction in high speed diesel CF Fraction 0.85 e
Efficiency of fuel utilization (furnace oil) hf Fraction 0.80 (CII, 2013)
Efficiency of fuel utilization (high speed diesel) hf Fraction 0.80 e
Emission factors of furnace oil (relevant oxidation is incorporated) for CH4 and N2O EFij,oxec Fraction 0.03,0.02 (DOE, 2014.)
Emission factors of high speed diesel (relevant oxidation is incorporated) for CH4 and N2O EFij,oxec Fraction 0.1, 0.2

fuel. It may be noted that in the overall GHG emissions mitigation
potential CO2 have maximum share as compare to the other gases
(CH4 and N2O). Scenario 4 of fuel mix use shows that fraction of
biomass use as a fuel have significant role in the overall emissions
likely to be mitigated. Because at 70% share of biomass considered
at all values of design DNI reduction in GHG emissions found in the
range of (32e36 thousand tonnes per annum).
4. Discussion
Though the benchmark value for various input parameters used
in estimating the potential of SIPH in dairy industry are not avail-
able, on the basis of a preliminary review of the available data it can
be safely surmised that the estimated potential could be an un-
derestimate by about 15%. However, a more detailed analysis is
warranted to reduce the uncertainty in the values of potential es-
timates reported in this study. Moreover, efforts should be made
towards collection and analysis of comprehensive data to arrive at
more accurate estimates of the parameters used so as to reduce
uncertainty in the estimated potential.
It is interesting to note that the locations in the states with large
annual milk production and processing also have high annual DNI
availability thus making the use of solar energy in the dairy in-
dustry relatively more attractive. These states are Andhra Pradesh,
Gujarat, Karnataka, Madhya Pradesh, Maharashtra, Punjab, Rajas-
than, Tamilnadu and Utter Pradesh.
The estimates of solar fraction (0.18e0.32) of SIPH systems used
in dairy industry as arrived at in this study are for systems that do
not have provision for thermal storage. With the development of
medium and high temperature storage (particularly steam) it is
expected that the same could also be internalized into the SIPH
systems leading to increased solar fraction, However the incre-
mental cost of integrated storage will have to be compared with
incremental benefits due to enhanced solar fraction.
A large number of milk processing plants still use biomass as a fuel
(such as fuel wood, agricultural residuals etc.) for meeting their

Table 7
Estimates of annual useful thermal energy requirements of milk processing in India (2011e2012).

State Total amount of milk Total amount of milk processed Annual thermal Annual thermal
annually processed TAMp in organized sector TAMpos energy requirement energy requirement of
(million tonnes) (million tonnes) ATER (GJ) pasteurization ATERp (GJ)

Andhra Pradesh 5.08 2.07 518,315 371,700

Bihar 2.79 0.29 72,037 51,660
Gujarat 4.12 3.81 955,808 685,440
Haryana 2.80 0.78 195,027 139,860
Himachal Pradesh 0.47 0.16 40,411 28,980
Karnataka 2.29 1.27 318,017 228,060
Kerala 1.14 0.42 105,420 75,600
Madhya Pradesh 3.42 1.32 330,316 236,880
Maharashtra 4.09 2.00 500,745 359,100
Orissa 0.72 0.15 38,654 27,720
Punjab 4.01 2.20 551,698 395,640
Rajasthan 5.68 1.52 381,269 273,420
Tamil Nadu 2.93 2.45 614,950 441,000
Uttar Pradesh 9.47 6.59 1,655,094 1,186,920
West Bengal 1.96 0.52 130,018 93,240

Total 50.97 25.55 6,407,779 4,595,220

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 A.K. Sharma et al. / Journal of Cleaner Production xxx (2016) 1e11 9

Table 8
Solar collector area required and performance of SIPH systems at some representative locations of milk processing plants in the state of Gujarat.

Location Arun 160 Parabolic trough

Collector area (m2) for Solar fraction for Collector area (m2) for Solar fraction for
design DNI (W/m2) of design DNI (W/m2) of design DNI (W/m2) of design DNI (W/m2) of

600 900 600 900 600 900 600 900

Anand 2948 1895 0.30 0.22 3212 2033 0.29 0.20

Jamnagar 2947 1894 0.32 0.24 3211 2035 0.31 0.23
Rajkot 2951 1897 0.32 0.25 3214 2035 0.31 0.24
Surat 2948 1895 0.31 0.24 3212 2033 0.30 0.23
Vadodara 2951 1897 0.31 0.24 3214 2037 0.31 0.23
Surendernagar 2951 1897 0.31 0.24 3215 2037 0.30 0.22
Kheda 2951 1897 0.29 0.22 3215 2037 0.28 0.21
Sabarkanta 2951 1897 0.32 0.25 3214 2036 0.30 0.23
Baruch 2951 1897 0.32 0.24 3215 2035 0.31 0.22

Table 9 ing plant. As a consequence, the choice of design DNI as well as the
Annual GHG emissions mitigation potential of SIPH in dairy industry in India. performance of the SIPH system may also vary at different loca-
Fuel Use Annual GHG emissions mitigation potential (thousand tonnes) tions. The choice of design DNI for sizing an SIPH system thus af-
Scenario fects the collector area required, useful energy delivered as well as
Design DNI ¼ 600 W/m2 Design DNI ¼ 900 W/m2
the amount of GHG emissions likely to be mitigated.
CO2 CH4 N2O Total CO2, CO2 CH4 N2O Total CO2,
As a typical example, for a design DNI of 600 W/m2, for all the
Equivalent Equivalent
locations in the state of Gujarat (a large share of milk processing
I 116 0.29 0.27 206 90 0.22 0.21 160
happens in Gujarat) for annual amount of CO2 mitigated has been
II 122 0.20 0.10 157 92 0.15 0.08 120
III 95 0.20 0.15 146 71 0.15 0.11 108 estimated at 15 thousand tonnes and 30 thousand tonnes for the
IV 42 0.09 0.07 66 32 0.07 0.05 49 cases of 100% furnace oil and 100% HSD substitution respectively.
V 144 0.21 0.06 167 110 0.16 0.04 126 However, for a design DNI of 900 W/m2 considering similar fuel
VI 138 0.37 0.37 260 105 0.29 0.28 198 replacements CO2 mitigated has been estimated at 12 thousand
tonnes and 23 thousand tonnes.
Information presented in the study could also be useful for other
process heating demand. While estimating the GHG mitigation po- industries that require process heat at intermediate temperatures
tential of SIPH in dairy industry of India the use of biomass has not and looking for green energy solutions. Similarly, the project de-
been internalized thereby implying the use of sustainable biomass velopers, solar energy technology manufacturers and suppliers,
only. Moreover, owing to sessional availability of biomass the milk financing institutions and other stakeholders can also make use of
processing plants may make use of other fuels also. To include such this information in making and implementing their own strategies
possibilities scenarios of fuel mix combination have been considered. for contributing towards increased use of solar energy for industrial
process heating and corresponding GHG mitigation.
5. Concluding remarks One of the challenges in this study was unavailability of data
about milk processing in unorganized sector of dairy industry.
The dairy sector in India has a significantly large potential for Similarly, the value of specific thermal energy requirement used in
solar energy based process heating to meet its demand for this study is based on a survey (CII, 2013) of limited number of milk
pasteurization and other thermal energy requirements. The solar processing units. A more detailed assessment could provide better
energy based process heating systems without any storage are insights in this regard. There are few other commercially available
estimated to meet 20e30% of the total process heating demand of solar collector designs (such as the Linear Fresnel Reflector and
the milk processing in the organized sector of the dairy industry. Scheffler Dish) that can also be considered meeting the process
This translates into the potential for solar collector area of over 1.62 heating demand of dairy industry. Finally, a detailed life cycle
million square meter using the performance characteristics of an analysis may help in consolidating the overall emissions from the
indigenous solar concentrator (Arun 160) being promoted in the process heating related activities in milk processing units.
country for meeting industrial process heating demand.
It is worth mentioning that, the value of available DNI and other
climatic conditions depend upon the location of the milk process- Appendix A

Table A1
DNI and other climatic variables at some representative locations with milk processing plants in the state of Maharashtra

Location Latitude (0N) Longitude (0E) Annual DNI (kWh/m2) Wind speed (m/s) Ambient temp. (
C)

Buldhana 20.31 76.10 1798 2.27 26.3

Dhule 20.89 74.86 1788 2.42 26.7
Latur 18.40 76.58 1707 2.87 27.1
Nagpur 21.15 79.90 1664 3.07 27.5
Nanded 19.15 77.30 1855 2.57 27.7
Nasik 20.00 73.78 1811 2.68 25.8
Sangali 16.86 74.56 1765 3.00 26.1
Satara 17.69 74.00 1753 2.60 25.3
Solapur 17.86 75.92 1681 2.14 28.0

Please cite this article in press as: Sharma, A.K., et al., Potential of solar industrial process heating in dairy industry in India and consequent
carbon mitigation, Journal of Cleaner Production (2016), http://dx.doi.org/10.1016/j.jclepro.2016.07.157
10 A.K. Sharma et al. / Journal of Cleaner Production xxx (2016) 1e11

Appendix B

Table B1
Solar collector area required and performance of SIPH systems at some representative locations of milk processing plants in states of India.

State Location Arun 160 Parabolic trough

Collector area (m2) for Solar fraction for design Collector area (m2) for Solar fraction for design
design DNI (W/m2) of design DNI (W/m2) of
DNI (W/m2) of DNI (W/m2) of

600 900 600 900 600 900 600 900

Andhra Pradesh Bijapur 2955 1893 0.26 0.22 3215 2035 0.24 0.19
East Godavari 2954 1896 0.28 0.24 3217 2037 0.25 0.22
Kolar 2949 1894 0.27 0.24 3215 2037 0.25 0.22
Koppal 2954 1897 0.29 0.24 3214 2034 0.27 0.22
Mysore 2957 1897 0.28 0.25 3214 2032 0.25 0.23
Tumkur 2951 1898 0.28 0.25 3217 2035 0.25 0.23
Karnataka Bangalore 2951 1897 0.27 0.22 3215 2035 0.25 0.2
Bijapur 2948 1894 0.26 0.21 3217 2037 0.25 0.2
Chittoor 2952 1897 0.28 0.23 3216 2036 0.26 0.21
Dharwad 2950 1893 0.28 0.24 3217 22,034 0.27 0.22
Koppal 2948 1894 0.29 0.21 3213 2032 0.26 0.2
Mysore 2951 1895 0.28 0.23 3215 2035 0.26 0.21
Madhya Pradesh Bhopal 2948 1896 0.28 0.24 3212 2031 0.26 0.21
Gwalior 2949 1893 0.32 0.25 3214 2033 0.3 0.23
Indore 2951 1896 0.31 0.24 3214 2034 0.29 0.22
Raigarh 2951 1895 0.27 0.23 3212 2032 0.25 0.2
Sagar 2951 1898 0.27 0.23 3214 2032 0.25 0.18
Satna 2949 1897 0.25 0.24 3211 2032 0.23 0.21
Shivpuri 2949 1898 0.26 0.22 3215 2035 0.24 0.2
Ujjain 2948 1894 0.3 0.2 3215 2035 0.28 0.23
Maharashtra Buldhana 2952 1896 0.29 0.22 3214 2036 0.27 0.21
Dhule 2950 1894 0.29 0.23 3214 2024 0.27 0.21
Latur 2948 1893 0.27 0.2 3214 2032 0.25 0.19
Nagpur 2951 1895 0.26 0.22 3215 2035 0.24 0.2
Nanded 2951 1895 0.27 0.23 3217 2035 0.25 0.21
Nashik 2953 1897 0.27 0.22 3215 2037 0.25 0.2
Sangali 2953 1897 0.27 0.22 3217 2037 0.25 0.2
Satara 2953 1897 0.27 0.21 3212 2037 0.25 0.2
Solapur 2952 1896 0.28 0.22 3215 2036 0.26 0.2
Punjab Bhatinda 2949 1894 0.27 0.23 3215 2037 0.25 0.21
Jalandhar 2954 1898 0.29 0.21 3214 2034 0.27 0.2
Ludhiana 2954 1896 0.28 0.2 3217 2037 0.25 0.19
Moga 2955 1893 0.26 0.22 3215 2035 0.24 0.2
Mohali 2955 1898 0.27 0.21 3212 2037 0.25 0.2
Patiala 2957 1897 0.28 0.21 3214 2032 0.25 0.2
Roopnagar 2951 1898 0.28 0.22 3217 2035 0.25 0.21
Rajasthan Ajmer 2952 1895 0.31 0.23 3216 2037 0.29 0.22
Bikaner 2951 1897 0.3 0.24 3217 2037 0.28 0.22
Dausa 2951 1897 0.33 0.27 3215 2035 0.31 0.25
Jhalawar 2951 1894 0.26 0.23 3213 2032 0.24 0.2
Jhunjhunu 2951 1897 0.32 0.25 3215 2034 0.3 0.24
Tonk 2947 1898 0.32 0.25 3217 2035 0.3 0.23
Udaipur 2951 1893 0.34 0.27 3220 2037 0.32 0.26
Tamilnadu Coimbatore 2953 1895 0.26 0.22 3217 2037 0.24 0.21
Cuddalore 2956 1897 0.28 0.21 3220 2037 0.26 0.19
Dharmapuri 2952 1896 0.27 0.23 3216 2037 0.25 0.21
Dindigul 2955 1897 0.26 0.2 3214 2036 0.24 0.2
Erode 2952 1896 0.29 0.23 3216 2037 0.27 0.21
Karur 2954 1894 0.28 0.22 3218 2036 0.26 0.21
Krishnagiri 2953 1892 0.27 0.24 3217 2035 0.25 0.22
Salem 2951 1897 0.28 0.23 3215 2035 0.26 0.21
Tiruchirapalli 2951 1893 0.26 0.2 3215 2035 0.24 0.18
Vellore 2949 1893 0.25 0.21 3213 2032 0.23 0.18
Utter Pradesh Ghaziabad 2951 195 0.28 0.23 3214 2034 0.26 0.2
Kanpur 2949 1893 0.26 0.2 3214 2033 0.24 0.19
Lacknow 2949 1897 0.29 0.23 3211 2032 0.27 0.21
Moradabad 2949 1893 0.26 0.23 3215 2035 0.25 0.21
Muzaffarnagar 2951 1896 0.28 0.21 3212 2032 0.25 0.19
Raebareli 2948 1895 0.28 0.22 3212 2031 0.25 0.2
Saharanpur 2948 1894 0.27 0.24 3215 2035 0.26 0.22
Varanasi 2951 1895 0.26 0.22 3214 2033 0.25 0.2

Please cite this article in press as: Sharma, A.K., et al., Potential of solar industrial process heating in dairy industry in India and consequent
carbon mitigation, Journal of Cleaner Production (2016), http://dx.doi.org/10.1016/j.jclepro.2016.07.157
 A.K. Sharma et al. / Journal of Cleaner Production xxx (2016) 1e11 11

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Please cite this article in press as: Sharma, A.K., et al., Potential of solar industrial process heating in dairy industry in India and consequent
carbon mitigation, Journal of Cleaner Production (2016), http://dx.doi.org/10.1016/j.jclepro.2016.07.157