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believed to be reliable. However, neither IREDA nor CII guarantee the accuracy or completeness of any information published herein and neither IREDA nor CII shall be responsible for any errors and omissions. IREDA and CII are also not responsible for any damages arising out of use of this information. This manual is published with the understanding that IREDA and CII are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional organization should be sought.
Introduction
In spite of the limitations, the growth in SME has been very significant. Comparing the growth of Small & Medium Enterprises over a period of 10 years (1994-2003), the following are some of the significant improvement areas: 1. The number of SME units has seen a significant rise. It has grown by over 40% in these 10 years 2. The production from the SMEs has seen a significant rise. The increase in production has been from Rs. 298,886 Crores in 1994-95 to Rs.763,013 Crores in the year 2002-03, an increase by over 150%. 3. The employment generation in SMEs had also been in a significant upward trend. In these 10 years, the employment generation has also grown by about 40%. 4. Exports from SMEs have increased by nearly 3 times in 2003 compared to the exports in 1994. Energy Conservation in Small & Medium Enterprises The number of SMEs has been on an increasing trend. SMEs today are looking at cost competitiveness for sustaining in the local and international markets. One of the excellent tools in achieving cost competitiveness has been energy conservation.
According to estimates, the total energy consumed in the SMEs is in the order of about 8000 MW. The various sectors highlighted in this report offer an annual energy saving potential of about 1000 MW which is equivalent to Rs. 28000 Million. This, in turn, creates an investment opportunity of Rs 42000 million, to achieve the projected energy savings. This indicates tremendous potential for energy conservation in the SME sector. Objective of this Manual: The objective of this Investors Manual for Energy Efficiency in Small & Medium Enterprises for the use of Bankers is a step in highlighting & bringing in investment opportunities for energy efficiency equipment. This manual covers various topics like energy saving potential for various industries, technologies available to improve energy efficiency, equipment suppliers, government policies / incentives available for the sector, terms of IREDA and other financial institutions extending support to such projects etc. The end objective of the activity is market development for energy efficiency / conservation products & services for SMEs.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Executive Summary
Introduction
Small & Medium Enterprises (SMEs) in India are playing a very major role in the overall development of the countrys economy. SMEs constitute one of the vibrant sectors of the Indian economy in terms of employment generation, the strong entrepreneurial base it helps to create and its share in industrial production and exports. These SMEs in India met the expectations of the Government in this respect. SMEs have developed progressively and have achieved several of its objectives: ! ! ! ! ! ! ! ! High contribution to domestic production Significant export earnings Operational flexibility Capacities to develop appropriate indigenous technology Import substitution Contribution towards defense production Technology oriented industries Competitiveness in domestic and export markets
SMEs are of vital importance to bankers & policy makers: For The Banking System SME Represents ! A Large & Growing Opportunity ! Emerging Markets Banking Revenue Estimated At Over $40Billion For Policy Makers, it shines as a very effective means to achieve ! High Employment " Employs Over 50% Of Labour Force Even In The Developed World ! High Economic Growth " 50-60% Share of GDP Engine Of Economic Growth ! Culture Of Entrepreneurship ! Wider Tax Base ! Alleviation Of Poverty DEFINING SME The definition of a Small & Medium Enterprise various widely Small Industries Development Bank of India (SIDBI), a nodal agency for small industries defines Medium sector enterprises as units having investment in plant and machinery upto Rs.10 crore. However, discussions with banks such as State Bank of India (SBI) indicate that, companies having turnover of less than 25 crores per annum can be considered as SME.
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
Executive Summary
IMPORTANCE OF SMES The potential of SME to generate employment has remained the strongest argument in their favour. The sector now employs 17 million people and is the second largest employer of India's workforce after agriculture. The role of SME in the economy can be seen from the fact that it now accounts for 95% of all industrial units in the country and 40% of total output. About Investors Manual Under the `India: Second Renewable Energy Project, Indian Renewable Energy Development Agency (IREDA) is operating a World Bank Line of credit (WBLOC) to finance projects in energy efficiency/ conservation sector. As a part of the above project, Technical assistance Plan (TAP) is envisaged for (i) institutional development and technical support to IREDA,(ii) improving the marketing of the energy efficiency and demand-side management investments (iii) Promoting private sector participation in end-use efficiency. As a part of the project, CII Godrej GBC has been assigned the task of Preparation of Investors Manual for Energy Effici ncy/ Conservation in Small and Medium e Scale Sector for the use of Bankers Objective of this Manual: The objective is to prepare an Investors Manual covering the topics like energy saving potential for various industries, technologies available to improve energy efficiency, equipment suppliers, government policies / incentives available for the sector, terms of IREDA and other financial institutions extending support to such projects etc. The end objective of the activity is market development for energy efficiency / conservation products & services. The whole effort is to prepare a simplified and user-friendly manual for the use of bankers, based on inputs from various stakeholders in energy efficiency sector. CII Godrej GBC adopted the following methodology in preparing this manual: 1. Classifying the SME sector/equipment under energy intensive category 2. Identifying different energy intensive SME sectors which are likely to invest in EE technologies 3. Identify available technologies and relate each of them to SME sector application. 4. Identifying energy saving potential for each of the energy intensive industry and list the major energy saving measures, which could be undertaken in each of the industry/equipment 5. Develop model financial structures for energy efficiency investments and its payback 6. A brief technical detail including schematics and cost benefit analysis for each of the proposed energy saving measures.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
7. Providing the list of equipment suppliers (both Indian as well as international), EPC contractors, Energy service companies etc. who can take up this energy saving measures 8. Giving the list of consultants / energy auditors etc, who can be approached for conducting energy audit, preparation of DPR etc. 9. A brief detail of government policy / incentives / concessions available etc. for identified energy saving projects / equipments. 10. Giving a brief detail of finance available for taking up energy efficiency projects from IREDA as well as from other financial institutions All the projects are all proven projects, which have been implemented successfully in Indian industry. The objective of highlighting these projects is to facilitate the potential investors & bankers, in having a quick reference of the various energy saving measures and also enable them make decisions on investment. Summary of this report This report focuses on energy conservation methodologies & case studies in 10 major sectors and 8 commonly used equipment in the Indian Small & Medium Enterprises (SMEs) Sectors covered under this manual 1. 2. 3. 4. 5. Leather Cement Pharmaceutical Ceramics Tea 6. Food processing 7. Paper 8. Textile 9. Sugar 10. Foundry
Major equipment covered under this manual 1. 2. 3. 4. Air compressors Centrifugal pumps Centrifugal fans Boilers & steam system 5. Refrigeration & air conditioning system 6. Electrical distribution 7. Electrical motors 8. Lighting
According to estimates, the total energy consumed in the SMEs is in the order of about 8000 MW. The various sectors highlighted in this report offer an annual energy saving potential of about 1000 MW which is equivalent to Rs. 28000 Million This, in turn, creates an investment opportunity of Rs 42000 million, to achieve the projected energy savings. This report will serve the objective of its preparation, in promoting / development of market for energy efficient equipment & suppliers in Indian industry.
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
Leather
Introduction
Leather Industry in India, occupies a place of prominence in the Indian economy, in view of its massive potential for employment, growth and exports. A large part (nearly 60-65%) of the production is from Small & Cottage Sector. The annual export value of Leather industry is poised to touch about 2 billion US dollars. Leather industry is amongst top 8 export earners for India. A estimated 15% of total purchase of leading global brands in footwear, garments, leather goods & accessories in Europe, is outsourced from India. India, being the second largest manufacturer of leather garments & footwear, predominantly, all companies are ISO Certified leather companies and meet international standard criteria. Leather industry has a large scope to grow in near future. Leather industry today is highly competitive and the industry has taken a major stride in Energy Efficiency to sustain their cost competitiveness. Several Phase shift projects have been implemented and some of the actual implemented case studies presented envisage significant energy saving opportunities in this sector
Install Variable Frequency Drive for Aqua- Hot & AquaCold Pumps
Background
Pumps are common equipment in Leather Industry. The load on a pump may either be constant or variable. The variation in the load may be due to various factors like process variations, changes in capacity or utilization etc. Conventionally, the output of the pump is adjusted according to the process requirements using 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 (like pump) to exactly match the process requirement.
Previous Status
The dyeing and tanning drums at leather preparation section require hot and cold water intermittently for mixing of the dye/tannin. The hot-cold water mix ratio is determined by the quantity and quality of the rawhides, besides the colour of the dye used. Maintaining the exact parameters is critical, for the effective penetration of dyes. To achieve this optimum temperature, leather industries utilize a fully automised "aquamix unit". The aquamix units, receive hot and cold water from two separate pumps. The hot-cold mix is then to the individual drums. The requirement and hence the flow rate of the hot and cold water varies with the temperature and the number of user points in operation. The flow was regulated by recirculation. Hot water and cold water requirement in all the tanks is not continuous and simultaneous. So once the set requirement was achieved, the hot water/ cold water was recirculated, without going to the process. The Hot and cold water pump therefore was in continuous operation at its full capacity, irrespective of the number of users in operation.
Implementation Methodology
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 the input to the VFD. The VFD varies the speed of the (RPM) pump so that only that quantity of the fluid demanded by the process is pumped.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Installation of VFDs for the Hot and cold water supply pumps was done during the regular operation of the plant itself. The recirculation valve was closed completely. The plant team did not face any problems during the implementation of the project. Benefits The implementation of this project resulted in saving of energy consumption of the pump and also better control of the system. Financial Analysis The installation of VFD for the pump resulted in an annual saving Rs.0.23 Million. The investment of Rs.0.30 Million was paid back in 18 months. Replication potential Installation of variable speed drives for pumps can be replicated in all applications where a pump is supplying to variable demand, which is the normal case in many Leather industries.
Annual Savings Rs. 0.23 millions Investment Rs. 0.30 millions Simple payback 18 months
Leather Proposal-1: Installation of Variable Frequency Drive for Aqua-hot & Aqua-cold pumps Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.300 -0.300 0.627 61.36% 0.300 0.240 0.230 -0.004 0.209 0.060 0.230 0.061 0.135 0.000 0.230 0.083 0.105 0.000 0.230 0.083 0.094 0.000 0.230 0.083 0.084 0.000 0.230 0.083 0.075 0.000 0.230 0.083 0.067 0.000 0.230 0.083 0.060 0.000 0.230 0.083 0.053 0.000 0.230 0.083 0.147 0.047 0.230 0.230 0.230 0.230 0.230 0.230 0.230 0.230 0.230 0.230 0.23 0.3 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Install Variable Frequency Drives (VFD) for CP - Cold and CP - Hot Water Supply Pumps
Background
Pumps are common equipment in Leather Industry. The load on a pump may either be constant or variable. The variation in the load may be due to various factors like process variations, changes in capacity or utilization etc. Conventionally, the output of the pump is adjusted according to the process requirements using 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 (like pump) to exactly match the process requirement.
Background
There are 24 numbers of dyeing/tanning drums in phase - I. These drums require hot (70C temperature) and cold water (ambient temperature) for effective mixing & application of chemicals, dye and tannin. The hot and cold water requirements for these drums are met by two separate pumps. The number of drums in operation varies between 8 and 20, depending upon the load and season. On an average, only 15 out of the 24 drums will be in operation at the same time, even during the peak season. This indicates that, the water requirement is not continuous. However, since the number of drums in operation at any point of time is not constant, both these pumps are in continuous operation. This results in continuous recirculation of water (quantity varies), back to the storage tanks, whenever the number of drums in operation varies. The operation of a pump with recirculation control is an energy inefficient practise. Also, both the pumps were observed to be operating with discharge valve throttling which is energy inefficient method of controlling the excess capacity of the pumps.
Implementation Methodology
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 the input to the VFD. The VFD varies the speed of the (RPM) pump so that only that quantity of the fluid demanded by the process is pumped.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Installation of VFDs for the CP Cold & CP Hot water supply pumps was done during the regular operation of the plant itself. The recirculation valve was closed completely. The plant team did not face any problems during the implementation of the project.
Benefits
The implementation of this project resulted in saving of energy consumption of the pump and also better control of the system.
Financial Analysis
The installation of VFD for the pump resulted in an annual saving Rs.0.11 Million. The investment of Rs.0.12 Million was paid back in 13 months.
Replication potential
Installation of variable speed drives for pumps can be replicated in all applications where a pump is supplying to variable demand, which is the normal case in many Leather industries.
Annual Savings Rs. 0.11 millions Investment Rs. 0.12 millions Simple payback 13 months
Leather Proposal-2: Installation of Variable Frequency Drive for CP-cold & CP-hot water supply pumps Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.120 -0.120 0.316 72.32% 0.120 0.096 0.110 0.005 0.094 0.024 0.110 0.031 0.063 0.000 0.110 0.039 0.050 0.000 0.110 0.039 0.045 0.000 0.110 0.039 0.040 0.000 0.110 0.039 0.036 0.000 0.110 0.039 0.032 0.000 0.110 0.039 0.028 0.000 0.110 0.039 0.025 0.000 0.110 0.039 0.071 0.023 0.110 0.110 0.110 0.110 0.110 0.110 0.110 0.110 0.110 0.110 0.11 0.12 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Reduce Rpm of the Auto Spray Machine Exhaust Blowers 1, 2 And 3 By 20%
A fan is typically a mechanical device that causes a movement of air, vapour & other gases in a given system. In Polishing sections, the aerosol mix, which are produced during the process, are forcefully sucked and let out into the atmosphere using exhaust fans. This is a typical application where the volume of air to be handled becomes the only criterion for the selection of fan. The exhaust air quantity is controlled based on the requirement to prevent excess suction at the machine. Typically, the control of the Exhaust fan is through the damper. The control of a centrifugal fan by damper is an energy inefficient method as part of the energy supplied to the fan is lost across the damper. The latest energy 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 Leather Industry, the exhaust fans offer a good scope for saving energy. The details are as below.
Background
There are 7 auto spray machines, which are used to provide a better finish to the leather. Chemicals are sprayed in an aerosol form, on to the leather surface. The exhaust blowers provided on each of these machines, remove the unabsorbed aerosol mix. The exhaust blowers 1, 2 and 3 are operating with suction damper control (50 - 60 % closed position). The operation of blowers with damper control is an energy inefficient method of capacity control. One of the better methods of optimizing the excess capacity of blowers and reducing the power consumption is by RPM reduction.
Implementation Strategy
The speed of the blowers was reduced during the stoppage of the plant for maintenance. The plant personnel were well trained in operation and therefore no problems were faced with implementation. The dampers were kept fully opened after the speed was installed.
Financial Analysis
The annual energy savings achieved was Rs. 0.27 Million and the investment was Rs. 0.03 million for installing 3 nos of pulleys, which got paid back in 2 Months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Annual Savings Rs. 0.27 millions Investment Rs. 0.03 millions Simple payback 2 months
Leather Proposal-3: Reduce RPM of the Auto spray machine exhaust blower 1, 2 and 3 by 20% Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.030 -0.030 0.958 602.62% 0.030 0.024 0.270 0.088 0.162 0.006 0.270 0.095 0.140 0.000 0.270 0.097 0.123 0.000 0.270 0.097 0.110 0.000 0.270 0.097 0.098 0.000 0.270 0.097 0.088 0.000 0.270 0.097 0.078 0.000 0.270 0.097 0.070 0.000 0.270 0.097 0.062 0.000 0.270 0.097 0.056 0.270 0.270 0.270 0.270 0.270 0.270 0.270 0.270 0.270 0.270 0.27 0.03 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.182 0.175 0.173 0.173 0.173 0.173 0.173 0.173 0.173 0.173
Previous Status
In a Leather Industry, electrical heating is utilized in the following areas where the temperature required varies from 60 - 90oC. Area Finned type heaters NTU conveyor dryer Finiflex machine Roto press Total Power Measured Power (kW) 21 25 28 24 98
The cost comparison between electrical heating and thermal heating in that industry is as follows:
! !
Cost of electrical heating (@Rs. 3.38/kWh) Cost of steam heating (Fuel being wood @ Rs.850/MT)
= =
The cost comparison indicates that electrical energy is about 4 times more expensive than thermal heating system.
Implementation Strategy
The electrical heaters were replaced with steam heaters (steam being utilized from existing wood fired boiler) during the stoppage of the plant for maintenance. The plant personnel were well trained in operation and therefore no problems were faced with implementation. The existing electrical are kept as standby.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Financial Analysis
The annual energy savings achieved was Rs. 0.69 Million and the investment was Rs. 0.20 million for installing steam heaters, which got paid back in 4 Months.
Annual Savings Rs. 0.69 millions Investment Rs. 0.20 millions Simple payback 4 months
Leather Proposal-4: Replace Electrical Heating with Steam Heating in Identified Areas Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.200 -0.200 2.363 243.05% 0.200 0.160 0.690 0.190 0.446 0.040 0.690 0.233 0.364 0.000 0.690 0.248 0.315 0.000 0.690 0.248 0.281 0.000 0.690 0.248 0.251 0.000 0.690 0.248 0.224 0.000 0.690 0.248 0.200 0.000 0.690 0.248 0.179 0.000 0.690 0.248 0.160 0.000 0.690 0.248 0.442 0.142 0.690 0.690 0.690 0.690 0.690 0.690 0.690 0.690 0.690 0.690 0.69 0.2 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Previous status
In an Leather Processing unit, the compressed air was generated at an operating pressure of 6.5 kg/cm2 (Average Pressure), by operating reciprocating compressors, having capacity of 150 Cfm. The pressure requirement in the Auto spray machine varies between 4 to 5 kg/cm2, which is achieved with pressure reducing valves (PRV's) installed close to the machine. In view of the requirement itself being 4-5 kg/cm2, the generating pressure in the compressor can be reduced. The air compressor is being operated between operating pressures of 6 kg/cm2 to 7 kg/cm2. The power drawn by any compressor being proportional to delivery pressure, lower setting of delivery pressure will result in substantial energy savings.
Implementation
The pressure setting of the compressor was modified to match the process requirement. This change in setting was done immediately and the plant team did not face any problems during the implementation of the project.
Benefits
The reduction in pressure has resulted in substantial reduction in power consumption of the air compressor. About 20% reduction in power consumption was achieved.
Financial Analysis
Reducing the average operating pressure of the air compressor, resulted in an annual savings of Rs 0.15 Million. This doesnt require any major investment.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Leather Proposal-5: Reduce Operating Pressure in Auto Spray Section Air Compressor Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.030 -0.030 0.958 602.62% 0.030 0.024 0.270 0.088 0.162 0.006 0.270 0.095 0.140 0.000 0.270 0.097 0.123 0.000 0.270 0.097 0.110 0.000 0.270 0.097 0.098 0.000 0.270 0.097 0.088 0.000 0.270 0.097 0.078 0.000 0.270 0.097 0.070 0.000 0.270 0.097 0.062 0.000 0.270 0.097 0.173 0.056 0.270 0.270 0.270 0.270 0.270 0.270 0.270 0.270 0.270 0.270 0.27 0.03 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Install Variable Frequency Drive (VFD) for the Screw Compressor in Dyeing Section
Background and concept
Variable speed drives eg. (Variable frequency drives) can be installed for all types of air compressors. 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 unload power consumption. Air leakages in the compressed air system also comes down since the average operating pressure is less. Generally, high capacity air compressors are operated with loading /unloading control, as in the case of screw & reciprocating compressors and with inlet vane control for centrifugal compressors. 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 pressure range. 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 connected to a common header, then by installation of VFD in one compressor, the energy savings achieved due to pressure reduction is cumulative in nature (power consumption comes down in all compressors). Since the average operating pressure with VFD is less (6kg/cm2 instead of 6.5 kg/cm2 as per earlier example) the air leakages in the system is also minimized. The installation of VFD facilitates in varying the speed of the compressor depending on the requirement. This completely avoids unloading and saves unload power consumption, which is normally 25 to 35 % of the full load consumption. Recently, screw compressors with built-in variable frequency drives have been introduced in the Indian market. This system facilitates fine tuning of the compressor capacity precisely to meet the fluctuating compressed air demand. It accurately measures the system pressure and adjusts the speed to automatically maintain a constant pressure.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Previous status
In a dyeing section of Leather Industry, the opening / closing of dyeing drum is pneumatically actuated. A screw compressor supplies the air required for the pneumatic cylinder operation. The compressor is rated for air supply to all 24 dyeing drums. However, normally, only about 12-14 drums are in operation. The study on the loading of the compressor indicates that the compressor is loaded for only 25% of operating hours and during the rest 75% of time, the no-load power drawn is 9.3 kW.
Project Implementation
The installation of VFD for the compressor was done during the normal operation of the plant itself. The plant team did not face any problems in implementation of the project and in subsequent operating pressure reduction.
Benefits
The unloading power consumption of the screw compressor was totally eliminated. The over all operating pressure was also reduced to 5.5 kg/cm2.
Financial Analysis
The annual savings achieved amounted to Rs. 0.43 million. The required an investment of Rs. 0.7 million for installing variable frequency drive with feed back control, was paid back in 20 Months.
Annual Savings Rs. 0.43 millions Investment Rs. 0.7 millions Simple payback 20 months
Leather Proposal-6: Install Variable Frequency Drive in Screw Compressor in Dyeing Section Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.700 -0.700 1.077 49.84% 0.700 0.560 0.140 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.430 0.430 0.430 0.430 0.430 0.430 0.430 0.430 0.430 -0.047 0.104 0.154 0.154 0.154 0.154 0.154 0.154 0.154 0.426 0.260 0.196 0.175 0.156 0.140 0.125 0.111 0.099 0.000 0.430 0.154 0.089 0.430 0.430 0.430 0.430 0.430 0.430 0.430 0.430 0.430 0.430 0.43 0.7 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.477 0.326 0.276 0.276 0.276 0.276 0.276 0.276 0.276 0.276
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Install Variable Frequency Drive (VFD) for Hydraulic Oil System in Vacuum Drier
Background
In Leather Industry, hydraulic power packs are used for several applications like, extrusion machines, pressing machines, Vacuum Drier etc. In the hydraulic system actuation takes place for holding the job only for about 20 30% of the operating time. After the holding operation only the required operating pressure has to be maintained. During the rest of operating time the excess quantity of oil pumped by the hydraulic system is recirculated back to the tank. The recirculation takes place for about 70-80% of the operating time, through a three-way recirculation valve provided for this purpose. The % opening of the recirculation valve is governed by a continuous feed back signal, depending on the amount of oil required for the process. Recirculation results in excess power consumption in the hydraulic pump for pumping the excess quantity of oil.
Previous status
In a Leather Processing unit, the hydraulic power pack in the vacuum drier section is in continuous operation. These conventional hydraulic power pack circuits consist of double pumping system. It caters to the hydraulic needs of the clamping unit and a part thereof is taken to the oil cooling. The loading and utilization pattern was studied in detail. The observations are as follows: " The average idle time is nearly 80% out of a cycle time of 120 seconds. " During the idle time oil pumped is re-circulated back to the reservoir. " Due to the continuous recirculation mode, heat pick-up by hydraulic oil is also high. The power consumption in hydraulic Pump was measured to be 4.5 kW during the off-load condition. This condition prevails for more than 80% of time.
The advantage is of two fold: " Power saving in the pump " Good process control by a simple re-profit
Benefits
Installation of VFD for oil pumps in Hydraulic power pacs resulted in an annual saving of Rs. 0.3 million. This required an investment of Rs 0.35 million for variable frequency drives with feed back control, which got paid back in 15 Months.
Replication potential
The project can be replicated in all the units where oil pumps are installed for pumping oil in the hydraulic power packs.
Annual Savings Rs. 0.3 millions Investment Rs. 0.35 millions Simple payback 15 months
Leather Proposal-7: Install Variable Frequency Drive For Hydraulic Oil System in Vacuum Drier Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.350 -0.350 0.847 68.00% 0.350 0.280 0.300 0.007 0.261 0.070 0.300 0.083 0.173 0.000 0.300 0.108 0.137 0.000 0.300 0.108 0.122 0.000 0.300 0.108 0.109 0.000 0.300 0.108 0.097 0.000 0.300 0.108 0.087 0.000 0.300 0.108 0.078 0.000 0.300 0.108 0.069 0.000 0.300 0.108 0.192 0.062 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.3 0.35 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Cement
Introduction
Cement plant are classified according to their Production Capacity, units with a capacity of upto 0.3 mn tpa are classified as mini cement plants and are eligible for concessional excise duty. Though the minimum economic size of a cement plant is 1 mn tpa, there are over 300 white and mini cement plants in India with a collective capacity of only 9 mn tpa (8 per cent of the total domestic installed capacity). The average cost of setting up a mini cement plant is about Rs 1400 per ton, while for a large cement plant it is about Rs 3500 per ton. The mini and small cement plants contribute less than 5% of overall production of cement in India and these productions units are primarily concentrated in Rajasthan, Madhya Pradesh, and Andhra Pradesh. Cement industry continues to globalize and become more competitive, in the process achieving targeted production levels while ensuring consistent product quality is critical to success. Maintaining a competitive edge depends on the highest achievable levels of operational efficiency and while keeping production cost as low as possible. Energy is the single largest operational cost for a cement plant. A plant's grinding processes is highly energy intensive product size reduction alone accounts for 70% of total energy consumed. In an increasingly competitive market, any reduction in energy consumption contributes to profitability. Optimization and control of grinding operations are key to reducing energy consumption in this sector resulting in reduced specific energy consumption. The actual implemented case studies in various cement units presented are similar both for small and large manufacturing units as the Equipments are similar in nature, except their capacities. .
Benefits
The annual energy saving potential achieved by implementing this proposal is Rs.1.1 millions. The investment required was Rs. 2.0 millions, which paid back in 22 months. Cost benefit analysis Annual Savings Rs. 1.1millions Investment Rs. 2.00 millions 22 months
Simple payback
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Cement Proposal-1: Install High Efficiency Fan for Pre-heater Fan Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.200 -0.200 3.848 376.55% 0.200 0.160 1.100 0.337 0.763 0.681 0.040 1.100 0.380 0.720 0.574 0.000 1.100 0.395 0.502 0.000 1.100 0.395 0.448 0.000 1.100 0.395 0.400 0.000 1.100 0.395 0.357 0.000 1.100 0.395 0.319 0.000 1.100 0.395 0.285 0.000 1.100 0.395 0.254 0.000 1.100 0.395 0.227 1.100 1.100 1.100 1.100 1.100 1.100 1.100 1.100 1.100 1.100 1.1 0.2 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Benefits
The annual saving potential realized was Rs. 0.34 millions. The investment required was Rs.0.50 millions, which paid back in 18 months. Cost benefit analysis
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Annual Savings Rs. 0.34 millions Investment Rs. 0.5 millions Simple payback 22 months
Cement Proposal-2: Install GRR / Variable Fluid Coupling for ESP Fan Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.500 -0.500 0.889 54.86% 0.500 0.400 0.340 -0.022 0.362 0.323 0.100 0.340 0.086 0.254 0.202 0.000 0.340 0.122 0.218 0.155 0.000 0.340 0.122 0.218 0.139 0.000 0.340 0.122 0.218 0.124 0.000 0.340 0.122 0.218 0.110 0.000 0.340 0.122 0.218 0.099 0.000 0.340 0.122 0.218 0.088 0.000 0.340 0.122 0.218 0.079 0.000 0.340 0.122 0.218 0.070 0.340 0.340 0.340 0.340 0.340 0.340 0.340 0.340 0.340 0.340 0.34 0.5 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Replacement of the Air-lift with Bucket Elevator for Rawmeal Transport to the Silo
Background
The 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 pneumatic conveying systems such as air-lift. The pneumatic conveying system consumes more power, nearly 3 to 4 times that of the mechanical conveying system. Bucket Elevator for raw meal conveying also. The pneumatic conveying system puts in air to the silo, which has to be removed. Conventionally, the pneumatic conveying system was being preferred as the mechanical system (particularly the Bucket elevator) was not very reliable and the plant required operation continuously. In the recent years with the improvement in the metallurgy of the bucket elevators links and chains, bucket elevators that can operate continuously in a reliable manner have been developed. These also have been installed in many plants with substantial benefits.
Previous status
In a million tonne dry process pre-calciner plant, operating with a Vertical Roller Mill (VRM), the raw meal was being conveyed with the help of an air-lift. Energy saving project The air-lift was replaced with a bucket elevator. The air-lift was retained to meet the standby requirements.
Replication potential
In each cement conveying to a higher elevation is required in 3 sections raw mill (raw meal conveying to silo), kiln (kiln feed conveying to the preheater top) and cement mill (cement conveying to cement silo). This project has been taken up by design in all the new plants for all the three and majority of 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)
Previous status
In a 2200 TPD dry process pre-calciner plant operating at a capacity of about 2350 TPD, the Kiln was being controlled with conventional PLC method.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Financial analysis
The implementation of this project resulted in an annual saving of Rs 3.0 millions (only the thermal energy saving). The investment made was around Rs 4.0 millions. The simple payback period was 16 months.
Replication potential
The system has been successfully installed in about 20 numbers of plants (particularly the latest plants). The potential exists in atleast 30 number of kilns in India. The investment potential is about Rs 120 millions (USD 2.4 millions) Cost benefit analysis Annual Savings Rs. 3.0 millions Investment Rs. 4.0 millions Simple payback 16 months
Cement Proposal-4: Install a High level Control System for Kiln Operation Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -4.000 -4.000 8.123 60.12% 4.000 3.200 3.000 -0.072 2.743 0.800 3.000 0.789 1.762 0.000 3.000 1.076 1.369 0.000 3.000 1.076 1.223 0.000 3.000 1.076 1.092 0.000 3.000 1.076 0.975 0.000 3.000 1.076 0.870 0.000 3.000 1.076 0.777 0.000 3.000 1.076 0.694 0.000 3.000 1.076 1.924 0.619 3.000 3.000 3.000 3.000 3.000 3.000 3.000 3.000 3.000 3.000 3 4 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Previous status
In 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 power consumption was 29.0 units / ton of OPC - 43. The mill chambers were 5.77 m & 6.75 m long with a diameter of 4.4 m. The plant went for capacity up gradation in the Kiln and Raw mill sections and also started producing blended Cement varieties such as PPC and PSC. This necessitated a requirement for higher Cement mill capacity.
Benefits
The implementation of this project resulted in the following benefits: ! 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 analysis
The total annual benefits amounted to Rs. 15 millions (only power saving). The investment made was around Rs 40 millions (in 1996). The simple payback period for this project was 32 months.
Note:
Three types of pre-grinding systems are presently available for Indian cement industry to increase 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 specific energy consumption. However the energy saving alone does not justify the investment in many cases. Hence, the plant should consider the implementation of this project in the capacity up gradation. The replication potential exists in 30 cement plants and the investment potential for this project is Rs 1200 millions (USD 24 millions)
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
Cost benefit analysis Annual Savings Rs. 15 millions Investment Rs. 40 millions Simple payback 32 months
Cement Proposal-5: Usage of High Efficiency Crusher as a Pre-Grinder before the Cement Mill Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -40.000 -40.000 26.886 30.30% 40.000 32.000 15.000 -6.099 18.838 8.000 15.000 2.511 9.956 0.000 15.000 5.381 9.619 6.846 0.000 15.000 5.381 9.619 6.113 0.000 15.000 5.381 9.619 5.458 0.000 15.000 5.381 9.619 4.873 0.000 15.000 5.381 9.619 4.351 0.000 15.000 5.381 9.619 3.885 0.000 15.000 5.381 9.619 3.469 0.000 15.000 5.381 9.619 3.097 15.000 15.000 15.000 15.000 15.000 15.000 15.000 15.000 15.000 15.000 15 40 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
21.099 12.489
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Benefits
The cost-economics of the proposed energy saving project will be as follows: Estimated parameters Annual savings Investment required Simple payback Units Rs.lakhs Rs.lakhs Month/s 0.94 0.20 3
Cement Proposal-6: Reduce RPM of CF Silo Aeration Blowers by 10% Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.200 -0.200 3.269 324.62% 0.200 0.160 0.940 0.280 0.660 0.589 0.040 0.940 0.323 0.617 0.492 0.000 0.940 0.337 0.603 0.429 0.000 0.940 0.337 0.603 0.383 0.000 0.940 0.337 0.603 0.342 0.000 0.940 0.337 0.603 0.305 0.000 0.940 0.337 0.603 0.273 0.000 0.940 0.337 0.603 0.243 0.000 0.940 0.337 0.603 0.217 0.000 0.940 0.337 0.603 0.194 0.940 0.940 0.940 0.940 0.940 0.940 0.940 0.940 0.940 0.940 0.94 0.2 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Pharmaceuticals
INTRODUCTION The chemical and Pharmaceutical industry has been one of the fastest growing industries in India. Today it occupies a very important position in the national economy, ranking fourth after iron and steel, engineering and textiles. The basic inorganic and organic chemicals produced in the industry provide the building blocks for several downstream industries, such as drugs, paper, synthetic rubber, dyestuff, plastics, polyesters, pesticides, paints, detergents, fertilizers etc. The chemical process industry has a share of about 12% in the total manufacturing output of the country and close to 15% by value in the gross industrial production. Downstream chemicals are essentially derived from basic petrochemicals. The chemical industry consists of over 14000 units with a total invested capital of over Rs 5800 bn. This investment is geographically concentrated in the five States of Maharashtra, Gujarat, Tamil Nadu, Uttar Pradesh and Andhra Pradesh. Bulk Drugs constitute a major part of the Pharmaceutical industry in India, playing a significant role in improving the health standards of the people It Consists of Medium and many small-scale units providing direct employment to about 2,00,000 and indirect employment to another 2,00,000 people The capital investment in more than the industry is about Rs.30000 Million. Today 90% of the domestic bulk drugs requirement is met by the Indian industry itself. The Bulk Drug industry contributes about Rs.51000 Million of exports, which is growing by over 20% every year. The growth and achievement of the Indian Drug Industry during the last five decades has been phenomenal and has been rated as one of the highest among the developing countries. India's bulk drug and pharmaceutical industry today has grown into a highly sophisticated industrial segment, confirming to the International standards of production Technology and Quality Control. This has thrown upon the intensity of energy playing a pivotal role in this sector. The actual implemented case studies presented imbibes the Energy Efficient practices adopted in Chemical & Pharmaceutical units.
Case study No 1
Install Variable Frequency Drive (VFD) for Fluidized Bed Drier (FBD) Blower
Background
One of the pharmaceutical units in South India utilizes fluidized bed dryer for drying requirement of its specialty chemicals. The operation of the dryer was reviewed by the plant team to identify opportunities for energy saving in the dryer. The FBD at this pharmaceutical unit is being operated on batch type operation, having a batch time of 45 minutes. The drier is operated for about 21 batches every day, on an average. In the FBD, the drying rate varies with time. A schematic of the drying rate with time is shown in the graph:
The decrease in moisture content is steep during the initial stages of drying and gradually reduces. During the last phase of drying, the moisture content remains almost steady. To ensure effective fluidization, the deciding parameter is the air velocity. minimum velocity should be ensured at all stages of fluidization. Energy Saving Proposal The plant team realized that good potential for energy saving exists by varying the air quantity depending on the drying rate. However, a minimum air flow can be maintained to ensure effective fluidization. The air flow should be maximum when the drying rate is maximum and the rate of decrease of moisture is steep. As the rate of decrease reduces, the air flow rate can also be gradually reduced. A
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
The change in fan flow rate was achieved by installing a VFD to the FBD fan. The change in speed was programmed depending on the batch timing. The rate of change of speed was arrived at on trail and error basis. Benefits Implementing this proposal has resulted in an annual energy saving of Rs. 0.138 millions. This called for an investment of Rs. 0.18 millions and had a simple payback period of 16 months.
Case study No 2
Present Status
In one of the distillation system in a pharmaceutical unit, the plant team reviewed the performance of the cooling water circuit in detail for possible energy savings. The observations made are as below: The cooling water demands of the distillation column were met through a dedicated cooling tower system. A cooling water pump was used to circulate water from the cooling tower to the distillation column. The return water from the process was taken back to the cooling tower top. The motor rating of the pump is 37 kW and the power consumed by the pump is 32.4 kW. The suction and the discharge of the pump were throttled and were opened to an extent of 50% and 25% respectively. The pressure at the discharge of the pump, after the control valve is 2.7 kg/cm2, indicating that head required for the pump is 27m. The throttling of the pump was a clear indication of the excess capacity/head in the pump. The valve control led to pressure loss across the control valve and hence energy loss.
Benefits
The installation of a Variable Frequency Drive (VFD) to the distillation column cooling water pump resulted in an annual energy saving of Rs.0.146 millions. The investment required was Rs.0.22 lakhs which paid back in 18 months.
Annual Savings Rs. 0.146 millions Investment Rs. 0.22 millions Simple payback 18 months
Pharmaceuticals Proposal-2: Optimize Operation of Distillation Column Cooling Water Pump Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.220 -0.220 0.378 53.62% 0.220 0.176 0.146 -0.011 0.157 0.140 0.044 0.146 0.037 0.109 0.087 0.000 0.146 0.052 0.094 0.067 0.000 0.146 0.052 0.094 0.059 0.000 0.146 0.052 0.094 0.053 0.000 0.146 0.052 0.094 0.047 0.000 0.146 0.052 0.094 0.042 0.000 0.146 0.052 0.094 0.038 0.000 0.146 0.052 0.094 0.034 0.000 0.146 0.052 0.094 0.030 0.146 0.146 0.146 0.146 0.146 0.146 0.146 0.146 0.146 0.146 0.146 0.22 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Present Status
The spin flash drier in one of the pharmaceutical units had design capacity of 600 kg/h with an evaporation rate of 300 kg/h. This drier was designed to reduce the moisture content from as high as 50% to less than 8% in the input feed material. The spin flash drier was provided with two stage cyclones for collecting the product. The drier is provided with exhaust blower/ID fan which is used to exhaust the drying air as well as the evaporated water vapor to the atmosphere through the chimney. As per design the 1st cyclone separator was provided to separate the dried product from the air stream while passing from drier to second cyclone through duct. The 2nd cyclone separator was provided to further separate the dried product from the air stream from the 1st cyclone. But during the actual operating conditions, the plant team observed that all the dried material was collected in the 1st cyclone itself and no material are collected in 2nd cyclone. Due to excess design cushion in ID fan, the draft was controlled by a damper provided at the 2nd cyclone bottom at material collection point. This resulted in fresh air infiltration through 2nd cyclone, resulting in increased power consumption of Spin flash drier ID fan.
Benefits The annual energy saving realized by implementing the Variable Frequency Drive is Rs.0.068 millions. This called for an investment (for VFD) of Rs. 0.1 millions, and had a simple payback period of 18 months.
0.044 0.044
0.044 0.044
Present Status
The spin flash drier was utilized in one of the pharmaceutical units in South India for drying the cotton after the centrifuge operation. This spin flash drier had design capacity of 600 kg/h with an evaporation rate of 300 kg/h. This drier was designed to reduce the moisture content from as high as 50% to less than 8% in the input feed material. Fresh air from the atmosphere was drawn across the steam preheater. The air gets preheated by the steam preheater and the preheated air was supplied to the LDO heater. The hot air from the LDO heater was supplied to the spin flash drier for drying operation. The average temperature of the exit air from the driers is 107oC. The equivalent quantity of heat let out from the spin flash drier is 59,888 kcal/hr (considering final exhaust temperature of about 70oC). The equivalent LDO consumption is about 5.9 kg/hr.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Benefits The annual energy saving realized by implementing this proposal was Rs 0.254 millions. The investment required for the installation of a new VFD was Rs. 0.2 millions simple payback period was 10 Months.
0.163 0.163
Install Heat Recovery System from the Hydrolysis Autoclave System for PreHeating Water
Background
Heat recovery from steam / condensate has been extensively utilized in several chemical / pharmaceutical industries. Newer opportunities are being constantly explored to maximize heat recovery options. In one of the pharmaceutical units, Hydrolysis-Autoclave system was utilized for one of the applications. During the pressure stabilization of the Hydrolysis autoclave, the reaction in the vessel turns exothermic, resulting in substantial generation of heat and pressure. To maintain the pressure in the autoclave, the heat generated was rejected to the atmosphere through a condenser. Tremendous amount of heat in the form of L.P steam was generated and was being let out into the atmosphere.
Present status
A conservative estimate made by the team indicated a substantial release of heat to the atmosphere to the extent of more than 4 TPD. Another section, lye dilution, was utilizing hot water in the plant. The usage of water is as under: Out of about 25m3/day of water is being used for lye dilution, the distribution is as under: ! ! ! 5 m3/day 5 m3/day 15 m3/day = = = Hot condensate Scrubber water Fresh Water
The utilization of hot water for lye dilution would result in reduction of steam consumption in this section.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Benefits
Installation of Heat Recovery System for the Hydrolysis Autoclave section has resulted in an annual savings of Rs 0.086 millions. This called for an investment of Rs 0.05 millions, which paid back in 7 months.
-0.050 0.069 0.059 0.055 0.055 0.055 0.055 0.055 0.055 0.055 0.055
Utilise the Condensate from Process Area for Boiler Feed Water or for Hot Water Use in Process
Background
Chemical & pharmaceutical industries are extensive users of steam. In many industries, the condensate collected after utilizing the heat available in the steam is not put back to the boiler fearing contamination. Contaminated condensate could result in several process problems. However, chemical & pharmaceutical units today are now looking at newer opportunities to maximize opportunities for good use of condensate.
Present Status
The condensate from the process areas in one of the pharmaceutical industry was collected in individual receivers and the hot water was used mainly for floor washing and equipment cleaning. The boiler feed water consisted only of 65% return condensate and the balance 35% was make-up DM water.
Benefits
The estimated annual savings achieved by recovering the condensate is Rs 0.195 millions. This required an investment of Rs 0.05 millions and got paid back in 4 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Pharmaceuticals Proposal-6: Utilise the Condensate from Process Area for Boiler Feed Water or for Hot Water Use in Process Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.050 0.040 0.195 0.056 -0.050 0.672 272.49% 0.124 0.010 0.195 0.066 0.103 0.000 0.195 0.070 0.089 0.000 0.195 0.070 0.079 0.000 0.195 0.070 0.071 0.000 0.195 0.070 0.063 0.000 0.195 0.070 0.057 0.000 0.195 0.070 0.051 0.000 0.195 0.070 0.045 0.000 0.195 0.070 0.040 0.195 0.195 0.195 0.195 0.195 0.195 0.195 0.195 0.195 0.195 0.195 0.05 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Present status
In one of the pharmaceutical units, the specifications of AHU fans operating in syrup manufacturing area are given below. AHU Fan 1 5 8 Design Pressure (mm H2O) 87 87 87 Rated Capacity Cfm 10,500 21,000 9,500 Developed pressure (mm H2O) 66 35 48
The operating pressure was much lower than the design pressure rise of these AHU fans. This has resulted in inefficient operation of the fans and thereby, higher power consumption.
Benefits
The annual energy saving achieved was Rs. 0.046 millions. This required an investment of Rs. 0.03 millions for changing the pulleys, which paid back in 8 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Pharmaceuticals Proposal-7: Reduce the Speed of AHU fan in Syrup Manufacturing Area Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.030 0.024 0.046 0.008 -0.030 0.146 115.44% 0.034 0.006 0.046 0.014 0.025 0.000 0.046 0.017 0.021 0.000 0.046 0.017 0.019 0.000 0.046 0.017 0.017 0.000 0.046 0.017 0.015 0.000 0.046 0.017 0.013 0.000 0.046 0.017 0.012 0.000 0.046 0.017 0.011 0.000 0.046 0.017 0.009 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.03 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.030 0.038 0.032 0.029 0.029 0.029 0.029 0.029 0.029 0.029 0.029
Ceramics
Introduction
The Ceramic industry is one of the age-old industries and has evolved over the centuries, from the potters wheel to a mo dern industry with sophisticated controls. This is one of the fast growing industries, with a projected growth rate of 8%. The average energy cost as a percentage of manufacturing cost is 20 to 25%. There are at present 14 units in the organized 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 about 2.5% 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 growth in the housing sector. Indian tiles are competitive in the international market. These are being exported to East and West Asian Countries. The ceramic industry is highly energy intensive. The energy consumed by the ceramic industry 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 are furnace oil, LSHS, LDO and HSD. The energy cost as a percentage of manufacturing cost, is presently around 20-25%. 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 special emphasis. In this section, several actual implemented case studies in Glass & Ceramic industry is highlighted.
Install Variable Frequency Drives (VFDs) for Producer Gas Air Blowers in Both Refractory and Stoneware Plants
Background
The producer gas generator in one of the ceramic units requires oxygen for combustion, which is supplied by the air blowers. These blowers were observed to be operating with discharge damper control (typically, 30-40% open). This indicates the excess capacity/ static pressure rise of the blower. The discharge damper opening is in closed loop with the rate of production and pressure of the producer gas. Hence, the capacity requirement of the blower varies continuously. The measured pressure drop across the damper, in case of the refractory plant is 180 mm WC, which is about 47% of the total pressure rise of the fan. Similarly, the measured pressure drop across the damper of the blower in the stoneware plant is 290 mm WC, which is about 60% of the total pressure rise of the fan.
Recommendation
It was recommended to install variable frequency drive for the producer gas air blowers, in the refractory and stoneware plants. The fans have to be operated with full damper opening, after the installation of VFD's. The VFD can be put in closed loop with the existing pressure sensor. This will continuously monitor the producer gas discharge pressure and give a signal to the blower to either reduce or increase the RPM of the blower, matching the varying capacity requirements.
Benefits
The annual energy saving realized is Rs.0.088 millions. This required an investment (for VFD's and controls) of Rs.0.14 millions, which had a simple payback period of 20 months. Cost benefit analysis
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Annual Savings Rs. 0.088 millions Investment Rs. 0.14 millions Simple payback 20 months
Install a Bunker with Slide-Gate Mechanism and Mechanical Feeding System for Bauxite and Clay Feeding to the Impact Mills
Background
In one of the ceramic unit in south India, there were five impact mills for crushing of the different raw materials used in refractory brick preparation. The mill circuit comprised of the following equipment: ! ! ! ! ! ! ! Impact mills - 2 for bauxite, 1 for clay, 1 for grog & 1 for special materials Primary bucket elevator Magnetic separator Vibrating screen Secondary bucket elevator Hopper Dust collection blowers
The feeding and utilization pattern of the milling circuit was studied in detail for possible energy savings. The observations are as follows: ! The feeding of the impact mills is done manually. The feeding rate or loading of mill per shift is fixed. ! The feeding sequence is can be split up as: " " " " Loading of trolleys at the raw material godown Transporting the trolley to the impact mills Loading of the impact mill based on bucket elevator current loading Taking the trolley back to godown for filling
! There is lot of idle time in the feeding sequence, for the mills and connected auxiliaries, such as, bucket elevators and vibrating screens. ! The estimated idle time for the mills is 30%, while that of the other auxiliaries is 45%. There is no useful work done during the idle running, resulting in power loss, which is estimated at about 14.0 kW.
Recommendation
The following measures were adopted in implementing the energy saving proposal: " Installing bunkers at the individual mills, with slide gate mechanism. These bunkers will double-up as feed device cum buffer storage. The slide gate can regulate the feed quantity to the individual mills.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
" The material feeding to the bunkers were mechanized, by installing a front-end loader. This avoided the manual element of feeding and hence, reduce the idle time. The following benefits were achieved, by the above modifications: " " " " Reduced idle time of mills and auxiliaries Increased output Reduced operating time of mills Reduction in power consumption
Benefits
The annual energy savings potential was Rs.0.68 millions. This required an investment (for the bunkers and vibro-feeders only) of Rs. 0.75 millions, which had a simple payback period of 14 months. Cost benefit analysis Annual Savings Rs. 0.68 millions Investment Rs. 0.75 millions Simple payback 14 months
Ceramics Proposal-2: Install Variable Frequency Drives (VFDs) for Producer Gas Air Blowers in Both Refractory and Stoneware Plants Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.750 -0.750 1.949 71.60% 0.750 0.600 0.680 0.029 0.651 0.582 0.150 0.680 0.190 0.490 0.391 0.000 0.680 0.244 0.436 0.310 0.000 0.680 0.244 0.436 0.277 0.000 0.680 0.244 0.436 0.247 0.000 0.680 0.244 0.436 0.221 0.000 0.680 0.244 0.436 0.197 0.000 0.680 0.244 0.436 0.176 0.000 0.680 0.244 0.436 0.157 0.000 0.680 0.244 0.436 0.140 0.680 0.680 0.680 0.680 0.680 0.680 0.680 0.680 0.680 0.680 0.68 0.75 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Insulation of the Top Portion of the Ring Chamber Kiln with Insulating Powder
Background
Generally, the top portion of the ring chamber kilns lacks proper insulation due to the construction intricacies. The normal trend is to have a low weight (Minimum layer of insulating bricks) on the 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 the radiation losses from the top portion of a ring chamber kiln.
Previous Status
In one of the refractory brick industry, the measured kiln surface temperature of 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 and a substantial scope to reduce the heat losses atleast to the level of that of the sides.
Financial Analysis
The annual energy saving achieved was Rs. 0.40 million. The Investment made was Rs. 0.20 million, which has got paid back in 6 months. Cost benefit analysis
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Annual Savings Rs. 0.40 millions Investment Rs. 0.20 millions Simple payback 6 months
Provision of Insulation for the Furnace Shell Electric Arc Furnace Insulated with Alumina Bricks on the Inner Side of the Shell
Background
In the ceramic fibre manufacturing industry, melting furnace is the major consumer of electrical energy. The melting of ceramic raw material is carried out in an electric arc furnace. The raw materials in powder form are fed into the furnace where it gets fused by the electric arcs. Later, the fused material is blown by compressed air to form ceramic fibres.
Previous Status
To estimate the amount of heat losses, the arc furnace heat balance was developed. The summary of the heat balance of the furnace is as follows: ! ! ! ! ! Item Power kW % of Total Power Actual heating (for melting) 115 31 Loss through water 160 43 Core reactor / transformer combination 55 15 Radiation loss and others 40 11 " Total 370 100 It is clear from the heat balance that the major heat loss is through cooling water. It was also found that, out of the 160 Kw heat loss through cooling water, 60 65 Kw was for cooling the shell. The balance 100 kw heat losses was through cooling water used for cooling electrodes, clamps, cables, etc.,
Benefits
The major benefit of this project was the minimisation of heat loss from furnace shell. The cooling water flow also reduced due to the minimized heat loss.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
The specific energy consumption reduced from 4.1 Kw / Kg of ceramic fibre to 3.75 Kw/kg of ceramic fibre produced, after implementation. This has resulted in an overall savings of 0.35 kw / Kg of ceramic fibre produced.
Financial Analysis
The annual savings achieved was Rs.1.08 million. This investment made was Rs. 0.14 million, which was paid back in 2 months.
Proposal-4: Provision of Insulation for the Furnace Shell Electric Arc Furnace Insulated with Alumina Bricks on the Inner Side of 1.08 0.14 0 1 1.080 0.140 0.112 1.080 0.347 -0.140 -0.140 3.817 519.72% 0.733 0.654 0.028 1.080 0.377 0.703 0.560 0.000 1.080 0.387 0.693 0.493 0.000 1.080 0.387 0.693 0.440 0.000 1.080 0.387 0.693 0.393 0.000 1.080 0.387 0.693 0.351 0.000 1.080 0.387 0.693 0.313 0.000 1.080 0.387 0.693 0.280 0.000 1.080 0.387 0.693 0.250 0.000 1.080 0.387 0.693 0.223 2 1.080 3 1.080 4 1.080 5 1.080 6 1.080 7 1.080 8 1.080 9 1.080 10 1.080 Discount Rate (i) 12%
Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation
1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV
Installation of Additional Insulating Layers for the Ring Chamber Kiln Doors
The ring chamber kiln normally has a temporary constructed door for loading and unloading of refractories. Conventionally the temporary door is constructed by sealing with a single layer of insulating bricks after completion of raw refractory loading. In most of the cases, the single layer insulation is inadequate leading to higher heat losses through 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 Status
The ring chamber kiln had 12 doors, through which the raw bricks (to be fired) were loaded inside the kiln. Once the raw bricks are fully loaded, the doorway was closed by constructing a single layer of insulating brick and sealing with insulating powder. The surface temperature of the temporary door was measured to be 80 110oC, resulting in high radiation losses.
Financial Analysis
The annual energy saving achieved was Rs. 0.30 million. The investment made was Rs. 0.10 million which has got pay back in 4 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Cost benefit analysis Annual Savings Rs. 0.30 millions Investment Rs. 0.10 millions Simple payback 4 months
Ceramics Proposal-5: Installation of Additional Insulating Layers for the Ring Chamber Kiln Doors Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.250 -0.250 0.698 75.44% 0.250 0.200 0.240 0.014 0.226 0.201 0.050 0.240 0.068 0.172 0.137 0.000 0.240 0.086 0.154 0.110 0.000 0.240 0.086 0.154 0.098 0.000 0.240 0.086 0.154 0.087 0.000 0.240 0.086 0.154 0.078 0.000 0.240 0.086 0.154 0.070 0.000 0.240 0.086 0.154 0.062 0.000 0.240 0.086 0.154 0.055 0.000 0.240 0.086 0.154 0.050 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.24 0.25 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Benefits
The 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.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Financial Analysis The annual saving achieved by this project was Rs. 2.70 million. This had an investment of Rs.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 consumption Cost benefit analysis Annual Savings Rs. 2.70 millions Investment Rs. 0.30 millions Simple payback 2 months
Ceramics Proposal-6: Optimisation of Kiln Loading Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.300 -0.300 9.577 602.62% 0.300 0.240 2.700 0.883 1.817 1.623 0.060 2.700 0.947 1.753 1.397 0.000 2.700 0.969 1.731 1.232 0.000 2.700 0.969 1.731 1.100 0.000 2.700 0.969 1.731 0.982 0.000 2.700 0.969 1.731 0.877 0.000 2.700 0.969 1.731 0.783 0.000 2.700 0.969 1.731 0.699 0.000 2.700 0.969 1.731 0.624 0.000 2.700 0.969 1.731 0.557 2.700 2.700 2.700 2.700 2.700 2.700 2.700 2.700 2.700 2.700 2.7 0.3 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Case Study 7
Previous Status
In one of the ceramic sanitary ware industry, an open flame tunnel kiln was used for firing applications. This kiln was using LPG as fuel with a direct firing mode. The operating parameters were as follows: " Cycle No. of cars Throughput@ LPG Specific Gas " Time (hours) No./day 240 kg /car(kg/day) consumption " MT / day MT / Ton 13 102 24480 3.36 0.137
Benefits
The 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 cars handled 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 Financial Analysis The 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.
Annual Savings Rs. 13.14 millions Investment Rs. 12.5 millions Simple payback 12 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case Study 8
Installation of Recuperators at the Cooling End of Kiln and Utilizing the Hot Air Produced for Drying Raw Wares
Background
In the ceramic industry, the raw materials are mixed through mixers, pressed and then converted to raw wares through moulds. The molded material has to be dried in batch driers before loading on to the kiln cars. The temperatures inside the dryers are maintained at 55 to 60oC so as to evaporate the moisture in the molded material. Conventionally ceramic plants use leco/coal as fuel, to generate hot air for drying. Some plants even use electrical heating system or fuels like furnace oil, LPG etc., for drying. In modern plants recuperators are provided to recover the heat from the exhaust gases of the Kiln. Thus the hot air generated by indirect heat exchange with Kiln exhaust air is used for drying purposes. This resulted in the elimination of usage of fuel or electrical heaters in the drying moulds.
Previous Status
In 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.
Benefits
The 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 Analysis
The annual saving achieved by this project was Rs. 1.52 million. The investment made was Rs. 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 Cost benefit analysis Annual Savings Rs. 1.52 millions Investment Rs. 3.00 millions Simple payback 24 months
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
Ceramics Proposal-8: Installation of Recuperators at the Cooling End of Kiln and Utilising the Hot Air Produced for Drying Raw Wares Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -3.000 -3.000 3.448 41.35% 3.000 2.400 1.520 -0.316 1.836 1.639 0.600 1.520 0.330 1.190 0.949 0.000 1.520 0.545 0.975 0.694 0.000 1.520 0.545 0.975 0.619 0.000 1.520 0.545 0.975 0.553 0.000 1.520 0.545 0.975 0.494 0.000 1.520 0.545 0.975 0.441 0.000 1.520 0.545 0.975 0.394 0.000 1.520 0.545 0.975 0.351 0.000 1.520 0.545 0.975 0.314 1.520 1.520 1.520 1.520 1.520 1.520 1.520 1.520 1.520 1.520 1.52 3 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Previous Status
In one of the ceramic tiles industry, on a continuous basis about 3000 3500 kg/hr at a temperature of 240C was getting vented from the kiln exhaust. The vertical driers located close to the kiln needed hot air at a temperature of 150C for drying.
There was a good potential to utilise this heat from the kiln exhaust and reduce the energy consumption in the vertical drive. These sort of projects are being adopted in similar units. The kiln exhaust line was connected to the suction line of the vertical drier. The schematic of the modification is highlighted in the figure.
Financial Analysis
The overall benefits that achieved by implementing this project was Rs.1.5 Million. The investment required including instrumentation was Rs.5.0 Million, which got paid back in 2 years.
Benefits of recuperators
Reduced 50% of the heat consumption in the vertical drier Waste heat from kiln utilized
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
Annual Savings Rs. 1.5 millions Investment Rs. 5.00 millions Simple payback 24 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study: A 200 tpd container glass manufacturing industry had a melting furnace with its sidewalls at a temperature of 230oC initially. The total surface area at this temperature was about 6 m2. The amount of heat loss with this surface temperature is 12000 kCal/h (@6100 kcal/m2h). The plant team increased the insulation levels, by incorporating AZS refractory bricks supported with high alumina and ceramic fibre layers and reduced the high alumina block = 120oC 950 surface temperature to 120oC (corres. heat loss is 950 kcal/m2h). The diagram of the setup is given in below: Apart from reducing the surface temperature, the plant also achieved significant savings by the reduced contamination of glass by the refractory material. Benefits: (check calculated based on assumed surface area; also check with excel glass proposal in backup)
Annual Savings Rs. 0.75 millions Investment Rs. 0.50 millions Simple payback 8 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Modifications in the Design of Crown to Reduce Radiation Loss and Improved Quality of Glass
Background
The 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 silica bricks with minimum residual quartz and better surfaces with minimum variation. It is now possible 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 gaps between bricks of about 1 to 3mm. With increased corrosion due to the alkaline nature of the melt the gaps gets widened resulting 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. Good potential to reduce radiation loss from these furnaces exists by suitably refurbishing the furnace crown. Case study A 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 between the bricks, resulting in radiation loss from the furnace. Subsequently due to corrosion, the gaps widened resulting in the development of rat holes on the crown. During shutdown, the plant refurbished their crown refractory with super silica bricks. The super 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 minimized to 1800 W/m2.
The latest trend in designing the crown would be to pull up one of the refractory blocks of the furnace, making the high pH alkaline droplet, drop back into the furnace, with out corroding the superstructures. This would maintain the quality of the batch with reduced rejects.
EnCon project
A 100 TPD flat glass manufacturing plant had a conventional crown in the furnace. It was found that the quality of the melt was reduced due to the mixing of impure particles from the superstructure onto the glass melt. The furnace was then redesigned during one of the shutdowns with the crown having one of the blocks pulled up. This made the droplets fall back into the furnace without carrying along with it the particle from the superstructures. There was a considerable reduction in the rejects % in the plant and this attributed to a net energy saving of about 2% in the plant. The refurbishment of the old worn out crown in the plant with newly designed crown amounted to about Rs 75 lakhs.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study - 12
The plant installed two nos. of 5000 cfm centrifugal compressors to meet this process demand by replacing the reciprocating compressors. The new specific energy consumption of compressed 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 this the cooling requirement of the compressed air system also came down by another 50% resulting in additional savings in energy consumption. Cost benefit analysis
Ceramics Proposal-12: Redesign the Mesh Belt in Lehr and Avoid Heat Loss Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -1.500 -1.500 0.854 27.77% 1.500 1.200 0.520 -0.244 0.764 0.682 0.300 0.520 0.079 0.441 0.352 0.000 0.520 0.187 0.333 0.237 0.000 0.520 0.187 0.333 0.212 0.000 0.520 0.187 0.333 0.189 0.000 0.520 0.187 0.333 0.169 0.000 0.520 0.187 0.333 0.151 0.000 0.520 0.187 0.333 0.135 0.000 0.520 0.187 0.333 0.120 0.000 0.520 0.187 0.333 0.107 0.520 0.520 0.520 0.520 0.520 0.520 0.520 0.520 0.520 0.520 0.52 1.5 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Annual Savings Rs. 0.52 millions Investment Rs. 1.5 millions Simple payback 35 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Replace Pneumatic Conveying with Mechanical Conveying System in the Soda-Ash Conveying System
Background
Soda ash is being added in to the furnace as one of the primary raw material. Soda ash is usually 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 the purpose. Pneumatic conveying system consumes nearly about 3 to 4 times more power than a mechanical conveying system. Also, the conveyed air needs to b separated from the conveyed material using a dust separation system, which also consumes additional power. Good potential to reduce power consumption in this area exists by replacing pneumatic systems with mechanical belt conveyor and bucket elevator systems.
Case study
In a float glass plant of capacity 600 TPD, soda ash was conveyed to the furnace pneumatically using compressed air at a pressure of 4.0 bar. There were two nos. of 1200cfm compressors being operated for this purpose. The total power consumption by the compressors was about 150 kW. The total quantity of soda ash conveyed is about 150TPD. The replacement of the pneumatic system was carried out and the energy consumption was reduced by onethird of the energy consumption by the pneumatic conveying system.
Benefits
The overall benefits that achieved by implementing this project was Rs.1.90 Million. The investment required including instrumentation was Rs.3.0 Million, which got paid back in 19 years. Cost benefit analysis Annual Savings Rs. 1.90 millions Investment Rs. 3.00 millions Simple payback 19 months
Ceramics Proposal-13: Replace Pneumatic Conveying with Mechanical Conveying System in the Soda-Ash Conveying System Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -3.000 -3.000 4.824 51.31% 3.000 2.400 1.900 -0.179 2.079 1.857 0.600 1.900 0.466 1.434 1.143 0.000 1.900 0.682 1.218 0.867 0.000 1.900 0.682 1.218 0.774 0.000 1.900 0.682 1.218 0.691 0.000 1.900 0.682 1.218 0.617 0.000 1.900 0.682 1.218 0.551 0.000 1.900 0.682 1.218 0.492 0.000 1.900 0.682 1.218 0.439 0.000 1.900 0.682 1.218 0.392 1.900 1.900 1.900 1.900 1.900 1.900 1.900 1.900 1.900 1.900 1.9 3 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Tea Industry
Introduction
Tea Plantation industry has grown from a cottage to large industry with an in front projection of divide and rule culture and today has a significant market share in global scenario India is the largest producer of tea and ranks fourth in terms of total tea exporters in the world. In the Budget 2005-06, tea industrys removal of the AED of Re1 per kg of tea has benefited this industry Indian tea production during Jan-Nov 2004, however, has been 4.5% yearly yield at 773mn kg. Exports have increased by 1.7% to 155.9mn kg during this period and exports rose by 8.3% during Jan-Oct 2004. This evolution has brought an angle change in the production capabilities to meet the increasing demand. The industry to meet the positive gradient demand has adopted Energy Efficient measures to substantially reduce the specific energy consumption. Some of the actual implemented case studies are presented to establish best Energy Efficient practices in this sector.
Install Waste Heat Recovery for Heater 1 for Pre-Heating Hot Air Generator Air
Background
Tea industry utilizes significant amount of thermal energy for its drying applications. These drying requirements are met by utilizing a hot air generator. These hot air generators are oil / solid fuel fired systems and contributes significantly to the overall energy consumption of the plant. Several energy saving measures have been implemented in the hot air generators in various tea industries. One of the extensively attractive projects is the installation of Waste Heat Recovery for the hot air generator input air.
Present Status
In one of the tea plants in south India, firewood fired hot air generators are utilized to cater to the drying requirements in the unit. The exhaust temperature of the flue gas leaving Heater was measured to be 215oC. The recommended outlet temperatures of flue gas for different fuels are as under: ! Oil ! Coal ! Wood : : : 160oC 140oC 130-140oC
Benefits
Heat recovery from the flue gas exhaust of heater has resulted in an annual saving of Rs. 0.1 millions. This required an investment of Rs. 0.15 millions with a simple payback period of 18 months.
Annual Savings Rs. 0.1 millions Investment Rs. 0.15 millions Simple payback 18 months
0.107 0.075 0.064 0.064 0.064 0.064 0.064 0.064 0.064 0.064
Insulate the Return Air Duct from Tea Dryer to the Heater
Background
Tea industry utilizes significant amount of thermal energy for its drying applications. These drying requirements are met by utilizing a hot air generator. Where thermal energy consumption is in significant proportions, insulation becomes extremely important. The surface temperatures should be maintained as minimum as possible to avoid the heat loss from the surfaces thereby resulting in excess fuel consumption. The supply and the return air duct from the Tea Dryer becomes very critical as far as insulation is concerned.
Present Status
One of the Tea Plants in South India had done well to insulate almost all the hot air ducts and keep the surface temperature within limits to minimize the radiation losses. While all the surface temperatures of air ducts were scanned regularly, the surface temperature of the return air duct from the tea dryer to the Heater was measured to be 70oC while the temperature at the inlet of the Heater was 60oC. There was a drop of 10oC in the duct since it was not adequately insulated.
Benefits
Implementing this proposal has resulted in an annual savings of Rs. 0.218 millions. This called for an investment of Rs. 0.04 millions with an attractive pay back period of 3 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
0.151 0.143 0.140 0.140 0.140 0.140 0.140 0.140 0.140 0.140
Install a Variable Frequency Drive (VFD) for the Hot Air Generator (Coal Fired) Fan of Heater 2
Background
Tea industry utilizes significant amount of thermal energy for its drying applications. These drying requirements are met by utilizing a hot air generator. These hot air generators are oil / solid fuel fired systems and contribute significantly to the overall energy consumption of the plant. Several energy saving measures have been implemented in the hot air generators in various tea industries. One of the areas focused is on the fans installed in the hot air generators.
Present Status
In one of the tea plants, the coal-fired hot air generator supply fan was studied for possible energy savings. The hot air generator fan was damper controlled and open to the extent of 50% The pressure across the damper and at the fan delivery was measured. The pressure loss across the damper was found to be about 46%. The load on the fan is fluctuating in nature depending on temperature in the dryer.
Present Status
Damper control is an energy inefficient practice of capacity control as part of the energy fed to the fan is lost across the damper. Good potential for energy saving exists by avoiding damper control and to meet the varying requirement from the fan. This was achieved by installing a variable frequency drive (VFD) to the hot air generator fan. There were other spin-off benefits achieved by installation of a Variable Frequency Drive: " Air temperature was precisely controlled and monitored " There was no need to frequently stop the dryer due to high / low temperatures. Benefits Installation of a Variable Frequency Drive for the hot air generator (coal fired) supply fan has resulted in an annual savings of Rs. 0.117 millions. This required an investment of Rs. 0.11 millions with an attractive payback period of 12 months.
Annual Savings Rs. 0.117 millions Investment Rs. 0.11 millions Simple payback 12 months
-0.110 0.107 0.083 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075
Present Status
All the withering fans in one of the tea plants were studied for possible energy savings. The withering section had about 24 axial fans in operation. Out of these, at least 9 fans were in operation at any given point of time. These fans were fitted with aluminum blades.
Benefits
The annual energy saving achieved by replacing the metal blades with FRP blades was Rs 0.146 millions. This called for an investment of Rs 0.36 millions with a simple pay back period of 30 Months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
0.197 0.119 0.094 0.094 0.094 0.094 0.094 0.094 0.094 0.094
Install Waste Heat Recovery System for One 250 kva Dg Set
Background
Tea industry utilizes significant amount of thermal energy for its drying applications. These drying requirements are met by utilizing a hot air generator. These hot air generators are oil / solid fuel fired systems and contribute significantly to the overall energy consumption of the plant. Several energy saving measures have been implemented in the hot air generators in various tea industries. One of the innovative project carried out by one of the tea plants is utilizing the waste heat available in the DG set.
Present Status
In one of the tea plants, DG sets were in continuous operation. The operation of the DG set was essential considering the availability and reliability of the grid supply. As a thumb rule, about one-third of the energy fed to the DG set is converted to useful electrical energy. Approximately, one third of energy fed is lost in jacket water and the balance one-third is lost in the DG set exhaust flue gas. The plant also has requirement of hot air. Hot air generators are used to meet the hot air requirement in the process.
Benefits
The annual saving achieved by installing the waste heat recovery system is Rs. 0.40 millions. The investment required was Rs. 0.5 millions which paid back in 15 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
0.400 0.292 0.257 0.257 0.257 0.257 0.257 0.257 0.257 0.257
Present Status
In a Tea Plant, the operation of fluidized bed dryers was studied. The fluidised bed dryer utilized in this plant had three chambers. The observations made by the plant team regarding the operation of the fluidized bed dryer were as follows: The measured exhaust temperature and relative humidity different chambers were as follows: Chamber No. Chamber No.1 Chamber No.2 Chamber No.3 Exhaust Condition (Temp / RH) 39oC / 70% RH 45oC / 40% RH 70oC / 13% RH
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Benefits
The annual saving achieved by recirculating the hot air from chamber 3 to chamber 1 of the hot air dryer was Rs. 0.275 millions. The investment required was Rs.0.1 millions, which paid back in 5 months.
0.205 0.184 0.176 0.176 0.176 0.176 0.176 0.176 0.176 0.176
Present Status
The study on the Heater in a tea plant indicates that various solid fuels like firewood, leco, imported coal, etc are being used. The consumption of these solid fuels varies based on the availability of the fuel. The coal and Leco are found to have very high percentage of fines. The Heater grates were not designed to take fines, which was resulting in high-unburnt loss in the ash. This was resulting in lower thermal efficiencies of the Heater. In spite of the calorific value of the firewood being lower at 3800 kcal / kg vis--vis 5000 kcal / kg for imported coal and 6000 kcal / kg for Leco, the cost of heating with firewood was much cheaper as indicated below: The table shows the cost comparison of various fuels used in the plant. Fuel Cost of Fuel Rs / Kg 1.69 3.80 3.41 Calorific Value Kcal / kg 3800 6000 5000 Heater efficiency % 77% 70% 70% Cost Rs / MM Kcal 578 904 974
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Resorting to wood firing will not result in energy savings. However, this gives tremendous advantage in terms of the cost of energy. Coal fired heater system was converted to 100% fire wood system.
Financial Analysis
Avoiding the usage of Leco and firewood and adopting firewood has resulted in an annual saving of Rs. 5.45 Lakhs. This did not call for any major requirement.
Food Processing
Introduction
The Food Processing Industry sector in India is one of the largest sector in terms of production, consumption, export and growth prospects. Government of India has accorded it a high priority, with a number of fiscal reliefs and incentives, to encourage commercialization and value addition. Important sub sectors in food processing industries are:- Fish-processing, Milk Processing, Meat & Poultry Processing, Packaged/Convenience Foods and Grain Processing etc. As per a recent study on the food processing sector, the turnover of the total food market is approximately Rs.250,000 crores (US $ 69.4 billion) out of which valueadded food products comprise Rs.80,000 crores (US $ 22.2 billion) Size of the semi-processed and ready to eat packaged food industry is over Rs. 4000 crores (US $ 1 billion) and is growing at over 20%. The actual implemented case studies in this sector encompass some of the Energy saving potential in this sector.
Install Carbon Molecular Sieve System for Generating Nitrogen from Compressed Air and Stop use of LPG
Present Status
A popular food processing plant utilizes nitrogen for its different packing and other needs. The process details are as follows:
! Nitrogen purity required for use is 99.5 % (Min.) ! LPG is used to produce nitrogen from air by consuming oxygen for its
burning.
! LPG consumption is to the tune of 45000 Kg/Annum. ! Around 10 M3 of nitrogen is produced per Kg of LPG. ! LPG being expensive drastically increases the cost of Nitrogen, produced
apart from other problems like safety hazards in handling and storage.
Principle of Operation
This system works on the simple principle of preferential adsorption of oxygen (and moisture to some extent) in air on the carbon molecular sieves leaving nitrogen free for use. These are high efficiency towers with very less purge losses and no safety hazards. It is also proposed to install ultra filters before the final nitrogen receiver to separate any fine carbon or other impurities in the nitrogen.
Implementation Methodology:
Installing CMS shall altogether stop the use of LPG, which is otherwise a safety hazard also apart from being very costly. There is minimum extra running costs apart from the compressors, which are anyway running now also.
Benefits
The annul benefits from the system was in the tune of Rs 1.35 millions. This called for an investment of Rs 0.10 millions on the new CMS system and had a simple payback period of 9 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Food Processing Proposal-1:Install Carbon Molecular Sieve System for Generating Nitrogen from Compressed Air and Stop use of LPG Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -1.000 -1.000 4.205 102.84% 1.000 0.800 1.350 0.197 1.029 0.200 1.350 0.413 0.747 0.000 1.350 0.484 0.616 0.000 1.350 0.484 0.550 0.000 1.350 0.484 0.491 0.000 1.350 0.484 0.439 0.000 1.350 0.484 0.392 0.000 1.350 0.484 0.350 0.000 1.350 0.484 0.312 0.000 1.350 0.484 0.866 0.279 1.350 1.350 1.350 1.350 1.350 1.350 1.350 1.350 1.350 1.350 1.35 1 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Replace Compressed Air with Blower Air for Wafers Pushing at Wafers Section
Background
Compressed air has been extensively used in various industries for a variety of applications. With the increased awareness on cost of compressed air, various plants are taking up measures to avoid / substitute the use of compressed air. One of the options evaluated by several units is to substitute compressed air with blower air.
Present status
In the wafers section of a plant, compressed air was used for pushing the wafer from the baking plate. Compressed air was drawn through two points (2 mm diameter) on each side of the LPG fired wafer baking plates. Compressed air for this application was earlier utilized at a pressure of 6.5 kg/cm2. The estimated compressed air consumption was about 10 cfm.
There was a good potential to replace compressed air with blower air for this application and save energy.
Implementation methodology:
Based on this observation, the plant team carried out a trial in the existing system by gradually reducing the pressure and thus employ a positive displacement blower for the operation
Benefits
The annual energy savings realized by substituting compressed air with blower air was Rs.0.34 lakhs. This required an investment (for blower) of Rs. 0.02 millions and had a simple payback period of 11 months.
Annual Savings Rs. 0.34 millions Investment Rs. 0.02 millions Simple payback 11 months
Food Processing Proposal-2: Replace Compressed Air with Blower Air for Wafers Pushing at Wafers Section Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.020 -0.020 1.218 1117.01% 0.020 0.016 0.340 0.116 0.200 0.004 0.340 0.121 0.175 0.000 0.340 0.122 0.155 0.000 0.340 0.122 0.139 0.000 0.340 0.122 0.124 0.000 0.340 0.122 0.110 0.000 0.340 0.122 0.099 0.000 0.340 0.122 0.088 0.000 0.340 0.122 0.079 0.000 0.340 0.122 0.218 0.070 0.340 0.340 0.340 0.340 0.340 0.340 0.340 0.340 0.340 0.340 0.34 0.02 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Case study No 3
Optimise Cooling Water Supply to the Syrup Cooling Plates & Vacuum Pumps
Present status
The performance of the cooling water system in confectionery section of a chocolate manufacturing plant was observed. The following are the details " Cooling water from cold well was catering to four syrup cooling plates and four vacuum pumps by gravity. During normal operating condition two syrup cooling plates and two vacuum pumps were utilized. " The hot return water from process was collected in a common hot water tank. A centrifugal pump was used to pump the hot water from the tank to the top of the cooling tower. This was operated based on level of hot water in the tank. The power consumption of the pump was 4.9 kW. " It was observed that the cooling water also flows through the standby syrup cooling plates and pumps. This led to additional power consumption in the cooling water pump since the idle operation was for longer duration of time.
Benefits
The annual energy saving potential is Rs 0.031 millions. This does not call for any major investment.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Benefits
The annual energy saving realized by implementing this is Rs. 0.03 millions for both the ovens. This called for an investment of Rs. 0.04 millions and had a simple payback period of 15 months.
food processing Proposal-4: Utilize Exhaust heat to preheat combustion air in biscut baking oven Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.040 -0.040 0.081 60.12% 0.040 0.032 0.030 -0.001 0.027 0.008 0.030 0.008 0.018 0.000 0.030 0.011 0.014 0.000 0.030 0.011 0.012 0.000 0.030 0.011 0.011 0.000 0.030 0.011 0.010 0.000 0.030 0.011 0.009 0.000 0.030 0.011 0.008 0.000 0.030 0.011 0.007 0.000 0.030 0.011 0.019 0.006 0.030 0.030 0.030 0.030 0.030 0.030 0.030 0.030 0.030 0.030 0.03 0.04 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study 5
Utilise the Heat from A/C Condenser Fans for Hot Room in Confectionery Section
Present Status
Confectionery section in one of the food processing industries manufactures candies and toffees. After packing these products, it had to be heated to a temperature of 450C to maintain brittleness. Hence all the packed products are stacked in a hot room which was maintained at temperature in the range of 45 500C. Steam was used to maintain the temperature in hot room. Heat required for a maximum quantity of two tons of product load was estimated to be around 15000 kCal. Hot room was available in Line 1 of the manufacturing line. Entire facility of confectionery packing-Line 1 was air conditioned with 2 x 7.5 TR chillers to maintain a temperature of 250C inside the room. Condenser fans of these chillers were installed outside the room. The temperature of hot air from these fans was measured to be about 480C.
Implementation Methodology:
The plant team installed condenser fans inside the building facing the hot room such that heat from condenser fans passes through the room. The waste heat from the condenser fans was sufficient for this application. An exhaust fan was also installed to take out the air from hot room. This was operated only when a desired temperature (45-500C) is attained. Otherwise door openings was sufficient to take out the air. Existing steam coils were kept as it is and was used as stand-by for higher load requirement.
Benefits
Implementing this proposal has resulted in an annual energy saving of Rs.0.3 millions. This called for an investment of Rs. 0.2 millions and had a simple payback period of 7 months time.
Food Processing Proposal-5: Utilise the Heat from A/C Condenser Fans for Hot Room in Confectionery Section Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.200 -0.200 0.950 113.16% 0.200 0.160 0.300 0.050 0.223 0.040 0.300 0.093 0.165 0.000 0.300 0.108 0.137 0.000 0.300 0.108 0.122 0.000 0.300 0.108 0.109 0.000 0.300 0.108 0.097 0.000 0.300 0.108 0.087 0.000 0.300 0.108 0.078 0.000 0.300 0.108 0.069 0.000 0.300 0.108 0.192 0.062 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.3 0.2 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Benefits
Implementation of this proposal resulted in an annual energy savings of Rs 1.36 millions. Investment required for replacement of the burners was Rs 0.35 millions, which paid back in 3 months time.
Food Processing Proposal-6: Replace / Rectify Burners of Ovens in Biscuit Plant Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.350 -0.350 4.687 271.56% 0.350 0.280 1.360 0.387 0.868 0.070 1.360 0.463 0.715 0.000 1.360 0.488 0.621 0.000 1.360 0.488 0.554 0.000 1.360 0.488 0.495 0.000 1.360 0.488 0.442 0.000 1.360 0.488 0.394 0.000 1.360 0.488 0.352 0.000 1.360 0.488 0.314 0.000 1.360 0.488 0.872 0.281 1.360 1.360 1.360 1.360 1.360 1.360 1.360 1.360 1.360 1.360 1.36 0.35 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Install New High Efficiency Fan (or) Install Next Lower Size Impeller for the Intake Air Fan at Wheat Godown
Present status
Fans are a smaller load in the food processing industry. However, while looking at energy saving opportunities, every single equipment is now analyzed for its performance and suitable measures are taken to achieve optimum operational efficiency. The intake section of the bucket elevator in the wheat godown of one of the food processing industry had a vibratory separator for separation of unwanted fines. This separator was provided with a cyclone separator and a fan for the fines separation. The plant team studied this fan in detail for possible energy savings. The following observations were made on the fan: ! The fan was operating with suction damper control. This indicated the excess capacity/ static head of the fan. ! The measured pressure drop across the damper was 124 mm WC, which was about 39% of the total pressure developed by the fan. ! The actual head required by the fan was only 200 mm WC. This confirms that the fan had excess design head. ! The operation of a fan with damper throttling is an energy inefficient method of capacity control, as a part of the energy supplied to the fan is lost across the damper. ! The measured airflow of the fan at this static pressure is 5400 m3/h. The estimated operating efficiency of fan, for these parameters is only 60%. ! This is very low, as the latest fans having backward curved blade impellers, have an operating efficiency of as high as 75%.
Option-1
Replacing the existing intake air fan at the wheat godown, with a new higher efficiency fan.
Option-2
Installing the next lower size impeller for the intake air fan and operating the fan with full damper opening.
Benefits
Option-1 The annual energy savings potential was Rs.19,800/-. This required an investment (for the new fan and motor) of Rs.30,000/-, and had a simple payback period of 19 months. Option-2 The annual energy savings potential was Rs.11,900/-. This required an investment (for the new impeller) of Rs.7,500/-, and had a simple payback period of 8 months. The plant team went ahead with option 1, replacing the existing fan with a new fan having higher operating efficiency.
Food Processing Proposal-7:Install New High Efficiency Fan (or) Install Next Lower Size Impeller for the Intake Air Fan at Wheat Godown Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.030 -0.030 0.051 53.35% 0.030 0.024 0.020 -0.002 0.019 0.006 0.020 0.005 0.012 0.000 0.020 0.007 0.009 0.000 0.020 0.007 0.008 0.000 0.020 0.007 0.007 0.000 0.020 0.007 0.006 0.000 0.020 0.007 0.006 0.000 0.020 0.007 0.005 0.000 0.020 0.007 0.005 0.000 0.020 0.007 0.004 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.0198 0.03 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.021 0.015 0.013 0.013 0.013 0.013 0.013 0.013 0.013 0.013
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Paper
Introduction
Paper has a long history, beginning with the ancient Egyptians and continuing to the present day. After hand-made methods dominated for thousands of years, paper production became industrialised during the 19th century. Originally intended purely for writing and printing purposes, a wide variety of paper grades and uses 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 paper industry is sustainable, from the forest through the production of paper, to the use and final recovery of the product. Its almost impossible to imagine a life wit out paper. In fact, paper is such a versatile h medium, its uses are only limited to the imagination. The Indian pulp and paper industry is over a hundred years old. It has grown in installed capacity from a paltry 0.15 million tons in the early fifties to the present level of 4.65 million tons (a growth of more than 30 times). The Indian paper industry is a mix of large integrated plants (> 25000 tons per annum capacity), medium size plants and small size paper plants based on waste paper. The capacities of 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 in actual operation, are about 380. The break-up of the mills, capacity-wise is as follows: ! Small (up to 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. In this section, several actual implemented case studies in pulp & paper industry is highlighted.
Case study -1
Install Variable Frequency Drive (VFD) for Dump Chest and Machine Chest Pumps
Background
Typically in paper industry the process pumps have excess capacity / head to take meet the maximum requirement. During normal operating conditions, the excess capacity leads to Recirculation of the pulp. The Recirculation is an inefficient practice. The power consumption of the pump remains constant irrespective of the process requirement. This leads to increase in power consumption in the centrifugal pumps. In paper plants, for few cases some minimum Recirculation is required to ensure the process requirement. The Recirculation quantity can be reduced and kept at very minimal level by installing variable frequency drives for the centrifugal pumps. This will result in significant energy saving.
Present Status
Level Box
Dump Chest
Machine Chest
In one of the small scale paper plant, the dump chest pump and the machine chest pumps were operating with Recirculation control. A centrifugal pump of following specifications is in operation for pumping the pulp from the dump chest to the machine chest. ! Capacity ! Head ! Impeller size 126 m3/hr 30 m 10.5
From the machine chest pulp is transferred to the level box using an another centrifugal pump of following specifications. ! Capacity ! Head ! Impeller size 126 m3/hr 30 m 10
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
There is a continuous overflow of pulp from the machine chest to dump chest and also from the level box to the machine chest. The quantity of overflow varies depending upon paper gsm and pulp requirement in the paper machine. In case of transferring pulp from machine chest to level box, there is need to maintain a minimum recirculation to ensure the required pulp level in the level box. The minimum quantity of overflow can be in the range of 10-15 % of the quantity of pulp pumped by the pump. In the existing system the excess quantity of overflow of pulp from the level box to the machine chest and from the machine chest to the dump chest is a clear indication of the excess capacity available in the centrifugal pumps. Pumping of excess quantity of pulp results in excess power consumption in the pumps.
Benefits
Installation of variable frequency drive has resulted in reduction in Recirculation quantity. The net power reduction in both the pumps is about 7.0 kW.
Financial analysis
Annual energy saving of Rs 0.24 millions was achieved. This required an investment of Rs 0.25 millions for installing variable frequency drive, which had a simple payback period of 12 Months.
Replication potential
This has very high replication potential in majority of medium and small-scale paper mills. This could be implemented in atleast 100 paper mills in India.
Paper Proposal-1: Install Variable Frequency Drive (VFD) for Dump Chest and Machine Chest Pumps Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.250 -0.250 0.698 75.44% 0.250 0.200 0.240 0.014 0.201 0.050 0.240 0.068 0.137 0.000 0.240 0.086 0.110 0.000 0.240 0.086 0.098 0.000 0.240 0.086 0.087 0.000 0.240 0.086 0.078 0.000 0.240 0.086 0.070 0.000 0.240 0.086 0.062 0.000 0.240 0.086 0.055 0.000 0.240 0.086 0.050 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.24 0.25 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.226 0.172 0.154 0.154 0.154 0.154 0.154 0.154 0.154 0.154
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study - 2
Install Variable Frequency Drive for Primary Centri Cleaner Pump (Fan Pump)
Background
In paper industry additional margin is kept in capacity / head of the pump to meet the maximum requirement. During the normal operating condition, to meet the lower process requirement, the control valve at the outlet of the pump is throttled. The throttling is varied to meet the variation in process requirement. Valve throttling is an inefficient mode of capacity control. This leads to pressure loss across the control valve and hence energy loss. This valve control can be eliminated and the pressure loss across the control valve can be avoided by installing the variable frequency drives. The speed of the pump can be varied to meet the process requirement. This will result in significant energy saving.
Present status
In one of the medium size paper plants, the primary centri cleaner pump is operated with valve control.
50 60 % Open
A centrifugal pump of following specifications is in operation for pumping the pulp from the white wash tank to the primary centri cleaner. ! Capacity ! Head ! Motor rating 504 m3/hr 30 m 75 HP
In the paper plant, papers of different sizes ranging from 100 gsm to 180 gsm are produced. During the lower gsm paper production the consistency of pulp requirement is low and hence the quantity of pulp pumped by the fan pump is more.
On the other hand, during the higher gsm paper production the consistency requirement is very high, hence the quantity of pulp pumped by the fan pump is low. The variation in paper size leads to a huge variation in quantity of pulp to be pumped by the fan pump. Presently, the required quantity of pulp is supplied to the paper machine by controlling a control valve provided at the outlet of the fan pump and also controlling control valve provided at the inlet of the individual cyclones in the centri cleaner. The control valve position is varied depending upon the paper size and production rate. The control valve position at the outlet of the fan pump varies in the range of 5060% open. This leads to significant pressure loss across the control valve and hence energy loss. Energy saving project Variable frequency drive was installed for the fan pump. The speed of the fan pump is varied to match with the pulp requirement depending of the paper size. The control valve throttling at the outlet of the pump was avoided and also the control valve opening at the inlet of the cyclones of the centri cleaner was increased.
Benefits
Installation of variable frequency drive for the fan pump has resulted in reduction in pressure loss across the control valve. This has resulted in the average electrical energy saving of about 17 kW.
Financial analysis
Annual energy saving of Rs 0.62 millions was achieved. This required an investment of Rs 0.30 lakhs for installing variable frequency drive, which had a simple payback period of 6 Months.
Replication potential
This has very high replication potential in majority of medium and small-scale paper mills. This could be implemented in atleast 100 paper mills in India.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
0.484 0.419 0.398 0.398 0.398 0.398 0.398 0.398 0.398 0.398
Case study - 3
Present status
In one of the medium size paper plant a pulper of capacity 8 m3/batch is in continuous operation and the other one is kept as standby. Presently the operation of the pulper is monitored manually. The batch time and completion of pulping process determined based on experience. The variation in power consumption / batch is in the order of 30-40%. This significant variation is mainly due to human intervention in the operation of the pulper.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Based on the above two data the target, units / batch was fixed. A LED display with following information was installed for the pulper. ! Target Batch Time ! Target Batch Power consumption Both, the batch time and batch power display, would be of Count-down type and as the batch progresses, the values will keep reducing. The energy monitoring system provides information to the operators to take proactive steps to complete the batch within the target power consumption. Based on the available online information, necessary steps such as improving the loading of pulper, avoiding the operation of pulper under loaded can be taken by the operators.
Benefits
The batch time of the pulping process is significantly reduced. This has resulted in significant reduction in specific energy consumption of the pulper. In an average, the specific energy consumption of the pulper is reduced by 5%.
Financial analysis
Annual energy saving of Rs 0.2 millions was achieved. This required an investment of Rs 0.1 millions for installing energy monitoring system for two pulpers with a LED display, which had paid back in 6 Months.
Paper Proposal-3: Install Energy Monitoring System for Pulper Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.100 -0.100 0.656 ##### 0.100 0.080 0.200 0.043 0.140 0.020 0.200 0.065 0.108 0.000 0.200 0.072 0.091 0.000 0.200 0.072 0.082 0.000 0.200 0.072 0.073 0.000 0.200 0.072 0.065 0.000 0.200 0.072 0.058 0.000 0.200 0.072 0.052 0.000 0.200 0.072 0.046 0.000 0.200 0.072 0.041 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.2 0.1 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.157 0.135 0.128 0.128 0.128 0.128 0.128 0.128 0.128 0.128
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study - 4
Install Dual Speed Motors for Couch Pit and Press Pit Agitators
Back Ground
The agitators in both couch pit and press pit are in continuous operation. The couch pit and press pit agitators are designed for load during paper breaks. But during the normal operating condition, only the trims from the paper machine fall into the pit. Hence the load on the agitators is very low during normal operation. The speed of the agitator remains constant irrespective of the load on the agitator. This leads to increased power consumption. There is a good potential to save energy by optimising the speed of the agitator during normal operating condition. This can be achieved by installing dual speed motor for the agitator. The agitator can be operated at lower speed during normal operation and whenever there is a paper breakage, the agitator could be operated at maximum speed. This results in significant energy saving.
Present status
In one of the medium size paper plant for a paper machine of capacity 80 tons/day, both couch pit and press pit agitators are in continuous operation. During normal operating condition, only trims are falling into the pit. The agitators are running at constant speed irrespective of the operating condition.
Benefits
Majority of time, the agitator is operated at lower speed. This has resulted in 40-45% reduction in power consumption.
Financial analysis
Annual energy saving of Rs 0.25 millions was achieved by installing dual speed motor for the agitator. This required investment of Rs 0.12 millions, which had a simple payback period of 6 Months.
Paper Proposal-4: Install Dual Speed Motors for Couch Pit and Press Pit Agitators Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.120 0.096 0.250 0.055 -0.120 0.823 152.64% 0.174 0.024 0.250 0.081 0.135 0.000 0.250 0.090 0.114 0.000 0.250 0.090 0.102 0.000 0.250 0.090 0.091 0.000 0.250 0.090 0.081 0.000 0.250 0.090 0.073 0.000 0.250 0.090 0.065 0.000 0.250 0.090 0.058 0.000 0.250 0.090 0.052 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.25 0.12 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.120 0.195 0.169 0.160 0.160 0.160 0.160 0.160 0.160 0.160 0.160
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study - 5
Install Thermo Compressor and Recover Flash Steam from Flash Vessel
Background
In paper plant steam is utilised in the paper machine at an operating pressure of 2.5 3.0 kg/cm2. The condensate from the paper machine is collected in a condensate tank. From the condensate tank, the condensate is pumped back to boiler feed water tank. When high-pressure condensate is exposed to atmospheric pressure, a part of condensate flashes into steam. The flash steam has significant heat energy. When flash steam is let out to atmosphere, the heat energy is lost. The flash steam can be recovered using thermo compressor. The thermo compressor operates based on venture principle. The thermo compressor consists of a nozzle, throat and a diffuser. This requires high pressure steam as motive steam. When high pressure steam is passed through the nozzle, it creates a suction effect. The throat is connected to the low pressure steam. The low pressure steam is sucked into the thermo compressor and mixes with high pressure steam. When the steam passes through the diffuser, the operating pressure increased to an intermediate pressure. The intermediate pressure steam can again be utilised for the process. The recovery of flash steam from the condensate tank reduces the overall steam consumption in the plant and there by fuel consumption in the boiler.
Present Status
In one of the medium size paper plant, steam is generated at an operating pressure of 10.5 kg/cm2 in the boiler. The steam pressure is reduced to 3.0 kg/cm2 using a pressure reducing valve and used for paper drying in the paper machine. The condensate at a pressure of 2-3 kg/cm2 from the paper machine is collected in a condensate tank, which is exposed to atmosphere. This results in flashing of condensate into flash steam. Flashing of steam to atmosphere results in heat loss. The flash steam is as costly as the cost of the live steam. Hence there is an immense need to recover the flash steam. The total quantity of flash steam loss is in the range of 225-250 kg/hr.
Flash Vessel
2.5 kg/cm2
Condensate Tanks
2.5 kg/cm2
Benefits
The flash steam from the tank is fully recovered. The recovered quantity of flash steam is in the range of about 0.5 ton/hr.
Financial analysis
Annual energy saving of Rs 0.66 millions was achieved. This required an investment of Rs 0.06 millions for the Thermo compressor, which had a simple payback period of 11 Months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Paper Proposal-5: Install Thermo Compressor and Recover Flash Steam from Flash Vessel Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.600 0.480 0.660 0.065 -0.600 1.979 85.39% 0.532 0.120 0.660 0.194 0.372 0.000 0.660 0.237 0.301 0.000 0.660 0.237 0.269 0.000 0.660 0.237 0.240 0.000 0.660 0.237 0.214 0.000 0.660 0.237 0.191 0.000 0.660 0.237 0.171 0.000 0.660 0.237 0.153 0.000 0.660 0.237 0.136 0.660 0.660 0.660 0.660 0.660 0.660 0.660 0.660 0.660 0.660 0.66 0.6 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.600 0.595 0.466 0.423 0.423 0.423 0.423 0.423 0.423 0.423 0.423
Case study - 6
Present status
In one of the medium size paper plant, in the bleaching section a circulation pump of following specifications is in operation. The circulation pump caters to the requirements of both vat dilution and ring dilution. The control valve at the inlet of both sections is severely throttled. The control valves are only 50% open. In addition, the vat dilution requirement, varies depending upon the process. The control valves are throttled to meet the requirement. The valve throttling leads to pressure loss and hence energy loss. The existing system is shown in diagram.
0.5-1.5 Kg/cm2
Filter
50
Seal Tank 50
Circulation Pump 375 m3/h, 25 m WC 60 HP
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Financial analysis
Annual energy saving of Rs 0.15 millions was achieved. This required an investment of Rs 0.30 millions for installing dedicated pumps and VFD for vat dilution pump. This had a simple payback period of 24 months.
Paper Proposal-6: Segregate Ring Dilution and Vat Dilution in Bleaching Section Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.300 0.240 0.150 -0.032 -0.300 0.338 40.81% 0.163 0.060 0.150 0.032 0.094 0.000 0.150 0.054 0.068 0.000 0.150 0.054 0.061 0.000 0.150 0.054 0.055 0.000 0.150 0.054 0.049 0.000 0.150 0.054 0.044 0.000 0.150 0.054 0.039 0.000 0.150 0.054 0.035 0.000 0.150 0.054 0.031 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.15 0.3 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.300 0.182 0.118 0.096 0.096 0.096 0.096 0.096 0.096 0.096 0.096
Case study - 7
Present Status
A centrifugal fan is in continuous operation for removing the exhaust gasses from fluidised bed boiler and sent to the chimney. A damper control is provided at the inlet of the ID fan and throttled. Damper control at the inlet of the fan is a clear indication of excess pressure /capacity available in the centrifugal fan. Damper control leads to pressure loss across the damper and hence energy loss. The pressure loss across the damper is about 31% of the total pressure developed by the fan. There is a good potential to save energy by optimising the operation of the centrifugal fan and avoiding the pressure loss across the damper control.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Benefits The pressure loss across the damper control is totally eliminated. The reduction in power consumption of about 3 KW was achieved. Financial analysis Annual energy saving of Rs 0.09 months was achieved. This required an investment of Rs 0.12 millions for installing variable frequency drive, which had a simple payback period of 17 Months.
Paper Proposal-7: Install Variable Frequency Drive for ID Fan in Boiler Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.120 -0.120 0.244 60.12% 0.120 0.096 0.090 -0.002 0.082 0.024 0.090 0.024 0.053 0.000 0.090 0.032 0.041 0.000 0.090 0.032 0.037 0.000 0.090 0.032 0.033 0.000 0.090 0.032 0.029 0.000 0.090 0.032 0.026 0.000 0.090 0.032 0.023 0.000 0.090 0.032 0.021 0.000 0.090 0.032 0.019 0.090 0.090 0.090 0.090 0.090 0.090 0.090 0.090 0.090 0.090 0.09 0.12 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.092 0.066 0.058 0.058 0.058 0.058 0.058 0.058 0.058 0.058
Case study - 8
Install Low Pressure Economiser for Preheating the Boiler Feed Water
Back Ground
In boiler the operating efficiency can be improved by reducing the flue gas temperature and thereby reducing the fluegas loss. For every 20oC drop in flue gas temperature, the operating efficiency of the boiler increases by 1%. The reduction in flue gas temperature is decided by the acid dew point temperature. If the flue gas temperature is about 20oC more than the acid dew point temperature, the boiler could be operated without much of corrosion problem. In smaller size boiler, the latest trend is installing low pressure economizer and recovering the heat from the flue gas. The low pressure economizer is a simple shell and tube heat exchanger installed in the flue gas path. Boiler feed water is pumped through the economizer for preheating. The advantages of low pressure economizer are : ! Excellent heat recovery unit with very attractive payback period. ! Since it is a low pressure equipment, It does not require IBR certification.
Present status
In one of the small size paper plant a boiler of 8 tons/hr capacity is in operation and another boiler is kept as stand by. The flue gas temperature of boiler is measured as 225oC at high flame. The flue gas temperature is very high. Coal is used as fuel in the boiler. The acid dew point temperature is in the range of 140-145oC. The flue gas temperature can be conveniently brought down to 180oC, without leading to corrosion. For every 20oC drop in flue gas temperature an efficiency improvement of 1% can be achieved.
Recommendation
We recommend to install low pressure economiser and preheat the boiler feed water. The schematic diagram of the proposed system is shown in the back up calculations. The supplier address is given in annexure C.
Benefits
An annual saving of Rs 0.6 millions can be achieved by implementing this proposal. This requires an investment of Rs 0.5 millions for low-pressure economiser. This will have a simple pay back period of 10 Months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Paper Proposal-8: Install Low Pressure Economiser for Preheating the Boiler Feed Water Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.500 0.400 0.600 0.072 -0.500 1.831 92.41% 0.472 0.100 0.600 0.179 0.335 0.000 0.600 0.215 0.274 0.000 0.600 0.215 0.245 0.000 0.600 0.215 0.218 0.000 0.600 0.215 0.195 0.000 0.600 0.215 0.174 0.000 0.600 0.215 0.155 0.000 0.600 0.215 0.139 0.000 0.600 0.215 0.124 0.600 0.600 0.600 0.600 0.600 0.600 0.600 0.600 0.600 0.600 0.6 0.5 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.500 0.528 0.421 0.385 0.385 0.385 0.385 0.385 0.385 0.385 0.385
Textile
Introduction The textile industry is one of the oldest in the country, more than 105 years old. The textile industry has undergone rapid changes over the years. There are more than 2324 units operating in the power-processing sector. Many new units are being set up and older units being modernised. Indian textile industry is worth around Rs 800 billion (US$ 22.05 billion) accounting for approximately 20% of Indias total industrial output. The textile industry is an important segment of the countrys economy, which contributes 3% to countrys 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 shows rise 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 cost varies between 12 15%, which includes electrical and thermal energy. The energy cost is next to the raw material cost and comparable to labour cost. Hence, energy conservation in a textile mill plays significant importance and is a priority area for maximising profits. The scope for energy conservation in the textile sector is normally around 15%.
Install Variable Frequency Drive (VFD) for Plan Sifters of Mill A and Mill B
Present Status
In a Textile Unit all the 7 plan sifters of Mill A and Mill B were observed to be lightly loaded. The rated power of the motors in Mill A and Mill B are 2 kW and 2.2 kW respectively. The plan sifters require very high starting torque, but during normal running, they consume less power. The actual measurements show that, the power drawn by plan sifters during normal running varies between 1.07 and 1.45 kW. The operating power factor is in the order of 0.51 to 0.68, which is very low. This leads to decrease in operating efficiency of the motors.
Benefits
The annual savings potential was Rs. 0.63 millions. This required was investment of Rs.1.2 millions (for two AC Drives) and was paid back in 23 months Cost benefit analysis Annual Savings Rs. 0.63 millions Investment Rs. 1.2 millions Simple payback 23 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
-1.200 0.748 0.490 0.404 0.404 0.404 0.404 0.404 0.404 0.404 0.404
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
-0.500 1.022 0.914 0.879 0.879 0.879 0.879 0.879 0.879 0.879 0.879
Case study - 3
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 atomisation Substantial energy savings ! Density of atomised water could be adjusted according to the requirement
Recommendations
It is recommend to install atomisers in lieu of conventional type nozzles, where spray pumps are running continuously.
Benefits
Installation 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 simple payback period of 10 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Cost benefit analysis Annual Savings Rs. 0.43 millions Investment Rs. 0.35 millions Simple payback 10 months
Textile Proposal-3: Install High Efficiency Atomisers in Lieu of Nozzles in Humidification Plants Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.350 0.280 0.430 0.054 -0.350 1.318 94.41% 0.336 0.070 0.430 0.129 0.240 0.000 0.430 0.154 0.196 0.000 0.430 0.154 0.175 0.000 0.430 0.154 0.156 0.000 0.430 0.154 0.140 0.000 0.430 0.154 0.125 0.000 0.430 0.154 0.111 0.000 0.430 0.154 0.099 0.000 0.430 0.154 0.089 0.430 0.430 0.430 0.430 0.430 0.430 0.430 0.430 0.430 0.430 0.43 0.35 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.350 0.376 0.301 0.276 0.276 0.276 0.276 0.276 0.276 0.276 0.276
Comparison
For G 5/1 Ring Frames
Comparative study on Impeller and Suction tube Spindle no. Conventional fan with 490 mm dia. Fan with suction tube 115 * 50 * 30* Energy efficient fan with 490 mm dia. with suction tube 150 * 100 * 85* Energy efficient fan with 460 mm dia. with suction tube 110* 70* 60*
* All measurements in mm WC
Recommendation
It is recommend to install energy efficient pnuemafil fans for existing ring frame machines. By installing energy efficient fans in atleast 2/3 machines, trial should be taken and after seeing the performance, all the Ring Frames should be converted with energy efficient fans.
Benefits
The total annual savings will be Rs. 0.78 million. The investment required is Rs. 0.40 million, which will get paid back in 6 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Cost benefit analysis Annual Savings Rs. 0.78 millions Investment Rs. 0.40 millions Simple payback 6 months
Textile Proposal-4: Install Energy Efficient Pnuemafil Fans in Ring Frames Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.400 0.320 0.780 0.165 -0.400 2.551 143.69% 0.549 0.080 0.780 0.251 0.422 0.000 0.780 0.280 0.356 0.000 0.780 0.280 0.318 0.000 0.780 0.280 0.284 0.000 0.780 0.280 0.253 0.000 0.780 0.280 0.226 0.000 0.000 0.000 0.780 0.780 0.780 0.280 0.280 0.280 0.202 0.180 0.161 0.780 0.780 0.780 0.780 0.780 0.780 0.780 0.780 0.780 0.780 0.78 0.4 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.400 0.615 0.529 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500
Recommendation
It 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 and will operate at lower speed.
Benefits
By 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 of Rs 2.00 million, for installing variable frequency drive for all the pumps, which gets paid back in 19 months. Cost benefit analysis Annual Savings Rs. 1.28 millions Investment Rs. 2.00 millions Simple payback 19 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
1.395 0.964 0.821 0.821 0.821 0.821 0.821 0.821 0.821 0.821
Install Variable Frequency Drive for Water Circulating Pumps of Jet Dyeing Machine
Background
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 pump for individual jet dyeing machine remains in continuous operation for circulating the hot water inside the machine. During the washing process the pressure requirement for water circulation varies over a period of time. The initial pressure requirement for water circulation is in the range of 1-1.5 kg/cm2. For maintaining the required pressure a control valve provided at the outlet of the centrifugal pump is manually throttled based on the pressure gauge indication provided at the down side of the control valve. This condition prevails for atleast 30-35% of the batch time. During the washing process, as heating of water takes place in the jet dyeing machines the pressure gradually increases. After certain period of time the required pressure for water circulation is in the range of 2.0-2.5 kg/cm2. The pressure requirement and the time taken for washing varies depending upon the fabrics. During the maximum pressure requirement the 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 occurs across the control valve. There is a good potential to save energy by avoiding the pressure loss across the control valve. This can be achieved by installing variable frequency drive for the centrifugal pumps. Instead of throttling the control valve the speed of the centrifugal pump has to be varied using the variable frequency drive to meet the required pressure.
Recommendation
It 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 speed of the centrifugal pump can be varied to meet the required pressure. Keep the control valve fully opened.
Benefits
On 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 installing variable frequency drive for all the pumps, which gets paid back in 30 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Cost benefit analysis Annual Savings Rs. 0.32 millions Investment Rs. 0.08 millions Simple payback 30 months
Textile Proposal-6: Install Variable Frequency Drive for Water Circulating Pumps of Jet Dyeing Machine Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.080 0.064 0.320 0.092 -0.080 1.105 279.02% 0.204 0.016 0.320 0.109 0.168 0.000 0.320 0.115 0.146 0.000 0.320 0.115 0.130 0.000 0.320 0.115 0.116 0.000 0.320 0.115 0.104 0.000 0.320 0.115 0.093 0.000 0.320 0.115 0.083 0.000 0.320 0.115 0.074 0.000 0.320 0.115 0.066 0.320 0.320 0.320 0.320 0.320 0.320 0.320 0.320 0.320 0.320 0.32 0.08 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.080 0.228 0.211 0.205 0.205 0.205 0.205 0.205 0.205 0.205 0.205
Recommendations Step 1
Install a variable frequency drive for the fan temporarily and gradually reduce the speed of the fan. Simultaneously gradually increase the damper openings. Periodically check the quality of the product. Identify the minimum speed of the fan at which 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 direct driven fans, convert the directly driven fans to belt driven fans and reduce the speed.
Benefits
On a conservative basis atleast 40% savings can be achieved. The annual energy saving potential is Rs 0.10 million. This requires an investment of Rs 0.03 million for changing the pulleys, which gets paid back in 3 Months. Cost benefit analysis Annual Savings Rs. 0.10 millions Investment Rs. 0.03 millions Simple payback 3 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Textile Proposal-7: Reduce the Speed of Exhaust Fans in Stenters Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.030 0.024 0.100 0.027 -0.030 0.342 235.39% 0.065 0.006 0.100 0.034 0.053 0.000 0.100 0.036 0.046 0.000 0.100 0.036 0.041 0.000 0.100 0.036 0.036 0.000 0.100 0.036 0.032 0.000 0.100 0.036 0.029 0.000 0.100 0.036 0.026 0.000 0.100 0.036 0.023 0.000 0.100 0.036 0.021 0.100 0.100 0.100 0.100 0.100 0.100 0.100 0.100 0.100 0.100 0.1 0.03 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.030 0.073 0.066 0.064 0.064 0.064 0.064 0.064 0.064 0.064 0.064
Avoid Idle Operation of Motors by Providing Stop Motion Circuit for Blow Room
Background
Hard pressed bales of raw cotton obtained from the market are first put through blow room where, by a combination of rapid beating and suction, the cotton lumps are broken down in size 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. Whenever the above mixtures are filled upto the pre-determined limit, the subsequent material transport motor is stopped. But all other motors, such as the beaters and stripper rollers etc., will be running idly, leading unnecessary energy consumption. Motor idle time varies between 10 to 12 hrs. All these idle running motors could be stopped step by step and could also be restarted at pre-determined time intervals whenever the demand arises. This is possible by introduction of stop motion circuit into the blow room.
Recommend
It is recommended to install stop motion circuit in blow room. As soon as cotton mixture will be 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 saved by avoiding idle operation of motors.
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 is 10 hrs out of 23 hrs of operation. Units saved = = = 9.31 kW X 10 hrs 93.1 kWh/day 33516 kWh/Annum
Benefits
The annual energy saving potential is Rs 0.13 million. This requires an investment of Rs 0.05 million for changing the pulleys, which gets paid back in 5 Months. Cost benefit analysis Annual Savings Rs. 0.13 millions Investment Rs. 0.05 millions Simple payback 5 months
Textile Proposal-8: Avoid Idle Operation of Motors by Providing Stop Motion Circuit for Blow Room Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.050 0.040 0.130 0.032 -0.050 0.437 187.05% 0.087 0.010 0.130 0.043 0.069 0.000 0.130 0.047 0.059 0.000 0.130 0.047 0.053 0.000 0.130 0.047 0.047 0.000 0.130 0.047 0.042 0.000 0.130 0.047 0.038 0.000 0.130 0.047 0.034 0.000 0.130 0.047 0.030 0.000 0.130 0.047 0.027 0.130 0.130 0.130 0.130 0.130 0.130 0.130 0.130 0.130 0.130 0.13 0.05 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.050 0.098 0.087 0.083 0.083 0.083 0.083 0.083 0.083 0.083 0.083
Recommendation
It is recommend to install Transvector nozzles at the identified cleaning points in the packing section.
Benefits
On a conservative basis, atleast 30% energy savings can be achieved by replacing the compressed 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.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Cost benefit analysis Annual Savings Rs. 0.08 millions Investment Rs. 0.01 millions Simple payback 2 months
Textile Proposal-9: Install Transvector Nozzle for the Cleaning Applications Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.010 0.008 0.080 0.026 -0.010 0.283 538.15% 0.048 0.002 0.080 0.028 0.041 0.000 0.080 0.029 0.037 0.000 0.080 0.029 0.033 0.000 0.080 0.029 0.029 0.000 0.080 0.029 0.026 0.000 0.080 0.029 0.023 0.000 0.080 0.029 0.021 0.000 0.080 0.029 0.018 0.000 0.080 0.029 0.017 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.080 0.08 0.01 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.010 0.054 0.052 0.051 0.051 0.051 0.051 0.051 0.051 0.051 0.051
Benefits
An annual energy savings potential of Rs. 1.49 million has been achieved by replacing the old inefficient motors with energy efficient motors. The investment made was around Rs. 1.10 million, which got paid back in 9 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Textile Proposal-10: Replace Old Conventional Motors with Energy Efficient Motors Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 1.100 0.880 1.490 0.219 -1.100 4.643 103.15% 1.135 0.220 1.490 0.456 0.825 0.000 1.490 0.535 0.680 0.000 1.490 0.535 0.607 0.000 1.490 0.535 0.542 0.000 1.490 0.535 0.484 0.000 1.490 0.535 0.432 0.000 1.490 0.535 0.386 0.000 1.490 0.535 0.345 0.000 1.490 0.535 0.308 1.490 1.490 1.490 1.490 1.490 1.490 1.490 1.490 1.490 1.490 1.49 1.1 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-1.100 1.271 1.034 0.955 0.955 0.955 0.955 0.955 0.955 0.955 0.955
Sugar
Introduction
Brazil and India are the largest sugar producing countries followed by China, USA, Thailand, Australia, Mexico, Pakistan, France and Germany. The world consumption is projected to grow to 160.7 MMT in 2010, and 176.1 MMT by 2015. According to ISO, the world sugar output is forecasted to reach 145.0 MMT and consumption to reach 147.0 MMT in 2004-2005 India is the largest producer-consumer of sugar in the world. The new sugar year 2005-06 began on 1st October 2005 with an opening stock of about 45 lakh tonnes. Sugar production in the country has been estimated at 180 lakh tonnes, while the consumption has been estimated at 185 lakh tonnes. It is also estimated that in the year 2006-07, sugar production will increase further to a record level of 225 lakh tonnes. Indian sugar industry is amongst the most diversified industry in the world, with an installed capacity to produce 847 MW co-generated power against a potential of 5000 MW. 50 more units with a capacity of 600 MW are in the process of putting up plants. The Government of India today recognizes this potential and has committed itself to promote renewable sources of energy. In this section, several actual implemented case studies in sugar industry is highlighted
Case study 1
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Financial Analysis
The additional saving benefit was Rs 8.0 million. Considering an average crushing of 2200 TCD for an operating season of 180 days, the reduction in power consumption is 28.8 Lakh units. This results in an energy cost saving of Rs. 8.0 million / season (Considering power export cost of Rs. 2.75 / kWh). The diffuser was installed by design.
Case study 2 Utilization of Exhaust Steam for Sugar Drier and Sugar Melter
Background
The sugar manufacturing process needs substantial amount of thermal energy, in the form of steam. The majority of steam requirement is at low pressures (0.6 to 1.5 ksc), while a small percentage of the steam consumption is at medium pressure of about 7.0 ksc. In the sugar mills, the requirement of steam at lower pressures is met from the exhaust of the turbine; while the medium pressure (MP)steam, in most of the plants, is generated bypassing the live steam generated from the boiler, through a pressurereducing valve. This is 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 cogeneration have become attractive, as additional power can be sold to the grid. One of the methods of improving cogeneration is the replacement of high-pressure steam with low-pressure steam, wherever feasible. In a sugar mill, there is a good possibility of replacing some quantity of MP steam users with exhaust steam, resulting in increased power generation. This case study describes one such project implemented in a 2500 TCD sugar mill. Previous Status In one of the 2500 TCD sugar mills, medium pressure steam at 7.0 ksc, generated by passing live steam at 42 ksc, through a pressure reducing valve (PRV), was being used in the following process users: ! Hot water superheating for use in the centrifuges ! Sugar drier blower ! Sugar melter
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
The temperature requirements for sugar drier blower and sugar melter are about 80C and90C respectively. The centrifuge hot water was to be heated to a temperature of about115 - 125C. Exhaust steam generated by passing live steam through a turbine was available at around1.2 ksc.
Benefits
The live steam consumption, amounting to about 0.3 TPH, in the sugar melter and sugar drier blowers, was replaced with exhaust steam. This resulted in additional power generation of about 35 units, which could be sold to the grid.
Financial Analysis
The annual energy saving achieved was Rs. 0.2 million. This required an investment of Rs. 0.02 million, which had a very attractive simple payback period of 2 months.
Note
Similarly, exhaust steam can partly substitute the use of live steam for hot water heating in centrifuges. The centrifuge hot water heater requires a temperature of about 115 -125C.Exhaust steam can be used for heating the centrifuge wash water to atleast 105C. The heating, from 105C to 125C can be carried out by live steam. This will partly substitute theuse of live steam and will increase the cogeneration power.
Sugar Proposal-2: Utilization of Exhaust steam for Sugar Drier and Sugar melter Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.020 -0.020 0.711 667.02% 0.020 0.016 0.200 0.066 0.120 0.004 0.200 0.070 0.103 0.000 0.200 0.072 0.091 0.000 0.200 0.072 0.082 0.000 0.200 0.072 0.073 0.000 0.200 0.072 0.065 0.000 0.200 0.072 0.058 0.000 0.200 0.072 0.052 0.000 0.200 0.072 0.046 0.000 0.200 0.072 0.128 0.041 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.2 0.02 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study 3
Benefits Achieved
The cooling achieved with the mist cooling system was about 31 - 32 C (i.e., a subcooling of 2 - 4 C was achieved). This resulted in avoiding the operation of one 75 HP pump completely. In addition, significant process benefits were achieved. The better cooling water temperatures, helped in maintaining steady vacuum conditions in the condensers. This minimized the frequent vacuum breaks, which occurred in the condensers (on account of the high cooling water temperatures) and also ensured better operating process parameters.
Financial Analysis
The annual energy savings achieved were Rs.0.32 million (assuming a cogeneration system with 120 days of sugar season and saleable unit cost of Rs.2.50/kWh). This required an investment of Rs.0.50 million, which had a simple payback period of 19 months.
Annual Savings Rs. 0.32 millions Investment Rs. 0.50 millions Simple payback 19 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study 4
Installation of Regenerative Type Continuous Flat Bottom High Speed Centrifugal for A - Massecuite Curing
Background
The syrup after concentration to its maximum permissible brix levels in the vacuum pans is passed to the crystallizers. From the crystallizers, the concentrated and cooled mass, comprising of molasses and crystals are fed to the centrifugal, so that the mother liquor and the crystals are separated, to obtain the sugar in the commercial form. The recent trend among the sugar mills is to install fully automatic centrifugal. The operations involved in the centrifuge are -starting, charging, control of charging speed, closing These centrifugal had the conventional type of braking system, with no provisions for recovery of energy expended during changeover to low speed or discharging speed. The power consumption in these centrifugal were of the massecuite gate, acceleration, washing with superheated wash water& steam, drying at high speed, change to low speed & control of discharging speed, opening the discharge cone, drying out the sugar, and starting the next charge. All these are carried out by an assembly of controls, programmed to operate in the correct sequence. At the end of the drying period, the centrifugal is stopped by means of a brake, which generally consists of brake shoes provided with a suitable friction lining and surrounding a drum, on which 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 partial recovery of the energy expended.
Previous status
One of the sugar mills had DC drives for their flat bottom high speed centrifugal of 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 recovery of energy expended during changeover to low speed or discharging speed. The power consumption in these centrifugal were of the partially recover the energy expended during the discharge cycle.
However, this corresponds to more than half the stored energy. With DC motors, a much greater proportion of the stored energy can be recovered. With the present day motors, supplied with thyristor controls, regenerative braking is obtained by 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.
Benefits achieved
The regenerative braking system recovers about 1.34 kW/100 kg of sugar produced, during the discharge cycle and feeds it back into the system. Hence, the net power consumption of the centrifugal with the regenerative braking system is only 0.66 kW/100 kg of sugar produced.
Financial analysis
This project was implemented as a technology up gradation measure.
Replication Potential
This project has a high replication potential of implementation in more than 75 plants in the country.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study 5
Previous status
One of the sugar mills with an installed capacity of 2500 TCD, had the multi-jet condensers for 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 requirements of these condensers. These pumps were designed to handle an average maximum crushing capacity of 3200 TCD.
Benefits achieved
There was a significant drop in water consumption in these condensers, in spite of an increase in 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 of about 350 HP (30% reduction). The actual average power consumption also has registered a significant drop of nearly 180 kW, which amounts to an annual energy saving of 5,18,400 units(for 120 days of sugar season).
Financial analysis
The 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.
Annual Savings Rs. 1.30 millions Investment Rs. 2.53 millions Simple payback 24 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study 6
Previous status
A sugar mill in Tamil Nadu operating for about 200 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
Turbines
! 1 number 2.5 MW ! 1 number 2.0 MW ! 1 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 power requirement of the plant during the sugar-season was met by the internal generation and during the nonseason from the grid.
Boilers
! 2 numbers of 70 TPH, 67 ATA ! Multi-fuel fired boilers Turbines 1 number of 30 MW turbo-alternator set (Extraction-cum-condensing type)
Mill drives
! 4 numbers of 900 HP DC motors for mills ! 2 numbers of 750 HP DC motors for mills ! 2 numbers of 1100 kW AC motors for fibrizer
Benefits
The installation of high-pressure boilers and high-pressure turbo-generators has enhanced the power generation from 9 MW to 23 MW. Thus, surplus power of 14 MW is available forexporting to the grid. 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
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Financial analysis
The annual monetary benefits achieved are Rs.204.13 million (based on cost of power sold to the grid @ Rs.2.548/unit, sugar season of 219 days and off-season of 52 days). This required an investment of Rs.820.6 million. The investment had an attractive simple payback period of 48 months.
Replication Potential
The sugar plants in India have tremendous potential for commercial cogeneration ie producing steam at a higher pressure and selling the extra power generated to the grid. The total cogeneration potential yet to be tapped in India has been estimated to be about 100 MW. The investment potential for atleast say about 50 plants is Rs 4000 million.
-820.600 366.411 189.776 130.898 130.898 130.898 130.898 130.898 130.898 130.898 130.898 -820.600 327.152 151.289 93.171 83.188 74.275 66.317 59.212 52.868 47.203 42.146
176.221 18.41%
1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV
Case study 7
Conventional system
In a typical sugar mill, the most commonly used evaporators are the quintuple effect evaporators. The typical vapour utilization system in the evaporators comprises of: ! Vapour bleeding from II- or III- effect for heating (from 35 C to 70 C) in the raw (or dynamic) juice heaters ! Vapour bleeding from I- effect for heating (from 65 C to 90 C) in the first stage of the sulphited juice heater
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
! Exhaust steam for heating (from 90 C to 105 C) in the second stage of the sulphited juice heater ! 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 is achieved, if the vapour from the last two effects can be effectively utilized in the process, as the vapour would be otherwise lost. Also, the load on the evaporator condenser will reduce drastically. Many of the energy efficient sugar mills, especially those having commercial cogeneration system, have adopted this practice and achieved tremendous benefits. The reduced steam consumption in the process, can result in additional power generation, which can be exported to the grid.
Present system
In a 2500 TCD sugar mill, the extensive use of vapour bleeding at evaporators, was adopted at the design stage itself. The plant has a quintuple-effect evaporator system. This system comprises of: ! Vapour bleeding from the V- effect, for heating (from 30 C to 45 C) in the first stage of the raw juice heater ! Vapour bleeding from the IV- effect, for heating (from 45 C to 70 C) in the second stage of the raw juice heater ! Vapour bleeding from the II- effect, for heating in the A-pans, B-pans and first stage of sulphited juice heater ! Vapour bleeding from the I- effect, for heating in the C-pans, graining pan and second stage of sulphited juice heater and Exhaust steam for heating in the clear juice heater However, to ensure the efficient and stable operation of such a system, the exhaust steam pressure 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 system for 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, to reduce the speed. This will reduce the power export to the grid and help achieve steady exhaust pressure and vice-versa.
Benefits achieved
The installation of the extensive vapour utilization system at the evaporators has resulted in improved steam economy. The specific steam consumption achieved (as % cane crushed) at various 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
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
Thus, the specific steam consumption (% on cane) is lower by atleast 7%. This means a saving of 3.5% of bagasse percent cane (or 35 kg of bagasse per ton of cane crushed).
Financial analysis
The 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 stage itself. 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.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study 8
Installation of Variable Speed Drive (VSD) for the Weighed Juice Pump
Background
The sugarcane is crushed in the mill house, to separate the juice and the bagasse. The juice obtained from the mill house is known as raw juice. The raw juice is screened, to remove all suspended matter and any entrained fibres. The juice is at this stage, known as strained juice. The strained juice is then sent to a weigh scale, from where it gets transferred to a weighed juice tank. This weighed juice is passed through the primary/ raw juice heaters to the sulphiters, with the help of weighed juice pumps. In the sulphiter, SO2 is injected continuously for colour removal. 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 and quality.
Previous status
In a 2600 TCD sugar mill, there was a weighed juice pump operating continuously to meet the process 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 getting emptied, 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 tip of the weigh scale is governed by, the cane crushing rate and also the quality (juice content)of cane. Moreover, the pump was designed for handling the maximum cane-crushing rate. The maximum head requirement is only 25 m (equivalent to 2.5 ksc), while the pump had a design head of 45 m. This also contributed to the excess margins in the pump, leading to operation with recirculation control. Hence, to keep the juice flow smooth and avoid the tank from getting emptied, the pump was operated with recirculation control. The pressure in the juice heater supply header is maintained by periodically throttling and adjusting the control valve in the recirculation line. The operations of a centrifugal pump with valve control or recirculation are energy inefficient methods of capacity control, as energy is wasted in pumping more quantity, than is actually desired. In the above context, it is advisable to have a uniform flow of juice and also avoid wastage of energy through re-circulation. This can be achieved in an energy efficient manner, by varying the RPM of the pump.
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Benefits Achieved
The installation of a Variable Frequency Drive for the weighed juice pump, resulted in the following 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. The installation of a VFD, can result in the reduction of the average power consumption by atleast another 40 - 50%.
Financial Analysis
The annual energy saving achieved (with the installation of a dyno-drive) was Rs.0.236 million. The investment made was Rs 0.25 million, with an attractive payback period of 12 months. Replication Potential Every sugar plant has about 10 -12 juice pumps in operation. The potential for application for VFD exists in atleast 3 pumps. This project has been taken up only in few of the newer sugar plants. The investment potential (100 plants x Rs 0.5 million/plant) is Rs 50 million.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Sugar Proposal-8: Installation of variable speed drive(VSD) for the weighed juice pump Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.250 -0.250 0.698 75.44% 0.250 0.200 0.240 0.014 0.201 0.050 0.240 0.068 0.137 0.000 0.240 0.086 0.110 0.000 0.240 0.086 0.098 0.000 0.240 0.086 0.087 0.000 0.240 0.086 0.078 0.000 0.240 0.086 0.070 0.000 0.240 0.086 0.062 0.000 0.240 0.086 0.055 0.000 0.240 0.086 0.154 0.050 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.240 0.24 0.25 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Case study 9
Conventional Systems
Following methods are adopted to control the flow of water in the Condenser to maintain correct vacuum and reduce consumption of water. Both the methods use pressure governing to regulate water flow.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Financial Analysis
The 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.
Sugar Proposal-9: Install Nozzle governing system for Multi Jet condensers Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -5.000 -5.000 65.408 265.96% 5.000 4.000 19.000 5.381 13.619 12.160 1.000 19.000 6.458 12.543 9.999 0.000 19.000 6.816 12.184 8.672 0.000 19.000 6.816 12.184 7.743 0.000 19.000 6.816 12.184 6.913 0.000 19.000 6.816 12.184 6.173 0.000 19.000 6.816 12.184 5.511 0.000 19.000 6.816 4.921 0.000 19.000 6.816 4.394 0.000 19.000 6.816 3.923 19.000 19.000 19.000 19.000 19.000 19.000 19.000 19.000 19.000 19.000 19 5 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case Study 10
Previous status
One of the sugar mills, had the following pan configuration for the massecuite curing:. 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 Batch vacuum pans of 80 Tons holding capacity (3 nos.) ! 2 nos. for A massecuite ! 1 no for B massecuite Continuous vacuum pan of 135 tons holding capacity ! 1 no. for C massecuite
The following operational parameters 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 reduces towards 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
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
! The continuous vacuum pan is automated, resulting in simpler operation. They are compact and hence, the space requirement is much lower The continuous vacuum pans have gained immense popularity on account of the salient features mentioned above.
Financial analysis
The 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 Potential
The installation of continuous vacuum pans through a proven project has been taken up on lyin about 20% of the plants. The potential of replication is therefore very high. However, the commercial viability of the project is high, only in case of plants with commercial cogeneration.
Sugar Proposal-10: Installation of fully automated continuous vacuum pans for curing Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -100.000 1.128 12.36% 100.000 80.000 19.260 -21.790 36.652 20.000 19.260 -0.265 15.566 0.000 19.260 6.910 8.791 0.000 19.260 6.910 7.849 0.000 19.260 6.910 7.008 0.000 19.260 6.910 6.257 0.000 19.260 6.910 5.587 0.000 6.910 4.988 0.000 6.910 4.454 0.000 19.260 6.910 3.977 19.260 19.260 19.260 19.260 19.260 19.260 19.260 19.260 19.260 19.260 19.260 19.260 19.26 100 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Foundry
Introduction There are more than 5,000 foundry units in India, having an installed capacity of approximately 7.5 million tonnes per annum. The majority (nearly 90%) of the foundry units in India falls under the category of small-scale industry. The foundry industry is an important employment provider and provides direct employment to about half a million people. A peculiarity of the foundry industry in India is its geographical clustering. Typically, each foundry cluster is known for catering to some specific end-use markets. For example, the Coimbatore cluster is famous for pump-sets castings, the Kolhapur and the Belagum clusters for automotive castings and the Rajkot cluster for diesel engine castings. Cupola is the predominant melting furnace employed more than 6000 are cupola based foundry units operating in small scale sector. The majority of cupolas in the cluster are of conventional type. Divided blast cupola (DBC) can be found in some of the foundry units. Most of the foundries use low ash coke. A number of foundry units (about 40%) have electric induction furnace, which is used to manufacture graded castings and for duplexing with cupola. The other units have rotary furnaces. Various studies undertaken and the data collected indicate the annual energy saving potential in Indian foundry industry is about 10-12% of the total energy bill. This includes short term and medium term projects, which have payback period of less than 2 years. If the long term energy saving projects are considered the energy saving potential in Indian foundry industry is as high as 15 20% of the total energy consumption. Energy Intensity in Indian Foundry industry Indian foundry industry is very energy intensive. The energy input to the furnaces and the cost of energy play an important role in determining the cost of production of castings. Major energy consumption in small foundry industry, coke is used for metal melting in the Cupola furnaces. In medium and large scale foundry industry is the electrical energy consumption for induction and Arc furnaces. Fuel oil is used for heat treatment 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. ENERGY CONSUMPTION PATTERN Electrical energy consumption Melting and holding furnaces are the major electrical energy consumers. The other electrical energy users include sand plant, major utilities such as compressors, auxiliary cooling water systems and lighting. Thermal energy consumption In Cupola furnaces, coal/coke is used as fuel for metal melting. Typical coke consumption in cupola furnace is about 135 kg/MT of molten metal. Fuel oil is used
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for metal melting in rotary furnaces. Specific consumption of fuel oil is about 135 lit/MT of molten metal. Heat treatment furnaces and ladle preheating furnaces are the other major users in foundry industry.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study - 1
Previous status
Medium frequency furnace is used for cast iron melting. The variation in per ton of metal melted is between 50 to 80 units. The lowest specific power consumption achieved is 650 units/ton of molten metal.
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.
Benefits
The variation in power consumption of the furnace is minimised. Atleast 20 kWH /batch reduction in power consumption was achieved.
Financial analysis
This amounted to an annual monetary saving (@ Rs 3.50/unit) of Rs 0.6 million. The investment made was Rs 0.20 million. The simple payback period for this project was 4 Months. Replicating Potential in Indian foundry industry There are about 5,000 foundry units are in operation in India. About 10% of the foundry units are utilising induction furnace for metal melting. Atleast 50% of units, utilising induction furnace for metal melting can incorporate the KWH indicator cum integrator for monitoring. The energy saving potential using KWH indicator is about Rs 15 Crores in Indian small scale foundry industry. The investment opportunity for KWH indicator is about Rs 10 Crores.
Annual Savings Rs. 0.6 millions Investment Rs. 0.20 millions Simple payback 4 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study 2
Previous status
In a small scale foundry industry a main frequency furnace of capacity 1 ton/batch was in operation. The specific power consumption of main frequency furnace was 725 units/ton of molten metal.
Financial analysis The total benefits amounted to a monetary annual savings of Rs 0.79 million. The investment made was around Rs 2.0 million. The simple payback period for this project was 31 Months.
Annual Savings Rs. 0.79 millions Investment Rs. 2.0 millions Simple payback 31 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study - 3
Present status
In one of the small scale foundry industry laboratory test method is followed for testing the molten metal. Time taken for the molten metal testing is about 15-20 min.
Benefits
This has resulted in overall reduction in metal holding time and hence reduction in energy consumption of about 10 units per ton of molten metal.
Financial analysis
The benefits amounted to a monetary annual savings of Rs 0.20 million. The investment made was around Rs 0.80 million. The simple payback period for this project was 46 Months.
Foundry Proposal-3: Install spectro meter for analyzing the molten metal Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.800 0.640 0.200 -0.158 -0.800 0.358 -0.800 0.175 18.54% 0.320 0.160 0.200 0.014 0.186 0.148 0.000 0.200 0.072 0.091 0.000 0.200 0.072 0.082 0.000 0.200 0.072 0.073 0.000 0.200 0.072 0.065 0.000 0.200 0.072 0.058 0.000 0.200 0.072 0.052 0.000 0.200 0.072 0.046 0.000 0.200 0.072 0.041 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.2 0.8 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study 4
Previous status
The returns from the molding section are directly used for the melting applications. The metal loss is about 6%. The heat loss is about 125 units / batch of metal melted. This contributes 2.5-3% of the total energy input to the furnace.
Benefits
The slag formation was minimized and hence metal loss was reduced from 6% to 2.53%. The power consumption is reduced by 8-10 units/batch.
Financial analysis
This amounted to an annual monetary saving (@Rs 3.50/unit) of Rs 0.52 million. The investment made was around Rs 2.00 million. The simple payback period for this project was 46 Months.
Foundry Proposal-4: Install online shot blastingmachine for cleaning Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -2.000 -2.000 0.511 19.55% 2.000 1.600 0.520 -0.387 0.810 0.400 0.520 0.043 0.380 0.000 0.520 0.187 0.237 0.000 0.520 0.187 0.212 0.000 0.520 0.187 0.189 0.000 0.520 0.187 0.169 0.000 0.520 0.187 0.151 0.000 0.520 0.187 0.135 0.000 0.520 0.187 0.120 0.000 0.520 0.187 0.333 0.107 0.520 0.520 0.520 0.520 0.520 0.520 0.520 0.520 0.520 0.520 0.52 2 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study - 5
Previous status
Temperature requirement for molten metal is 1460oC. The molten temperature overshoots beyond 1480oC.
Benefits
Eliminates overshoot in molten metal temperature. Reduction in energy consumption of about 5 units/ton of molten metal is achieved.
Financial analysis
The total benefits resulted to an annual saving of Rs 0.20 million. The investment made was Rs 0.20 million. The simple payback period for this project was 12 Months.
Foundry Proposal-5: Monitor temperature of molten metal continuously suing online infrared thermometer Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.200 -0.200 0.587 78.30% 0.200 0.160 0.200 0.014 0.166 0.040 0.200 0.057 0.114 0.000 0.000 0.200 0.200 0.072 0.072 0.091 0.082 0.000 0.000 0.200 0.200 0.072 0.072 0.073 0.065 0.000 0.200 0.072 0.058 0.000 0.200 0.072 0.052 0.000 0.200 0.072 0.046 0.000 0.200 0.072 0.041 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.200 0.2 0.2 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.186 0.143 0.128 0.128 0.128 0.128 0.128 0.128 0.128 0.128
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study 6
Install Waste Heat Recovery System for the Stress Relieving Furnaces to Recover Heat from the Exhaust Flue Gas
Back ground
In the Stress relieving furnace the castings are heated to a temperature of about 550oC and then 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. The Exhaust flue gas temperature is in the range of 615-625oC. The percentage of heat loss through 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. This can be achieved by installing an air preheater and preheating the combustion air supply to the stress relieving furnace. In the air preheater the combustion air supply can be preheated to a temperature of about 180oC. After air preheater the flue gas can be sent to atmosphere.
Benefits
Preheating of combustion air has resulted in about 4% reduction in fuel consumption.
Financial analysis
The total benefits amounted to a monetary annual savings of Rs 0.32 million. The investment made was around Rs 0.30 million. The simple payback period for this project was 12 Months.
Foundry Proposal-6: Install Waste Heat Recovery System for the stress releiving furnaces to recover the heat from the exhaust flue gas Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.300 -0.300 0.953 83.04% 0.300 0.240 0.320 0.029 0.291 0.260 0.060 0.320 0.093 0.227 0.181 0.000 0.320 0.115 0.146 0.000 0.320 0.115 0.130 0.000 0.320 0.115 0.116 0.000 0.320 0.115 0.104 0.000 0.320 0.115 0.093 0.000 0.320 0.115 0.083 0.000 0.320 0.115 0.074 0.000 0.320 0.115 0.066 0.320 0.320 0.320 0.320 0.320 0.320 0.320 0.320 0.320 0.320 0.32 0.3 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study -7
Present status
In one of the foundry industry compressed air pressure is maintained at 6.5 kg/cm2 in the main header. Majority of the compressed air is utilized for the pneumatic operations in the core making m/cs, pneumatc lifts, pneumatic grinders and cleaning i operations etc. The total number of cleaning points in core making sections is 10 and that in the Aluminium Die Casting (ADC) section is 18. The quantity of compressed air utilized for cleaning operation is estimated as 200 cfm in the core-making area and about 250 cfm in the Aluminium Die Casting section.
Benefits
Implementation of the project resulted in atleast 30% reduction in compressor power consumption.
Financial analysis
Implementation of the proposal resulted in monetary benefit of Rs 0.36 million. Investment made was Rs 0.3 million. The payback period was 11 Months.
Foundry Proposal-7: segregate the high pressure and low pressure compressed air users Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.300 -0.300 1.098 92.41% 0.300 0.240 0.360 0.043 0.317 0.283 0.060 0.360 0.108 0.252 0.201 0.000 0.360 0.129 0.164 0.000 0.360 0.129 0.147 0.000 0.360 0.129 0.131 0.000 0.360 0.129 0.117 0.000 0.360 0.129 0.231 0.104 0.000 0.360 0.129 0.093 0.000 0.360 0.129 0.083 0.000 0.360 0.129 0.074 0.360 0.360 0.360 0.360 0.360 0.360 0.360 0.360 0.360 0.360 0.36 0.3 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Air Compressors
Introduction
Compressed air, also called as the fourth utility plays a vital role in the manufacturing process of any industry. The generation of compressed air is one of the major energy consuming activity taking place in any industrial operation. Often Compressors are referred to as Power Guzzlers. An approximate estimate indicates that around 1500 MW is consumed nationwide, just to compress air in industry. Moreover, the use of compressed air is increasing linearly with our industrial growth. This presents a worthy target for the application of energy conservation technologies. Many energy conscious engineers exposed to factory environments believe that, atleast 10% of this can be saved. Therefore, it is in the national interest that compressed air be generated and used with efficiency & economy, wherever possible. This not only results in energy savings, but also a saving in rupees. Air compressors form a significant energy consumer in the following industries: ! ! ! ! ! ! Foundry Automobile & auto components Textile Cement Paper Synthetic fibre, etc.
In this section, several actual implemented case studies in air compressors and its auxiliaries are highlighted.
Whenever there is a significant variation in the power consumption of the compressor from the above-mentioned values, it signifies that the compressor may be energy inefficient. The reasons for higher specific power consumption can be the age of the compressor, wear and 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 the replacement of the compressor with a new one. The choice of the type of compressor depends on 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 engineering unit. Capacity test was conducted on the compressor. The details about the rated volume of the compressor against its actual delivered volume with the power consumption were (@ 6 kg/ cm2) ! Rated volume (Cfm) ! Actual volume (Cfm) ! Power consumption (KW) : : : 744 565 103
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
It was observed that the volumetric efficiency of the compressor was about 75% and that the specific power consumption (SEC) was 0.182 kW/cfm. As mentioned in the table earlier, the typical norm for power consumption of an air compressor operating at 7.0-kg/cm2 pressures is 0.14 kW/cfm. Similarly, the typical power consumption of a compressor operating at 6.0-kg/cm2 pressure should be 0.12 kW/cfm.
Benefits
The implementation of this project resulted in reduction of energy consumption of compressors.
Financial Analysis
The replacement of the old compressor with new energy efficient compressor resulted in an annual savings of Rs.0.95 million. The investment (for new reciprocating type air compressors) amounted to Rs.1.5 million, which had a simple payback period of 20 Months
Replication potential
The replacement of old compressors with new energy efficient compressor is a project with huge replication potential. On a conservative basis, this project could be replicated in at least in about 100 installations. The investment potential for this project is Rs 100 millions.
Air Compressors Proposal-1: Replace old inefficient compressors with new Energy efficient compressors Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 1.500 1.200 0.950 -0.090 -1.500 1.040 -1.500 2.412 51.31% 0.928 0.300 0.950 0.233 0.717 0.571 0.000 0.000 0.950 0.950 0.341 0.341 0.434 0.387 0.000 0.950 0.341 0.346 0.000 0.950 0.341 0.309 0.000 0.950 0.341 0.276 0.000 0.950 0.341 0.246 0.000 0.950 0.341 0.220 0.000 0.950 0.341 0.609 0.196 0.950 0.950 0.950 0.950 0.950 0.950 0.950 0.950 0.950 0.950 0.95 1.5 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Install Variable Frequency Drive for Screw Compressor Catering to Varying Demand of Compressed Air
Background and concept
Variable speed drives eg. (Variable frequency drives) can be installed for all types of air compressors. 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 unload power consumption. ! Air leakages in the compressed air system also come down since the average operating pressure is less. Generally, high capacity air compressors are operated with loading /unloading control, as in the case of screw & reciprocating compressors and with inlet vane control for centrifugal compressors. 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 pressure range. 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 connected to a common header, then by installation of VFD in one compressor, the energy savings achieved due to pressure reduction is cumulative in nature (power consumption comes down in all compressors). Since the average operating pressure with VFD is less (6kg/cm2 instead of 6.5 kg/cm2 as per earlier example) the air leakages in the system is also minimized. The installation of VFD facilitates in varying the speed of the compressor depending on the requirement. This completely avoids unloading and saves unload power consumption, which is normally 25 to 35 % of the full load consumption. Recently, screw compressors with built-in variable frequency drives have been introduced in the Indian market. This system facilitates fine tuning of the compressor capacity precisely to meet the fluctuating compressed air demand. It accurately measures the system pressure and adjusts the speed to automatically maintain a constant pressure.
Previous status In an auto component manufacturing unit three screw compressors of 600 Cfm were available for compressed air supply through out the plant. Another compressor of 750 cfm was available and the same was used to meet the peak demand. Among the three screw compressors in continuous use, two compressors were always on loading. 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. The compressor had a power consumption of 98 kW on load and 22 kW during unload mode. Energy Saving Project Variable Frequency drive with feed back control was installed for the screw compressor, which was operating in the load unload mode. The pressure sensor provided in the main header sensed 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 Implementation The installation of VFD for the compressor was done during the normal operation of the plant itself. The plant team did not face any problems in implementation of the project and in subsequent operating pressure reduction. Benefits The unloading power consumption of the screw compressor was totally eliminated. The over all operating pressure was also reduced to 5.5Kg/cm2. Financial Analysis The annual savings achieved amounted to Rs 0.43 million. The required an investment of Rs 0.7 million for installing variable frequency drive with feed back control, was paid back in 20 Months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Previous status
In 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 some of the users are given below. Area Pressure Kg/cm2 Unit1 4.0 Receiving end Quantity Cfm 1900 600
The fall in pressures at the receiving end was mainly due to the losses, which were taking place in the transmission line, which had a length of about 1.5 Km.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Implementation The 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 units during the scheduled preventive maintenance. The plant team did not face any problems during the implementation of the project. Benefits The operation of two compressors of capacity 1500 Cfm each, in the compressor house was avoided. Financial Analysis Segregation of high pressure and low-pressure users of compressed air and installation of dedicated compressors for low-pressure users, led to an annual savings of Rs 1.04 million. This required an investment of Rs 1.5 millions, which got paid back in 18 Months. Replication potential The 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
Air Compressors Proposal-3 : segregate high pressure and low pressure compressed air users Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 1.500 1.200 1.040 -0.057 -1.500 2.738 55.87% 0.980 0.300 1.040 0.265 0.617 0.000 1.040 0.373 0.475 0.000 1.040 0.373 0.424 0.000 1.040 0.373 0.378 0.000 1.040 0.373 0.338 0.000 1.040 0.373 0.302 0.000 1.040 0.373 0.269 0.000 1.040 0.373 0.240 0.000 1.040 0.373 0.215 1.040 1.040 1.040 1.040 1.040 1.040 1.040 1.040 1.040 1.040 1.04 1.5 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-1.500 1.097 0.775 0.667 0.667 0.667 0.667 0.667 0.667 0.667 0.667
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Replace Refrigeration / Desiccant Type Air Dryers with Heat of Compression Air Dryers, in Case of Reciprocating Air Compressors
Background
The heat available in the compressed air (temperature of 120 deg C) is utilized for regeneration of the desiccant, 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 is considerable power saving in this type of Air Dryers
After-Filter V1
AC
Dry air to process
V2
A
Saturated Air from
Heating
AC
V3 Service 100 %
AC2
V1
Heating
V2 V3 Service
100 %
AC1
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Air from compressor passes through V2, gets cooled in AC1 and enters vessel B through V3. After cooling the desiccant in vessel B air passes through 4-way valves V1, V2 and V3 and enters vessel A, which is in service. The air on getting dry, enters After-cooler AC2 via V1, gets cooled to about 35-40oC. This air dried to an atmospheric dew point of 40oC is now ready for use. The cooling cycle is normally for about 1 hour duration.
Previous status
In an engineering unit, the compressed air to the plant was broadly classified into instrument air and the process air. The instrument air requirement was being met with using two 1100 cfm-reciprocating compressors. Usually, one of the two Compressors was operated continuously to cater the instrument 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 compressors capacity.
Benefits
This has resulted in zero purge loss and achievement of (-) 40 deg c atmospheric dew point as required.
Financial Analysis
The estimated annual savings achieved was Rs.1.23 million. The investment required amounted to Rs.2.00 million, which got paid back in 20 Months.
Replication Potential
HOC dryers can be installed in place of refrigeration/desiccant type dryers wherever the capacity of the reciprocating compressor is above 500 cfm. The most recent development has been the development of HOC dryers for screw compressors also. This is commercially available in India and this recent development gives HOC dryers a tremendous opportunity to be used as a retrofit for screw compressors also.
Air Compressors Proposal - 4: Replace Refrigeration / Desiccant Type Air Dryers with Heat of Compression Air Dryers, in Case of Reciprocatings Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -2.000 -2.000 3.083 49.89% 2.000 1.600 1.230 -0.133 1.363 1.217 0.400 1.230 0.298 0.932 0.743 0.000 1.230 0.441 0.561 0.000 1.230 0.441 0.501 0.000 1.230 0.441 0.448 0.000 1.230 0.441 0.789 0.400 0.000 1.230 0.441 0.357 0.000 1.230 0.441 0.319 0.000 1.230 0.441 0.284 0.000 1.230 0.441 0.254 1.230 1.230 1.230 1.230 1.230 1.230 1.230 1.230 1.230 1.230 1.23 2 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Install Blower for Water Removal from the Bottle Surface and Avoid Compressed Air Usage
Background
Compressed air has been extensively used in various industries for a variety of applications. With the increased awareness on cost of compressed air, various plants are taking up measures to avoid / substitute the use of compressed air. One of the options evaluated by several units is to substitute compressed air with blower air.
Present status
In the bottling section in one of the bottling units, after filling the beverage in the bottles, the date and batch numbers are printed on the bottles. Before the printing operating the water particles on the surface of the water bottles were removed by blowing the compressed air continuously. Each bottling section was fitted with a nozzle for blowing the compressed air on the bottle surface. The compressed air was supplied at an operating pressure of 1 kg/cm2. This was achieved by throttling a control valve at the inlet of the nozzle and reducing compressed air supply at 5.0 kg/cm2 from the main header. The quantity of compressed air supply in each line was estimated as 20 cfm.
Hence, there was a good potential to save energy by replacing the compressed air with blower air.
Recommendation
The plant team had installed a blower of capacity 25 cfm and replaced compressed air with blower air for removing the water particles from the surface of the beverage bottles. Benefits The annual energy savings realized was Rs.0.35 Lakhs. This required an investment of Rs. 0.40 Lakhs for installing a positive displacement blower in one line, which paid back in 14 Months.
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
Air Compressors Proposal - 5: Install Blower for Water Removal from the Bottle Surface and Avoid Compressed Air Usage Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.400 -0.400 0.994 69.30% 0.400 0.320 0.350 0.011 0.339 0.303 0.080 0.350 0.097 0.202 0.000 0.350 0.126 0.160 0.000 0.350 0.126 0.143 0.000 0.350 0.126 0.127 0.000 0.350 0.126 0.114 0.000 0.350 0.126 0.102 0.000 0.350 0.126 0.091 0.000 0.350 0.126 0.081 0.000 0.350 0.126 0.072 0.350 0.350 0.350 0.350 0.350 0.350 0.350 0.350 0.350 0.350 0.35 0.4 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Present Status
One of the engineering units in south India was evaluating various options for reducing compressed air consumption in the unit. There were about 25 cleaning points located all round the plant The plant team decided that for all cleaning operations the volume of the airflow was the criteria. High pressure air at 6.0 kg/cm2 was not required for cleaning application. Air at a pressure of 2.0 - 2.5 kg/cm2 can be used effectively for cleaning operations.
Air Compressors Proposal - 6: Install Transvector Nozzles for Cleaning Application Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.630 -0.630 2.140 87.29% 0.630 0.504 0.710 0.074 0.568 0.126 0.710 0.210 0.399 0.000 0.710 0.255 0.324 0.000 0.710 0.255 0.289 0.000 0.000 0.710 0.710 0.255 0.255 0.258 0.231 0.000 0.710 0.255 0.455 0.206 0.000 0.710 0.255 0.184 0.000 0.000 0.710 0.710 0.255 0.255 0.164 0.147 0.710 0.710 0.710 0.710 0.710 0.710 0.710 0.710 0.710 0.710 0.71 0.63 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Replace Compressed Air with Blower Air in the Raw Water Treatment Plant
Background
Compressed air has been extensively used in various industries for a variety of applications. With the increased awareness on cost of compressed air, various plants are taking up measures to avoid / substitute the use of compressed air. One of the options evaluated by several units is to substitute compressed air with blower air.
Present status
The possibility of reducing the compressed air usage was studied in detail by the plant team. In the water treatment plant, compressed air was used for aeration for about 8 hrs/day. The compressed for aeration air was drawn through a diameter line from the main header at a pressure of about 7.0 kg/cm2. The estimated volume or airflow for aeration was estimated to be 60 cfm. For effective aeration purposes, volume of airflow is the criteria, not the pressure.
Recommendation
The plant team replaced the compressed air with blower air for agitation in water treatment plant by installing a positive displacement blower. The specifications of the blower were: ! Capacity ! Pressure Benefits The annual energy saving realized by this substitution of compressed air was Rs 0.05 Million. This called for an investment of Rs 0.035 Million for the positive displacement blower, which paid back in 9 Months. 80 cfm 0.5 kg/cm2
Annual Savings Rs. 0.05 millions Investment Rs. 0.035 millions Simple payback 9 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Centrifugal Pumps
Introduction
Pump is common equipment, used to increase the mechanical energy of a fluid and impart the fluid a motion through pipe, equipment or the ambient atmosphere. The energy increase may be used to increase the velocity, the pressure or the elevation of the fluid. Pumps find application in various types of industries, such as Paper, Sugar, Chemical, Fertilizers, Refineries and Steel etc. The public water works, thermal power stations, sewage treatment plants also find major application for pumps. The electrical energy consumption in the agricultural sector is predominantly for pumping (used for irrigation).
Cement Plant Commercial buildings & hotels Public water works Others Total
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Install Variable Frequency Drive for Oil Pump in Hydraulic Power Packs and Reduce Idle Operation
Background
In engineering Industry, hydraulic power packs are used for several applications like moulding machines, 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 the operating time. After the holding operation only the required operating pressure has to be maintained. During the rest of operating time the excess quantity of oil pumped by the hydraulic system is recirculated back to the tank. The recirculation takes place for about 70-80% of the operating time, through a three-way recirculation valve provided for this purpose. The % opening of the recirculation valve is governed by a continuous feed back signal, depending on the amount of oil required for the process. Recirculation results in excess power consumption in the hydraulic pump for pumping the excess quantity of oil.
Benefits
Installation of VFD for oil pumps in Hydraulic power pacs resulted in an annual saving of Rs. 0.3 million. This required an investment of Rs 0.35 million for variable frequency drives with feed back control, which got paid back in 15 Months.
Replication potential
The project can be replicated in all the units where oil pumps are installed for pumping oil in the hydraulic power packs.
Centrifugal Pumps Proposal - 1: Install Variable Frequency Drive for Oil Pump in Hydraulic Power Packs and Reduce Idle Operation Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.350 -0.350 0.847 68.00% 0.350 0.280 0.300 0.007 0.293 0.261 0.070 0.300 0.083 0.173 0.000 0.300 0.108 0.137 0.000 0.300 0.108 0.122 0.000 0.300 0.108 0.109 0.000 0.300 0.108 0.097 0.000 0.300 0.108 0.087 0.000 0.300 0.108 0.078 0.000 0.300 0.108 0.069 0.000 0.300 0.108 0.062 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.300 0.3 0.35 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.192 0.192
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case Study 2
Install Variable Frequency Drives (VFDs) for Pumps Catering Varying Demand Instead of Operating with Recirculation /Valve Throttling
Background
Pumps are common equipment in any engineering industry. The load on a pump may either be constant or variable. The variation in the load may be due to various factors like process variations, changes in capacity or utilization etc. Conventionally, the output of the pump is adjusted according to the process requirements using 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 (like pump) to exactly match the process requirement.
Previous status
The heating requirements of the electroplating section in an automobile unit were being met by oil-fired thermic fluid heating systems. In the section, thermic fluid is supplied through heating coils to multiple numbers of tanks (10-12 tanks) the requirement and hence the flow rate of the thermic fluid varied with the temperature and the 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 set temperature 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, irrespective of the number of users in operation.
Implementation Methodology
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 the input to the VFD. The VFD varies the speed of the (RPM) pump so that only that quantity of the fluid demanded by the process is pumped. Installation of VFDs for the thermic fluid pumps was done during the regular operation of the plant itself. The recirculation valve was closed completely. The plant team did not face any problems during the implementation of the project.
Benefits
The implementation of this project resulted in saving of energy consumption of the pump and also better control of the system.
Financial Analysis
The installation of VFD for the pump resulted in an annual saving Rs.0.20 Million. The investment of Rs 0.20 Million was paid back in 12 months.
Replication potential
Installation of variable speed drives for pumps can be replicated in all applications where a pump is supplying to variable demand, which is the normal case in many engineering industries.
Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation
0.2 0.2 0 1 0.200 0.200 0.160 0.200 0.014 -0.200 0.587 78.30% 0.166
-0.200 0.186 0.143 0.128 0.128 0.128 0.128 0.128 0.128 0.128 0.128
1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Previous Status
In a chemical unit, a refrigeration unit of capacity 125 TR was in operation for chilled water requirement in the plant. The condenser cooling system for the refrigeration unit was studied in detail. The observations made during the detailed energy audit were as follows: ! Two centrifugal pumps of following specifications were in operation for the cooling water supply to the condenser of the refrigeration unit. " Capacity " Head 125 TR 30 m
Two pumps were installed with variable frequency drive and operated at a reduced frequency of 42.5 Hz. ! During the study, it was observed that cooling water flow takes place through the idle condenser also. Cooling water flow through the idle condenser was not necessary. This led to excess power consumption in the cooling water pumps for pumping the excess cooling water. ! The control valve provided at the outlet of the condenser was throttled. This was done to maintain a pressure of 1 kg/cm2 at the outlet of the condenser, which in turn given a feed back to the pressure based interlock to the compressor. The valve control leads to pressure loss across the control valve and hence energy loss.
Benefits
The annual energy saving achieved by implementing this proposal was Rs 0.093 millions. This did not require any investment.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Avoid Hot Well Pump Operation in Chilled Water System by Connecting Return Header Directly to Chiller
Background
The auxiliaries in the chilling system contribute significantly to the overall power consumption of the unit. The auxiliaries include chilled water pumps, AHU fans and condenser water pumps. The pumping system offers substantial potential for energy saving.
Previous status
The chilled water system in a pharmaceutical unit, comprising of the chiller compressor, hot well & cold well pumps was studied for possible energy savings. The observations made on the system were as follows: " The design specifications of the pumps were:
! The hot well pump was used to pump the hot return water from the hot well though the chiller to the cold well. While, the cold well pump was used to pump chilled water from the cold well to the process users. ! The cold well pump was being operated with valve throttling (60% open). This indicated the excess capacity/ head available in the pump. ! The chilled water header was maintained at a pressure of 3.6 kg/cm2. The pump delivery pressure (before delivery valve) was 4.4 kg/cm 2. This implies that pressure drop across the delivery valve was 18%. ! Apart from this, the pump was also being operated with recirculation control. A part of the chilled water from the cold well pump discharge is sent back to the hot well, by-passing the process users.
! The pressure in the return chilled water header was about 1.7 - 2.2 kg/cm2, depending on the number of users in operation. This pressure was dropped across a valve on the return header, which is connected to the hot well. ! The pressure required at the inlet to the chiller is about 1.8 2.0 kg/cm2. The pressure at the outlet of the chiller was 0.7 kg/cm2, indicating that the pressure drop across chiller is about 1.0 1.3 kg/cm2.
Benefits
The annual energy saving achieved by this proposal was Rs. 0.535 millions. This required an investment (for return line modification & bypass line) of Rs. 0.15 millions, which had an attractive simple payback period of 4 months. Cost benefit analysis Annual Savings Rs. 0.535 millions Investment Rs. 0.15 millions
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Centrifugal Pumps Proposal - 4: Avoid Hot Well Pump Operation in Chilled Water System by Connecting Return Header Directly to Chiller Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.150 0.120 0.535 0.149 -0.150 1.835 250.69% 0.345 0.030 0.535 0.181 0.282 0.000 0.535 0.192 0.244 0.000 0.535 0.192 0.218 0.000 0.535 0.192 0.195 0.000 0.535 0.192 0.174 0.000 0.535 0.192 0.155 0.000 0.535 0.192 0.139 0.000 0.535 0.192 0.124 0.000 0.535 0.192 0.110 0.535 0.535 0.535 0.535 0.535 0.535 0.535 0.535 0.535 0.535 0.535 0.15 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.150 0.386 0.354 0.343 0.343 0.343 0.343 0.343 0.343 0.343 0.343
Case study 5
Install Variable Frequency Drive (VFD) for the Chilled Water Supply Pumps
Background
The auxiliaries in the chilling system contribute significantly to the overall power consumption of the unit. The auxiliaries include chilled water pumps, AHU fans and condenser water pumps. The pumping system offers substantial potential for energy saving
Previous status
Chilled water system is one of the major electrical energy consumers in this chemical unit. There were 4 nos. of (normally 2 in operation, 2 as standby) Screw type chiller compressors of 725 TR, 600 kW rating with NH3 as the refrigerant for chilled water generation. The operation of the chilled water supply pump was studied for possible energy savings. The observations on the system were as follows: There were 3 chilled water supply pumps (1 in operation, 2 as standby) for supply of chilled water to the different users in the plant. The design specifications of the pump were: ! Capacity ! Head ! Motor Rating 600 m3/h 50 m WC 110 kW (77.3 kW)
The pump was operated with discharge valve throttling. The required header pressure to ensure chilled water flow to all the users was about 3.6 kg/cm2 (or 36 m WC). This confirmed that the pump has excess design head, which is controlled using the delivery valve. The measured pressure drop across the delivery valve was about 18% of the total head developed by the pump. Moreover, the pump is also operating with recirculation control. The chilled water demands of the process were varying in nature - not all the users require chilled water at the same time.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
The plant team installed a variable frequency drive (VFD) for the chilled water supply pump and operated at a lower RPM. The pump was operated with a closed loop pressure sensor control. After installation of VFD, valve throttling was completely avoided.
Benefits
The annual energy saving achieved by implementing this proposal was Rs. 6.77 Lakhs. This required an investment (for VFD and controls) of Rs 12.00 Lakhs, which had a simple payback period of 21 months.
-0.120 0.469 0.443 0.434 0.434 0.434 0.434 0.434 0.434 0.434 0.434
Utilise the Spare Condensers in Chilled Water and Chilled Brine System
Previous status
The refrigeration system was one of the major electrical energy consumers in the entire plant. The plant had a chilled water system operating at about +7C and a chilled brine system operating at about 10C. The plant had a total connected chilled water load of 2900 TR, comprising of 4 systems of 725 TR each. Similarly, the total chilled brine load in the plant was about 144 TR, comprising of 2 systems of 72 TR each. For day-to-day operations, only 2 systems of 725 TR capacities each of chilled water system and 1 system of 72 TR capacity-chilled brine was in operation. This implied that chilled water & chilled brine systems have 100% back-up. Each chilled water system had two sets of condensers, operating in parallel. The present cooling water flow through each of the condensers was 325 m3/h. The pressure drop across condenser on the cooling water side was about 3.0 kg/cm2, which was very high. Similarly, the pressure of NH3 at the inlet to condensers was about 15.0 kg/cm2. This corresponds to a temperature of 75 80C, which was the superheat temperature. Hence, additional power was consumed for cooling NH3 from the superheat temperature of 75C to 40C, which was the saturation temperature of NH3 at 15.0 kg/cm2. The present LMTD of heat transfer, for cooling water T of 6C (inlet at 30C and outlet at 36C) was 6.54C. There was a good potential to utilise the spare condensers of the stand-by systems for increasing the area available for cooling and also achieve energy savings.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
! The outlet from the individual condensers sets should also be connected to a loop header. This loop header should also be provided with isolation valves, such that, the outlet from any of the condenser sets can be taken to the individual receivers.
Benefits
The annual energy saving achieved by interconnecting the spare condensers was Rs. 1.48 millions. This required an investment (for proposed modifications) of Rs. 0.8 millions and with an attractive simple payback period of 7 Months.
Annual Savings Rs. 1.48 millions Investment Rs. 0.8 millions Simple payback 7 months
-0.800 1.179 1.006 0.949 0.949 0.949 0.949 0.949 0.949 0.949 0.949
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Centrifugal Fans
Introduction
Fans and Blowers are commonly used equipment in almost all the industries, such as cement, paper, sugar, power plants, etc. The power consumed by the fans varies between 5% to 30% of the total power, depending on the type of industry and application. With the tremendous growth potential predicted for the Indian Industries in the future, the utilization of the fans and blowers will be on the rise resulting in increased energy consumption by the fans. With this growth, increasing competitiveness and the increasing gap between demand and supply of energy, there is an imperative need to operate equipments in an energy efficient manner. The fans and blowers being major energy consuming equipment and present in almost all the industries, good benefits can be achieved by operating them in an energy efficient manner. This also contributes to the national interest. Definition The definition of fans, blowers and compressors has been defined in the following manner as per ASME. The specific pressure, i.e, the ratio of the discharge pressure over the suction pressure is used for defining the fans, blowers and compressors as highlighted below :
Case study No. 1 Replace the Low Efficiency Exhaust Fans with New Fans of Higher Efficiency
Background A fan is typically a mechanical device that causes a movement of air, vapour & other gases in 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 typical application where the volume of air to be handled becomes the only criterion for the selection of fan. Axial fans are ideally suited for such applications involving a lower head and higher volume of air to be handled. Their efficiency is also much better compared to centrifugal fans.
Previous status
In an engineering unit, manufacturing end rings for rotating equipment, the exhaust fan in the plating section was utilized to remove the fumes generated during the plating operation. A centrifugal 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, consuming 17.8 kW. The corresponding efficiency was only 39%.
Annual Savings Rs. 0.18 millions Investment Rs. 0.1 millions Simple payback 7 months
Centrifugal Fans Replace the Low Efficiency Exhaust Fans with New Fans of Higher Efficiency Furnaces Savings/Year (Rs Million) Discount Rate (i) 0.18 Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation -0.100 -0.100 0.584 133.57% 0.100 0.080 0.180 0.036 0.129 0.020 0.180 0.057 0.098 0.000 0.180 0.065 0.082 0.000 0.180 0.065 0.073 0.180 0.180 0.180 0.180 0.1 0 1 2 3 4
1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV
Install VFDs for Hot Air Circu lation Fans in Preheating Furnaces
Background
Heat treatment is the process of altering the properties of a metal by subjecting it to a sequence of temperature changes. Hence the time of retention at specific temperature and rate of cooling 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 common process in all the engineering industries. The major equipment used in heat treatment of any metal or alloy is the furnace. Fans are used for forceful circulation of air to aid the heat transfer process. Fans ensure uniform heat transfer which result in faster heating. The operation of the fans can be aligned with the operating cycle of the furnace, to optimize energy savings. VFDs find applications in optimizing the speed of the circulation air fans based on the temperature cycle.
Previous status
In an engineering unit, Preheating furnaces were used for heat treatment. The typical loading of the furnace was in the range of 42 45 tons/ batch/ preheating furnace (max capacity 50 T). The process is described below: Each preheating furnace is divided into six zones, with each zone having a heater bank. The heater banks are arranged in a vertical fashion on top of the furnace. The rating of the heaters in 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 furnace is about 620 deg C. Each zone is also provided with circulating air fans for forced heat circulation. The desired metal temperature for hot rolling is about 530C (minimum). After accounting for the ingot rolling time and temperature loss from preheating furnace outlet to the hot rolling mill of about 40 60C (between top ingot & bottom ingot), the metal is heated upto a temperature of 590- 600C. The air temperature required to maintain this metal temperature is 620C. Once the furnace charging is complete and the batch time starts, the heaters and fans are switched ON automatically. It takes a bout 2 3 hours for the air temperature to be raised from a starting temperature of 360 380C to 620C. The total time taken for heating the metal from the ambient temperature to 580-590C is about 7 hrs. Once the set temperature is achieved, the heaters get switched OFF automatically. The ingots are then allowed to soak for the remaining 5 hours. The heaters operate on thermostat controls in ON-OFF mode during this period, primarily to take care of the radiation and hot air losses.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
The average power consumption during the heating phase of then batch time is about 1000 kWh, 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 by conduction/ 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 between metal and air. The detailed analysis of time vs. temperature profile of the 6-zones revealed that, at the end of the heating cycle and during the soaking phase, the air velocity required to maintain the heat transfer rate between air and metal is lower, due to lower temperature differential.
Benefits
The annual savings achieved due to implementation of the project, amounted to Rs.0.36 million. This required an investment of Rs.0.40 million, which had a simple payback period of 14 months. Replication potential The project finds tremendous replication potential in all furnaces where hot air circulation fans are in use for heat treatment. By conservative estimates, the project can be implemented at least in 150 engineering units across the country
Centrifugal Fans Proposal-2: Install VFDs for Hot Air Circulation Fans in Preheating Furnaces Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.400 -0.400 1.030 71.11% 0.400 0.320 0.080 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.360 0.360 0.360 0.360 0.360 0.360 0.360 0.360 0.360 0.014 0.100 0.129 0.129 0.129 0.129 0.129 0.129 0.129 0.309 0.207 0.164 0.147 0.131 0.117 0.104 0.093 0.083 0.000 0.360 0.129 0.074 0.360 0.360 0.360 0.360 0.360 0.360 0.360 0.360 0.360 0.360 0.36 0.4 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.346 0.260 0.231 0.231 0.231 0.231 0.231 0.231 0.231 0.231
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Install Variable Frequency Drive for Circulating Air Fans in Vertical Drier
Background
The circulating air fan is utilized to circulate hot air from the hot air generator to the vertical drier. A fraction of air is vented out. Fresh air is added into the system by a fan as well as by air infiltration due to suction of circulating air fan. The fresh air addition happens depending on the temperature inside the drier. If the temperature goes up, the fresh air addition increases. Moreover, the circulation air rate is constant though the 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 status
Two Vertical driers were used for different kilns in the plant. Constant temperature in the driers was 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 the temperature.
Financial Analysis
Installation of Variable Frequency Drive for circulating air fans in Vertical Driers resulted in an annual energy saving of Rs 0.695 Million. This required an investment of Rs 0.65 Million and had a simple payback period of 12 months.
Benefits
(a) (b) Reduction in power consumption of the circulating air fan by at least 25% Reduction in thermal energy consumption
Centrifugal Fans Proposal-3:Install Variable Frequency Drive for Circulating Air Fans in Vertical Drier Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.650 -0.650 2.072 83.22% 0.650 0.520 0.695 0.063 0.564 0.130 0.695 0.203 0.392 0.000 0.695 0.249 0.317 0.000 0.695 0.249 0.283 0.000 0.695 0.249 0.253 0.000 0.695 0.249 0.226 0.000 0.695 0.249 0.202 0.000 0.695 0.249 0.180 0.000 0.695 0.249 0.161 0.000 0.695 0.249 0.446 0.143 0.695 0.695 0.695 0.695 0.695 0.695 0.695 0.695 0.695 0.695 0.695 0.65 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Install a Variable Frequency Drive (VFD) for the Hot Air Generator (Coal Fired) Fan of Heater 2
Background
Tea industry utilizes significant amount of thermal energy for its drying applications. These drying requirements are met by utilizing a hot air generator. These hot air generators are oil / solid fuel fired systems and contributes significantly to the overall energy consumption of the plant. Several energy saving measures have been implemented in the hot air generators in various tea industries. One of the areas focused is on the fans installed in the hot air generators.
Present Status
In one of the tea plants, the coal-fired hot air generator supply fan was studied for possible energy savings. The hot air generator fans were damper controlled and open to the extent of 50% The pressure across the damper and at the fan delivery was measured. The pressure loss across the damper was found to be about 46%. The load on the fan is fluctuating in nature depending on temperature in the dryer.
Present Status
Damper control is an energy inefficient practice of capacity control as part of the energy fed to the fan is lost across the damper. Good potential for energy saving exists by avoiding damper control and to meet the varying requirement from the fan. This was achieved by installing a variable frequency drive (VFD) to the hot air generator fan. There were other spin-off benefits achieved by installation of a Variable Frequency Drive: ! Air temperature was precisely controlled and monitored ! There was no need to frequently stop the dryer due to high / low temperatures.
Benefits
Installation of a Variable Frequency Drive for the hot air generator (coal fired) supply fan has resulted in an annual savings of Rs. 0.117 millions. This required an investment of Rs. 0.11 millions with an attractive payback period of 12 months.
Centrifugal Fans Proposal-4:Install a Variable Frequency Drive (VFD) for the Hot Air Generator (Coal Fired) Fan of Heater 2 Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.110 -0.110 0.348 82.82% 0.110 0.088 0.117 0.010 0.095 0.022 0.117 0.034 0.066 0.000 0.117 0.042 0.053 0.000 0.117 0.042 0.048 0.000 0.117 0.042 0.043 0.000 0.117 0.042 0.038 0.000 0.117 0.042 0.034 0.000 0.117 0.042 0.030 0.000 0.117 0.042 0.027 0.000 0.117 0.042 0.024 0.117 0.117 0.117 0.117 0.117 0.117 0.117 0.117 0.117 0.117 0.117 0.11 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.107 0.083 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Install Variable Frequency Drive for Boiler Forced Draft (FD) Fan
Background
FD & ID fans contribute to a significant extent in the overall auxiliary power consumption of the boiler. Several steps have been taken in the FD & ID fans in the boiler to reduce the auxiliary power consumption. Matching the requirement with the design offers excellent potential in this regard.
Present status
In one of the small chemical unit, the following were the observations regarding the FD fan of the boiler: The design flow rate of the FD fan was 6300 m3/h while the actual operating requirement was measured to be about 1816 m3/h. The design capacity of the fan was much higher than the requirement. To match the operating parameters with the delivery of the fan, the suction of the fan is damper controlled.
Benefits
Installing VFD to the boiler FD fan resulted in an annual energy saving of Rs. 0.75 months. This called for an investment of Rs. 0.75 months and had a simple payback period of 12 months.
Centrifugal Fans Proposal-5:Install Variable Frequency Drive for Boiler Forced Draft (FD) Fan Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.075 -0.075 0.220 78.30% 0.075 0.060 0.075 0.005 0.062 0.015 0.075 0.022 0.043 0.000 0.075 0.027 0.034 0.000 0.075 0.027 0.031 0.000 0.075 0.027 0.027 0.000 0.075 0.027 0.024 0.000 0.075 0.027 0.022 0.000 0.075 0.027 0.019 0.000 0.075 0.027 0.017 0.000 0.075 0.027 0.048 0.015 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Present Status
In one of the engineering unit, the performance of the combustion air supply fan of the furnaces was studied in detail for possible energy saving. The observations made were as follows: A centrifugal fan of following specifications was in operation for both atomizing air and combustion air supply for the furnaces, ! Capacity ! Pressure 3000 cfm 28 WC
Static pressure measurements were carried out in the centrifugal fans. The pressure at the outlet of the centrifugal fan was measured as 500 mmWC. For atomizing the fuel, air pressure requirement (500 mm WC) is much higher than the combustion air requirement (100 mm WC). The quantity of atomizing air requirement is only 15% of the total quantity of air requirement. In the existing system a tapping from the main header at a pressure of 500 mmWC was taken and given for the atomizing air requirement. The damper provided at the inlet of the burner for combustion air supply was heavily throttled.
After installing correct size fans the damper opening in the combustion air supply line was increased.
Benefits
The annual energy saving achieved by segregating combustion and atomizing air was Rs 0.157 millions. This required an investment of Rs 0.2 millions for new fans, which paid back in 16 Months.
Annual Savings Rs. 0.157 millions Investment Rs. 0.2 millions Simple payback 16 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Present status
In one of the pharmaceutical units, the specifications of AHU fans operating in syrup manufacturing area are given below. AHU Fan 1 5 8 Design Pressure (mm H2O) 87 87 87 Rated Capacity CFM 10,500 21,000 9,500 Developed pressure (mm H2O) 66 35 48
The operating pressure was much lower than the design pressure rise of these AHU fans. This has resulted in inefficient operation of the fans and thereby, higher power consumption.
Benefits
The annual energy saving achieved was Rs. 0.046 millions. This required an investment of Rs. 0.03 millions for changing the pulleys, which paid back in 8 months.
Centrifugal Fans Proposal-7: Reduce the Speed of AHU Fan in Syrup Manufacturing Area Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.030 -0.030 0.146 115.44% 0.030 0.024 0.046 0.008 0.034 0.006 0.046 0.014 0.025 0.000 0.046 0.017 0.021 0.000 0.046 0.017 0.019 0.000 0.046 0.017 0.017 0.000 0.046 0.017 0.015 0.000 0.046 0.017 0.013 0.000 0.046 0.017 0.012 0.000 0.046 0.017 0.011 0.000 0.046 0.017 0.009 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.046 0.03 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.038 0.032 0.029 0.029 0.029 0.029 0.029 0.029 0.029 0.029
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Replace the Low Efficiency Exhaust Fans with New Fans of Higher Efficiency
Background A fan is typically a mechanical device that causes a movement of air, vapour & other gases in 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 typical application where the volume of air to be handled becomes the only criterion for the selection of fan. Axial fans are ideally suited for such applications involving a lower head and higher volume of air to be handled. Their efficiency is also much better compared to centrifugal fans.
Previous status
In an engineering unit, manufacturing end rings for rotating equipment, the exhaust fan in the plating section was utilized to remove the fumes generated during the plating operation. A centrifugal 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, consuming 17.8 kW. The corresponding efficiency was only 39%.
Financial Analysis
Implementation of this project resulted in an annual savings of Rs. 0.18 millions. The investment required for the fan was 0.1 million. The simple pay back period for the project was 7 months.
Replication potential
There is a tremendous potential to replace centrifugal fans with higher efficiency axial fans in applications where the required head is lower than 75 mm of WC.
Centrifugal Fans Proposal-8: Replace the Low Efficiency Exhaust Fans with New Fans of Higher Efficiency Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.100 -0.100 0.584 133.57% 0.100 0.080 0.180 0.036 0.129 0.020 0.180 0.057 0.098 0.000 0.180 0.065 0.082 0.000 0.180 0.065 0.073 0.000 0.180 0.065 0.065 0.000 0.180 0.065 0.058 0.000 0.180 0.065 0.052 0.000 0.180 0.065 0.047 0.000 0.180 0.065 0.042 0.000 0.180 0.065 0.037 0.180 0.180 0.180 0.180 0.180 0.180 0.180 0.180 0.180 0.180 0.18 0.1 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.144 0.123 0.115 0.115 0.115 0.115 0.115 0.115 0.115 0.115
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Boilers Introduction
Boilers are large mechanical equipment. In all boilers two primary processes are involved, viz. Combustion & release of heat from fuel (except waste heat boiler) and heat transfer and generation of steam from feed water. Most of the boiler components are designed with these two primary objectives in mind. Boilers vary widely in size and shape. The smallest industrial boiler could be of the size of a small living room while very large utility boilers could be taller that 100 maters and bigger than a tennis court in area. Boilers are classified under many different groupings. The most important classification relates to end use and hence are classified as industrial and utility boilers. Under each of the above groupings, boilers can be further classified on the basis of the heat source (coal, oil, gas, biomass or waste heat) and can be generating steam temperatures ranging from saturation level to super heated steam with 600o C temperature. In all the cases, design involves sizing of the boiler to achieve the most efficient method of extracting and transferring this heat to water and generate steam. There are special boilers used for heating organic compounds like thermic fluids and the guiding principles remain the same in their cases also. The ultimate purpose of the boiler is to take out the energy from fuel through the medium of steam. The heat that can be carried through by steam would depend on the steaming rate, pressure and temperature of steam. It is therefore necessary that these parameters are chosen with adequate care to effect energy economy. In most of the industrial applications the steam quantity is directly dictated by the mass flow requirements of the end use. However, the pressure and temperature can be so chosen, that the steam can be put to use for power generation through a steam turbine before being drawn for the process use. The choice of pressure and temperature would then depend on the final required steam pressure. In order to allow flexibility of operations, the design quantity of steam generation can be kept 10% to 15% higher than the maximum anticipated steam requirements. It is also necessary, not to prescribe high boiler outlet pressure as it may end up with large scale pressure reduction in process steam requirements.
Steam System
Steam has been a popular mode of conveying energy, since the industrial revolution. The following characteristics of steam make it so popular and useful to the industry: ! ! ! ! Highest specific heat and latent heat Highest heat transfer coefficient Easy to control and distribute Cheap and inert
Steam is used for generating power and also used in process industries, such as, sugar, paper, fertilizer, refineries, petrochemicals, chemical, food, synthetic fibre and textiles. In the process industries, the high pressure steam produced in the boiler is first expanded in a steam turbine for generating power. The extraction or bleed from the turbine, which are generally at low pressure, are used for the process.
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
This method of producing power, by the steam generated for process in the boiler, is called cogeneration. Steam generated in a boiler, is distributed through a network for various process application, after conditioning the steam to suit process requirement. Efficient transmission and utilization of steam is essential, for maintaining the required steam parameters at every utility point, in the power and process industries. This can be achieved by keeping the transmission losses & heat losses to a minimum value and recovery of heat, wherever possible.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Present status
In one of the automotive ancillary unit, the flue gas exit temperature from a boiler of capacity 1.2 TPH was about 220-230oC. The review of the boiler internals indicated that the boiler does not have any economiser for recovering heat from the flue gas. The waste heat available in the flue gas was not being utilized.
Benefits
Implementing this proposal resulted in an annual energy saving of Rs. 0.067millions. This called for an investment of Rs.0.1 million and had a simple payback period of 18 months.
Boilers & Steam Systems Proposal-1: Utilize Existing Economiser for Feed Water Preheating Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.100 -0.100 0.174 54.11% 0.100 0.080 0.067 -0.005 0.064 0.020 0.067 0.017 0.040 0.000 0.067 0.024 0.031 0.000 0.067 0.024 0.027 0.000 0.067 0.024 0.024 0.000 0.067 0.024 0.022 0.000 0.067 0.024 0.019 0.000 0.067 0.024 0.017 0.000 0.067 0.024 0.015 0.000 0.067 0.024 0.043 0.014 0.067 0.067 0.067 0.067 0.067 0.067 0.067 0.067 0.067 0.067 0.067 0.1 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Present status
An automotive rubber component manufacturing facility had 2 boilers rated for a total capacity of 1.0 TPH. Boiler blow down was carried out by the plant team twice a shift, once during the lunch time and the other during the shift change time, 6 times a day in total. The plant team tried to estimate the blow down quantity, the estimated value being 60 lts / blow-down. The blow down was being carried out without any measurement. The TDS requirement mentioned by the OEM was 3000 ppm. However, when the plant team procured a TDS meter and measured the TDS content in the blow down water, the present TDS level in the boiler blow-down water was 750 ppm only.
Benefits
Optimising the frequency of boiler blow-down resulted in an annual energy saving of Rs. 0.032 millions. This called for any investment of Rs. 0.03 millions for TDS measurement and has a simple payback period of 12 months.
Boilers & Steam Systems Proposal-2: Optimize the Frequency of Boiler Blow Down Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.030 -0.030 0.095 83.04% 0.030 0.024 0.032 0.003 0.026 0.006 0.032 0.009 0.018 0.000 0.032 0.011 0.015 0.000 0.032 0.011 0.013 0.000 0.032 0.011 0.012 0.000 0.032 0.011 0.010 0.000 0.032 0.011 0.009 0.000 0.032 0.011 0.008 0.000 0.032 0.011 0.007 0.000 0.032 0.011 0.021 0.007 0.032 0.032 0.032 0.032 0.032 0.032 0.032 0.032 0.032 0.032 0.032 0.03 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Present status
An automotive rubber component manufacturing facility had 2 boilers rated for a total capacity of 1.0 TPH. The combustion analysis was carried out to analyse the oxygen % in flue gas. The combustion analysis of the boiler revealed the following: ! Oxygen ! Carbon Monoxide ! Flue gas temperature = < = 17.2 18.0% 250 ppm 220C
Benefits
Optimizing the excess air in flue gas has resulted in an annual energy saving is Rs.0.1 million. This called for an investment (for combustion analyser) of Rs. 0.05 million, which had a simple payback period of 6 months.
Annual Savings Rs. 0.1 million Investment Rs. 0.05 millions Simple payback 6 months
0.078 0.068 0.064 0.064 0.064 0.064 0.064 0.064 0.064 0.064
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Replace Electrical Heating with Steam Heating in Furnace Oil Day Tank
Background
All the smaller capacity industrial boilers are furnace oil fired systems. The furnace oil requires heating and tracing to maintain viscosity to ensure fluidity. The normal practice is to install electrical heating systems in furnace oil main storage tank and day tank. Various plants have now converted the electrical heating system to steam heating system in day tank too. This step is carried out considering the cost of electrical and thermal heating systems.
Present status
In one of the soft drink bottling units, the following observations were made regarding the furnace oil heating system: Furnace oil was used as fuel in the boiler. The furnace oil in the day tank was maintained at a temperature of 50-550C. Electrical heaters were used for the heating applications in the day tank. The cost of electrical heating and thermal heating was analysed based on the cost of fuel. The costs of electrical heating and thermal heating are given below. ! Cost of electrical heating Rs 4302 / MM kCal Rs 1279 / MM kCal
Benefits
The annual energy saving achieved by installing thermal heating system in day tank was Rs. 0.039 millions. This required an investment of Rs. 0.05 millions for installing steam coils with temperature control, which paid back in 15 Months.
Annual Savings Rs. 0.4 millions Investment Rs. 0.05 millions Simple payback 15 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Install Variable Frequency Drive for Boiler Forced Draft (FD) Fan
Background
FD & ID fans contribute to a significant extent in the overall auxiliary power consumption of the boiler. Several steps have been taken in the FD & ID fans in the boiler to reduce the auxiliary power consumption. Matching the requirement with the design offers excellent potential in this regard.
Present status
In one of the small chemical unit, the following were the observations regarding the FD fan of the boiler: The design flow rate of the FD fan was 6300 m3/h while the actual operating requirement was measured to be about 1816 m3/h. The design capacity of the fan was much higher than the requirement. To match the operating parameters with the delivery of the fan, the suction of the fan is damper controlled.
Benefits
Installing VFD to the boiler FD fan resulted in an annual energy saving of Rs. 0.075 millions. This called for an investment of Rs. 0.075 millions and had a simple payback period of 12 months.
Boilers & Steam Systems Proposal-5: Install Variable Frequency Drive for Boiler Forced Draft (FD) Fan Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.075 -0.075 0.220 78.30% 0.075 0.060 0.075 0.005 0.062 0.015 0.075 0.022 0.043 0.000 0.075 0.027 0.034 0.000 0.075 0.027 0.031 0.000 0.075 0.027 0.027 0.000 0.075 0.027 0.024 0.000 0.075 0.027 0.022 0.000 0.075 0.027 0.019 0.000 0.075 0.027 0.017 0.000 0.075 0.027 0.048 0.015 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0.075 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Present status
The plant had one Bagasse fired boiler rated for 60 TPH, 61 ata, 480 deg C. Two ID fans were installed which were rated for 1,20,000 m3/h at 650 mm WC. It is observed that both the fans are being operated with the inlet dampers open at 20 to 30 %. Pressure drops across the dampers and pressure rise of the fans were measured and was observed to be more than 50 % of the total pressure rise in the fans. This was resulting in a significant energy loss in the system.
Benefits
Implementation of this proposal resulted in an annual energy savings of Rs.2.735 millions. This required an investment of Rs.0.20 millions, which paid back in 9 months time.
Boilers & Steam Systems Proposal-6: Install Variable Speed Drives (VSD) for ID Fans Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.200 -0.200 9.754 901.79% 0.200 0.160 2.730 0.922 1.614 0.040 2.730 0.965 1.407 0.000 2.730 0.979 1.246 0.000 2.730 0.979 1.113 0.000 2.730 0.979 0.993 0.000 2.730 0.979 0.887 0.000 2.730 0.979 0.792 0.000 2.730 0.979 0.707 0.000 2.730 0.979 0.631 0.000 2.730 0.979 1.751 0.564 2.730 2.730 2.730 2.730 2.730 2.730 2.730 2.730 2.730 2.730 2.73 0.2 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Present status
In one of the bulk drug manufacturing unit, the possibility of recovering the heat from the boiler blow down was explored. The observations made regarding the boiler blow down are given below. In this pharmaceutical unit, an oil-fired boiler was in operation for steam generation. The average steam generation was about 2-2.5 tons/h. The steam to fuel ratio maintained was about 16: 1. In the boiler, intermittent blow down was practiced. The blow down was automatically done based on the TDS level. The TDS level in the boiler drum was maintained at 5000 ppm. The quantity of blow down is estimated as 8% of the total quantity of steam generated i.e about 5 tons/day. Normally the blow down from the Boiler would be about 1-2% for the feed water with TDS level of less than 100 ppm. The blow down quantity here was high due to higher TDS content in the feed water (350 to 400 ppm). These higher blows down was leading to to higher heat loss and hence lower operating efficiency of boiler.
Benefits
The annual energy saving achieved by installing boiler blow down heat recovery system was Rs 0.67 millions. This required an investment of Rs 0.8 millions for installing the heat recovery system. This had a simple payback period of 14 Months.
Annual Savings Rs. 0.67 millions Investment Rs. 0.80 millions Simple payback 14 months
0.659 0.487 0.430 0.430 0.430 0.430 0.430 0.430 0.430 0.430
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Introduction With the advent of technology and development of science, more and more buildings are coming up requiring specialized services for comfortable human habitation. One of the most important dimensions which is now no more a luxury but has become almost a necessity is air-conditioning. Almost all occupied areas where people work and where equipment is housed are either properly ventilated or air-conditioned depending upon the need. The equipment such as refrigeration compressors, condensers, evaporators, condenser water pumps, chilled water pumps, cooling tower and general insulation practices are common for both refrigeration and air-conditioning systems. Vapour Absorption Chiller These chillers are ideally suited where waste heat or steam from turbines outlet (Cogeneration system) is available. Apart from conventional waste heat sources, the heat in the jacket water of DG sets can also be utilized in vapor absorption machines. For example, with jacket water of 6 MW DG set, approximately 225 TR at 8oC can be generated. This gives an idea of the potential for vapour absorption chiller. Hence, absorption chiller is preferred the following situations: ! Plants with Co-generation ! Waste heat source is available. ! High capacity DG sets where jacket water can be utilized for absorption chiller. ! Where the power cost is phenomenally high The disadvantage of vapor absorption chiller is that the condenser water flow requirement is 1.5 to 1.8 times when compared to vapour compression system for a given tonnage of refrigeration. The evaporation rate at cooling towers being high, more make up water is required at cooling tower. So, wherever, the water availability is problem, the selection of vapour absorption chillers becomes difficult.
Present Status
In a chemical unit, a refrigeration unit of capacity 125 TR was in operation for chilled water requirement in the plant. The condenser cooling system for the refrigeration unit was studied in detail. The observations made during the detailed energy audit were as follows: " Two centrifugal pumps of following specifications were in operation for the cooling water supply to the condenser of the refrigeration unit. ! Capacity ! Head 125 TR 30 m
Two pumps were installed with variable frequency drive and operated at a reduced frequency of 42.5 Hz. " During the study, it was observed that cooling water flow takes place through the idle condenser also. Cooling water flow through the idle condenser was not necessary. This led to excess power consumption in the cooling water pumps for pumping the excess cooling water. " The control valve provided at the outlet of the condenser was throttled. This was done to maintain a pressure of 1 kg/cm2 at the outlet of the condenser, which in turn given a feed back to the pressure based interlock to the compressor. The valve control leads to pressure loss across the control valve and hence energy loss.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Benefits The annual energy saving achieved by implementing this proposal was Rs 0.093 millions. This did not require any investment.
Present status
In one of the commercial buildings, the air conditioning system was studied in detail for possible energy saving. The review of the control system of the air conditioners indicated that the compressors were being operated with manual control. The compressors were put on or off depending on the room temperature and feedback from occupants. There was no automatic control system for the air conditioners. Sub-cooling has been observed in several areas during the day.
Benefits
The annual energy saving achieved by installing the control system was Rs. 0.114 millions. This called for an investment of Rs. 0.16 millions and had a simple payback period of 17 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Chillers & Auxiliaries Proposal-2: Improve Control Systems for Air Conditioning Compressors Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.160 -0.160 0.303 57.31% 0.160 0.128 0.114 -0.005 0.106 0.032 0.114 0.029 0.067 0.000 0.114 0.041 0.052 0.000 0.114 0.041 0.046 0.000 0.114 0.041 0.041 0.000 0.114 0.041 0.037 0.000 0.114 0.041 0.033 0.000 0.114 0.041 0.030 0.000 0.114 0.041 0.026 0.000 0.114 0.041 0.073 0.024 0.114 0.114 0.114 0.114 0.114 0.114 0.114 0.114 0.114 0.114 0.114 0.16 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Present status
There were about 15 window air conditioners running all day through in server rooms in one of the commercial banking building. All the air conditioners were operating with thermostat controllers. This was resulting in sub-cooling in many rooms.
Benefits
The annual savings achieved by installation of energy saver was Rs.0.083 millions. The investment required was Rs. 0.120 millions, which paid back in 18 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Chillers & Auxiliaries Proposal-3: Install Tics For Window Air conditioning Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.120 -0.120 0.218 55.75% 0.120 0.096 0.083 -0.005 0.078 0.024 0.083 0.021 0.049 0.000 0.083 0.030 0.038 0.000 0.083 0.030 0.034 0.000 0.083 0.030 0.030 0.000 0.083 0.030 0.027 0.000 0.083 0.030 0.024 0.000 0.083 0.030 0.021 0.000 0.083 0.030 0.019 0.000 0.083 0.030 0.053 0.017 0.083 0.083 0.083 0.083 0.083 0.083 0.083 0.083 0.083 0.083 0.083 0.12 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Case study 4
Avoid Hot Well Pump Operation in Chilled Water System by Connecting Return Header Directly to Chiller
Background
The auxiliaries in the chilling system contribute significantly to the overall power consumption of the unit. The auxiliaries include chilled water pumps, AHU fans and condenser water pumps. The pumping system offers substantial potential for energy saving.
Present status
The chilled water system in a pharmaceutical unit, comprising of the chiller compressor, hot well & cold well pumps was studied for possible energy savings. The observations made on the system were as follows: ! The design specifications of the pumps were:
" The hot well pump was used to pump the hot return water from the hot well though the chiller to the cold well. While, the cold well pump was used to pump chilled water from the cold well to the process users. " The cold well pump was being operated with valve throttling (60% open). This indicated the excess capacity/ head available in the pump. " The chilled water header was maintained at a pressure of 3.6 kg/cm2. The pump delivery pressure (before delivery valve) was 4.4 kg/cm 2. This implies that pressure drop across the delivery valve was 18%. " Apart from this, the pump was also being operated with recirculation control. A part of the chilled water from the cold well pump discharge is sent back to the hot well, by-passing the process users. " The pressure in the return chilled water header was about 1.7 - 2.2 kg/cm2, depending on the number of users in operation. This pressure was dropped across a valve on the return header, which is connected to the hot well.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
" The pressure required at the inlet to the chiller is about 1.8 2.0 kg/cm2. The pressure at the outlet of the chiller was 0.7 kg/cm2, indicating that the pressure drop across chiller is about 1.0 1.3 kg/cm2.
Benefits
The annual energy saving achieved by this proposal was Rs. 0.535 millions. This required an investment (for return line modification & bypass line) of Rs. 0.15 millions, which had an attractive simple payback period of 4 months.
Chillers & Auxiliaries Proposal-4: Avoid Hot Well Pump Operation in Chilled Water System by Connecting Return Header Directly to Chiller Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.150 -0.150 1.835 250.69% 0.150 0.120 0.535 0.149 0.345 0.030 0.535 0.181 0.282 0.000 0.535 0.192 0.244 0.000 0.535 0.192 0.218 0.000 0.535 0.192 0.195 0.000 0.535 0.192 0.174 0.000 0.535 0.192 0.155 0.000 0.535 0.192 0.139 0.000 0.535 0.192 0.124 0.000 0.535 0.192 0.343 0.110 0.535 0.535 0.535 0.535 0.535 0.535 0.535 0.535 0.535 0.535 0.535 0.15 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Install Variable Frequency Drive (VFD) for the Chilled Water Supply Pumps
Background
The auxiliaries in the chilling system contribute significantly to the overall power consumption of the unit. The auxiliaries include chilled water pumps, AHU fans and condenser water pumps. The pumping system offers substantial potential for energy saving
Present status
Chilled water system is one of the major electrical energy consumers in this chemical unit. There were 4 nos. of (normally 2 in operation, 2 as standby) Screw type chiller compressors of 725 TR, 600 kW rating with NH3 as the refrigerant for chilled water generation. The operation of the chilled water supply pump was studied for possible energy savings. The observations on the system were as follows: There were 3 chilled water supply pumps (1 in operation, 2 as standby) for supply of chilled water to the different users in the plant. The design specifications of the pump were: " Capacity " Head " Motor Rating 600 m3/h 50 m WC 110 kW (77.3 kW)
The pump was operated with discharge valve throttling. The required header pressure to ensure chilled water flow to all the users was about 3.6 kg/cm2 (or 36 m WC). This confirmed that the pump has excess design head, which is controlled using the delivery valve. The measured pressure drop across the delivery valve was about 18% of the total head developed by the pump. Moreover, the pump is also operating with recirculation control. The chilled water demands of the process were varying in nature - not all the users require chilled water at the same time.
The plant team installed a variable frequency drive (VFD) for the chilled water supply pump and operated at a lower RPM. The pump was operated with a closed loop pressure sensor control. After installation of VFD, valve throttling was completely avoided.
Benefits
The annual energy saving achieved by implementing this proposal was Rs. 0.677 millions. This required an investment (for VFD and controls) of Rs 1.2 millions, which had a simple payback period of 21 months.
Chillers & Auxiliaries Proposal-5: Install Variable Frequency Drive (VFD) for the Chilled Water Supply Pumps Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -1.200 -1.200 1.629 45.93% 1.200 0.960 0.677 -0.102 0.695 0.240 0.677 0.157 0.415 0.000 0.677 0.243 0.309 0.000 0.677 0.243 0.276 0.000 0.677 0.243 0.246 0.000 0.677 0.243 0.220 0.000 0.677 0.243 0.196 0.000 0.677 0.243 0.175 0.000 0.677 0.243 0.157 0.000 0.677 0.243 0.140 0.677 0.677 0.677 0.677 0.677 0.677 0.677 0.677 0.677 0.677 0.677 1.2 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.779 0.520 0.434 0.434 0.434 0.434 0.434 0.434 0.434 0.434
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Utilise the Spare Condensers in Chilled Water and Chilled Brine System
Present status
The refrigeration system was one of the major electrical energy consumers in the entire plant. The plant had a chilled water system operating at about +7C and a chilled brine system operating at about 10C. The plant had a total connected chilled water load of 2900 TR, comprising of 4 systems of 725 TR each. Similarly, the total chilled brine load in the plant was about 144 TR, comprising of 2 systems of 72 TR each. For day-to-day operations, only 2 systems of 725 TR capacities each of chilled water system and 1 system of 72 TR capacity-chilled brine was in operation. This implied that chilled water & chilled brine systems have 100% back-up. Each chilled water system had two sets of condensers, operating in parallel. The present cooling water flow through each of the condensers was 325 m3/h. The pressure drop across condenser on the cooling water side was about 3.0 kg/cm2, which was very high. Similarly, the pressure of NH3 at the inlet to condensers was about 15.0 kg/cm2. This corresponds to a temperature of 75 80C, which was the superheat temperature. Hence, additional power was consumed for cooling NH3 from the superheat temperature of 75C to 40C, which was the saturation temperature of NH3 at 15.0 kg/cm2. The present LMTD of heat transfer, for cooling water T of 6C (inlet at 30C and outlet at 36C) was 6.54C. There was a good potential to utilise the spare condensers of the stand-by systems for increasing the area available for cooling and also achieve energy savings.
" The outlet from the individual condensers sets should also be connected to a loop header. This loop header should also be provided with isolation valves, such that, the outlet from any of the condenser sets can be taken to the individual receivers.
Benefits
The annual energy saving achieved by interconnecting the spare condensers was Rs. 1.48 millions. This required an investment (for proposed modifications) of Rs. 0.8 millions and with an attractive simple payback period of 7 Months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Replace Shell & Tube Condensers with Evaporative Condensers in Refrigeration System
Background
One of the pharmaceutical units had water-cooled condensers for their chilled water and chilled brine systems. The cooling water required for this purpose was catered from the process cooling tower. The present trend in the industry is to replace the shell & tube type condensers with evaporative condensers. The evaporative condensers consume only about 20% of the total power consumption of a typical shell & tube condenser system. A schematic diagram of the system was shown below: Air Out
Refrigerant In
In the system, the refrigerant piping is taken out into a tube coil bundle, located within the evaporative condenser body. A small quantity of cooling water was sprayed over the coils, and an induced draft was created in the system, using a fan located at the top of the unit. This forced evaporative-cooling enhances the heat transfer rate. The other salient features of evaporative condensers as compared to shell & tube condensers are as below: " " " " " Improved water to air contact Increased water flow rate over the refrigerant coil Enhanced heat transfer resulting in lower condensing temperature Lower static head requirement of pump Lower pressure drop across tube coil bundle, leading to reduction in fan power consumption " Compact modular design " Easy maintenance
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
All the above characteristics lead to lower pump and fan power consumption typically only 20% of that of shell & tube condensers.
Benefits
The annual energy savings achieved by installing evaporative condensers was Rs.3.10 millions. This required an investment (for evaporative condensers) of Rs.7.50 millions and paid back in 29 months.
4.140 2.526 1.988 1.988 1.988 1.988 1.988 1.988 1.988 1.988
Present status
In one of the pharmaceutical units, the specifications of AHU fans operating in syrup manufacturing area were given below. AHU Fan 1 5 8 Design Pressure (mm H2O) 87 87 87 Rated Capacity Cfm 10,500 21,000 9,500 Developed pressure (mm H2O) 66 35 48
The operating pressure was much lower than the design pressure rise of these AHU fans. This has resulted in inefficient operation of the fans and thereby, higher power consumption.
Benefits
The annual energy saving achieved was Rs. 0.046 millions. This required an investment of Rs. 0.03 millions for changing the pulleys, which paid back in 8 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Electrical Distribution
Introduction Distribution is a system through which the electrical power received from the grid / own captive power generation is carried to various equipment, where the electrical energy converted to other forms of energy. In an electrical system, the distribution losses vary widely and depend upon various factors such as layout of the distribution system, characteristics of the load being connected, performance of the equipment, etc., The losses in the distribution system vary anywhere between 1.0% to 2.5% of input power. These losses can be minimised by proper selection of energy efficient equipment and suitable capacity at the design stage itself. Some of the criteria, which have to be met by the electrical distribution system, are as follows: ! ! ! ! Stable voltage Uninterrupted power Minimum harmonic distortion Minimal losses
Equipment selection plays an important role in achieving the above mentioned criteria and to achieve energy efficiency right from the beginning of the project. Great care should be taken on energy efficiency for the following major components used in the electrical distribution. ! ! ! ! ! Transformers Electrical cables / bus bars Capacitors Motors Lighting
Energy conservation could be achieved by proper location i.e. layout of electrical equipment, viz. Main Receiving Sub-station (MRSS), transformers, switchgears etc. In addition to operational consideration / flexibility, loss in distribution system could be brought down by bringing the source closer to the load centre. Detailed load flow and analysis of system losses should be studied before locating various equipment.
Factor
Controller
and
Reduce
In all industrial electrical distribution systems, the major loads are inductive in nature. Typical inductive loads are A.C. Motors, induction furnaces, transformers and ballasttype lighting. Inductive loads require active power to perform the work and reactive power to create and maintain electro-magnetic fields. Active power is measured in kW (Kilo Watts). Reactive power is measured in kVAr (Kilo Volt-Amperes Reactive). The vector sum of the active power and reactive power make up the total (or apparent) power used (kVA). The ratio of kW to kVA is called the power factor, which is always less than or equal to unity. Theoretically, when electric utilities supply power, if all loads have unity power factor, maximum power can be transferred for the same distribution system capacity. However, as the loads are inductive in nature, with the power factor ranging from 0.2 to 0.9, the electrical distribution network is stressed for capacity at low power factors. The solution to improve the power factor is to add power factor correction capacitors to the plant power distribution system. They act as reactive power generators, and provide the needed reactive power to do kW of work. This reduces the amount of reactive power, and thus total power, generated by the utilities. The benefit of operating the plant at high power is given below: ! Reduced kVA (Maximum demand) charges in electricity board bill ! Reduced transformer & distribution losses within the plant ! Better voltage at motor terminals and improved performance of motors ! A high power factor eliminates penalty charges imposed when operating with a low power factor ! A high power factor gives incentive on energy bill from some of the state electricity boards
Previous Status
In a small scale engineering industry, having a contract demand of 500 kVA with electricity board had a power factor of 0.85.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Benefits
The savings achieved was Rs. 1.1 Lakhs. The investment for auto power factor controller was Rs.1.2 Lakhs. The simple payback period was 13 months.
Annual Savings Rs. 0.11 millions Investment Rs. 0.12 millions Simple payback 13 months
Distribution Proposal-1: Install Auto Power Factor Controller and Reduce Distribution Losses Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.120 -0.120 0.316 72.32% 0.120 0.096 0.110 0.005 0.094 0.024 0.110 0.031 0.063 0.000 0.110 0.039 0.050 0.000 0.110 0.039 0.045 0.000 0.110 0.039 0.040 0.000 0.110 0.039 0.036 0.000 0.110 0.039 0.032 0.000 0.110 0.039 0.028 0.000 0.110 0.039 0.025 0.000 0.110 0.039 0.071 0.023 0.110 0.110 0.110 0.110 0.110 0.110 0.110 0.110 0.110 0.110 0.11 0.12 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Previous status
In a small scale foundry, the cable loss was estimated based on the voltage drop study. The actual voltage drop in few of its feeders was more than 10 volts. The acceptable limit is less than 5 Volts. The voltage drop was high due to the poor power factor the feeder (Less than 0.60). The estimated loss was 2.5 kW in each feeder.
Benefits
The annual savings achieved by reducing cable loss was Rs.0.06 millions. The investment made for the capacitor banks were Rs. 0.04 millions, which paid back in 8 months.
Annual Savings Rs. 0.06 millions Investment Rs. 0.04 millions Simple payback 8 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Distribution Proposal-2: Reduce Cable Loss by Improving Feeder Power Factor Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.040 -0.040 0.190 113.16% 0.040 0.032 0.060 0.010 0.045 0.008 0.060 0.019 0.033 0.000 0.060 0.022 0.027 0.000 0.060 0.022 0.024 0.000 0.060 0.022 0.022 0.000 0.060 0.022 0.019 0.000 0.060 0.022 0.017 0.000 0.060 0.022 0.016 0.000 0.060 0.022 0.014 0.000 0.060 0.022 0.012 0.060 0.060 0.060 0.060 0.060 0.060 0.060 0.060 0.060 0.060 0.06 0.04 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
0.050 0.041 0.038 0.038 0.038 0.038 0.038 0.038 0.038 0.038
Previous status
The load current in single phase load feeder was varied from 130 to 170 Amps in phases and the neutral current was about 40 Amps.
Benefits
The annual energy saving achieved by implementing this project was Rs.7.3 millions. The total investment for neutral compensator was Rs.0.08 millions, which was paid back in 13 months.
Annual Savings Rs. 7.3 millions Investment Rs. 0.08 millions Simple payback 13 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Distribution Proposal-3: Install Neutral Compensator for Unbalanced Loads Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.080 -0.080 26.394 5879.74% 0.080 0.064 7.300 2.596 4.200 0.016 7.300 2.613 3.736 0.000 7.300 2.619 3.332 0.000 7.300 2.619 2.975 0.000 7.300 2.619 2.656 0.000 7.300 2.619 2.372 0.000 7.300 2.619 2.118 0.000 7.300 2.619 1.891 0.000 7.300 2.619 1.688 0.000 7.300 2.619 4.681 1.507 7.300 7.300 7.300 7.300 7.300 7.300 7.300 7.300 7.300 7.300 7.3 0.08 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Amorphous CRGO Amorphous CRGO Amorphous CRGO 180 250 200 365 450 570 900 1000 1250 1500 3200 4800 5200 6050 7650 4000 6550 8000 9000 11800 98.7 99 99.1 99.2 99.2 98.2 98.53 98.54 98.65 98.68
Amorphous metal core transformers are available upto 1000 kVA in India. These transformers are ideally suited at design stage of the plant. The maximum energy saving potential is 70% of core loss. Significant energy saving is achieved over the transformer life cycle of 20 to 25 years.
Previous status
One of the chemical plants had a 500 kVA conventional old transformer for distribution of supply. The energy loss was high compared to the latest amorphous core transformers.
Benefits
The annual energy saving achieved by implementing this project was Rs.0.50 millions. The total investment for new amorphous metal core transformer was Rs.0.4 millions, which was paid back in 96 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Annual Savings Rs. 0.50 millions Investment Rs. 0.4 millions Simple payback 96 months
Distribution Proposal-4: Install Energy Efficient Amorphous Core Transformer Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.400 -0.400 1.537 95.90% 0.400 0.320 0.500 0.065 0.389 0.080 0.500 0.151 0.278 0.000 0.500 0.179 0.228 0.000 0.500 0.179 0.204 0.000 0.500 0.179 0.182 0.000 0.500 0.179 0.162 0.000 0.500 0.179 0.145 0.000 0.500 0.179 0.129 0.000 0.500 0.179 0.116 0.000 0.500 0.179 0.321 0.103 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.5 0.4 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Motors
Introduction
Motor converts electrical energy into mechanical energy. Industrial electric motors can be broadly classified as induction motors, direct current motors or synchronous motors. Induction motors are the most commonly used prime mover for various equipments in industrial applications. More than 90% of the motors used in small scale industries are AC squirrel cage induction motors. In induction motors, the induced magnetic field of the stator winding induces a current in the rotor. This induced rotor current produces a second magnetic field, which tries to oppose the stator magnetic field, and this causes the rotor to rotate. The 3-phase squirrel cage motor is the workhorse of industry; it is rugged and reliable, and is by far the most common motor type used in industry. These motors drive pumps, blowers and fans, compressors, conveyers and production lines. Motor Efficiency The energy consumed by the motor over its life cycle is 60 100 times of the initial cost. Therefore the efficiency of the motor is more important during selection and operation. Motor efficiency is defined as the ratio of mechanical power output to electrical power input. The efficiency of the motor depends on the capacity and the percentage loading of the motor. The full load efficiency of the motor varies from 75% to as high as 95% depending on the size, type and loading. In industry the actual loading of the motors vary from 40% to 80%. This is because, the motors are selected to take care of the starting torque requirement and varying process conditions. There various methods to improve the operating efficiency of the motors in industry are described in the following case studies. All these case studies are applicable for all type of industries.
Previous Status
The loading of some of the drilling & grinding machines and lathes were lesser than 40%. The operating efficiency of these under loaded motors were much lesser than design efficiency.
Benefits
Implementation of this proposal resulted in an annual saving of Rs. 0.15 millions. The investment was Rs. 0.2 Lakhs, which paid back in 16 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Motors Proposal-1: Install Auto Star Delta Star Converters in Lightly Loaded Motors Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 2.000 1.600 1.500 -0.036 -2.000 4.062 60.12% 1.371 0.400 1.500 0.395 0.881 0.000 1.500 0.538 0.685 0.000 1.500 0.538 0.611 0.000 1.500 0.538 0.546 0.000 1.500 0.538 0.487 0.000 1.500 0.538 0.435 0.000 0.000 1.500 1.500 0.538 0.538 0.388 0.347 0.000 1.500 0.538 0.310 1.500 1.500 1.500 1.500 1.500 1.500 1.500 1.500 1.500 1.500 1.5 2 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-2.000 1.536 1.105 0.962 0.962 0.962 0.962 0.962 0.962 0.962 0.962
Previous Status
There were 30 numbers of 15 kW conventional ring frame motors operating at lower efficiency due to several rewinding.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Rated kW 15 15
Benefits
The annual energy savings achieved by replacing the old inefficient motors was Rs. 1.26 millions. The investment made was Rs. 0.9 millions, which got paid back in 9 months.
-0.250 0.162 0.108 0.090 0.090 0.074 0.090 0.074 0.090 0.074 0.090
Previous Status
In a sugar plant, 22 kW cane carrier drive was operating with Eddy current drive system.
Benefits
The annual energy savings achieved by replacing the eddy current drive with variable frequency drive was Rs.0.105 millions. The investment was Rs. 0.15 millions, for VFD and motor, which paid back in 17 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Motors Proposal-3: Replace Eddy Current Drive with Variable Frequency Drive Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.150 0.120 0.105 -0.005 -0.150 0.277 56.37% 0.099 0.030 0.105 0.027 0.062 0.000 0.105 0.038 0.048 0.000 0.105 0.038 0.043 0.000 0.105 0.038 0.038 0.000 0.105 0.038 0.034 0.000 0.105 0.038 0.030 0.000 0.105 0.038 0.027 0.000 0.105 0.038 0.024 0.000 0.105 0.038 0.022 0.105 0.105 0.105 0.105 0.105 0.105 0.105 0.105 0.105 0.105 0.105 0.15 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.150 0.110 0.078 0.067 0.067 0.067 0.067 0.067 0.067 0.067 0.067
Replace Motor-Generator (MG) Based Welding Set with Thyrister Based Welding Set
Background
In a small scale auto component manufacturing industry, Motor Generator (MG set) based welding machine was used for welding application. MG set consists of AC motor driving a direct-coupled DC generator. The overall efficiency of MG set is low because of two rotating equipment. Also, the no-load power consumption of MG set is continuous even when the welding machine is in off condition. During the loading cycle, there will be I2R loss in both AC motor and DC generator. The overall efficiency of MG set is only around 80 - 85%. Thyristor based welding sets are available for welding application. The operating efficiency of these sets is very high (96 to 98%). The reliability of such machines is also high and working successfully in many applications. The no-load power consumption of welding sets is negligible. There is a good potential to replace the M-G set based welding machine with thyristor based welding machine.
Previous status
Motor Generator set was used in a old welding machine. The rating of the machine was 43.5 kVA, 500 Amps. The no-load power consumption of the MG set was 1.8 2.0 kW. The power consumption during operation was about 14 kW.
Benefits
The annual savings potential is Rs.0.043 millions. The investment required is Rs.0.15 millions, which will be paid back in 42 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
-0.150 0.071 0.038 0.028 0.028 0.028 0.028 0.028 0.028 0.028 0.028
Lighting
Introduction
Lighting is the most commonly used and essential equipment in all the industries. The power consumption by the industrial lighting varies between 2 to 10% of the total power depending on the type of industry. Innovation and continuous improvement in the field of lighting, has given rise to tremendous energy saving opportunities in the area. Lighting is an area, which provides a major scope to achieve energy efficiency at the design stage, by incorporation of modern energy efficient lamps, luminaries and gears. Basic components of a lighting system Most of the lighting equipment, comprise of the following three basic components: ! Lamp ! Luminaries ! Gears Energy efficiency in lighting at design stage recommendations To achieve the optimum energy efficiency, one has to focus on the following three critical aspects of lighting technology at the design stage: 1. Light generation Light sources must be made more efficacious. That is, they must produce more light for the same amount of electrically consumed, without sacrificing quality. 2. Light distribution Optimum matching of a lam and its luminaire, results in achieving energy efficiency in light distribution 3. Lighting control The correct selected of energy efficient lamp and luminaire, results in achieving energy efficiency, only if the system has an effective lighting control system. Since, the effective lighting control system makes the light adaptable to different lighting needs. The lighting control system could be the use of dimmers, presence detectors and electronic controllers. In other words, there is a need to have a highly flexible and adaptable lighting installation which will permit change of lighting levels to suit varying conditions.
Previous Status
In a small scale garment industry, lighting power consumption was more than 25% of the total power consumption. The lighting feeder voltage was around 240 Volts, which lead to higher energy consumption.
Benefits
The annual saving achieved by implementing this proposal was Rs. 0.14 millions. The investment made for lighting voltage stabilizer was Rs 0.25 millions, which paid back in 22 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Lighting Proposal-1: Install Lighting Transformer for Main Lighting Feeder Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV 0.250 0.200 0.140 -0.022 -0.250 0.336 45.60% 0.144 0.050 0.140 0.032 0.086 0.000 0.000 0.140 0.140 0.050 0.050 0.064 0.057 0.000 0.140 0.050 0.051 0.000 0.000 0.000 0.000 0.000 0.140 0.140 0.140 0.140 0.140 0.050 0.050 0.050 0.050 0.050 0.045 0.041 0.036 0.032 0.029 0.140 0.140 0.140 0.140 0.140 0.140 0.140 0.140 0.140 0.140 0.14 0.25 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
-0.250 0.162 0.108 0.090 0.090 0.090 0.090 0.090 0.090 0.090 0.090
Case study No 2
Replace 40 Watts Fluorescent Tube Lights with 36W Colour-80 Series Lamps
Background
Conventional fluorescent tube lights are used in majority of industries. The actual efficacy of these lamps is 69 lumens / Watt. The life of these lamps is about 8000 hrs. Nowadays, Colour-80 series fluorescent lamps are available with very high efficacy. There is a good potential to save energy, by replacing 40-Watts fluorescent lamps with 36 watts colour-80 series lamps. Colour-80 series lamps have 40% more light output and better colour property than conventional tube lights. The actual power is reduced by 4 watts/lamp and due high light output the number of lamps also reduced. The colour -80 series lamps are best suitable for inspection, machining areas, paint shops etc. The comparison between conventional and colour-80 series lamps are given below: Lamps Conventional Tube light Colour-80 series lamp Previous status In a small scale textile plant, there were about 500 tube lights used for illumination purpose. All these lamps were of conventional 40 Watts tube lights. Watts 40 36 Efficacy 69 lumens/Watt 90 lumens/Watt Life 8000 hrs 12,000 hrs
Benefits
The total annual energy saving potential was Rs 0.155 millions. The investment for colour-80 series lamps was Rs 0.08 millions, which was paid back in 7 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Lighting Proposal-2: Replace 40 Watts Fluorescent Tube Lights with 36W Colour-80 Series Lamps Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 6 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.080 -0.080 0.354 142.22% 0.080 0.064 0.155 0.033 0.122 0.109 0.016 0.155 0.050 0.105 0.084 0.000 0.155 0.056 0.099 0.071 0.000 0.155 0.056 0.099 0.063 0.000 0.155 0.056 0.099 0.056 0.000 0.155 0.056 0.099 0.050 0.155 0.155 0.155 0.155 0.155 0.155 0.155 0.08 0 1 2 3 4 5 6 Discount Rate (i) 12%
The comparison of power consumption for conventional ballast and the energy efficient electronic ballast is given below: Ballast Conventional ballast Electronic ballast Power Consumption 14 - 15 W / Tube 2 W / Tube
Previous status
There were about 250 tube lights glowing continuously for 24 hours in a machine shop. All these lamps were fitted with copper ballast. The power consumption was around 14 watts/lamp.
Benefits
The annual savings achieved was Rs.0.09 millions. The investment for replacing copper ballast with electronic ballast was Rs 0.09 millions, which will be paid back in 12 months.
Annual Savings Rs. 0.09 millions Investment Rs. 0.09 millions Simple payback 12 months
Lighting Proposal-3: Replace Copper Ballast in Fluorescent Lam ps w ith Electronic Ballast Savings/Year (Rs M illion) Investm ent (Rs M illion) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Incom e (D)=A-B Tax @ 35.875 % on Incom e(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+ i)^ n NPV (Rs. M illion) IRR Basis of Calculation 1. Investm ent being for energy efficiency equipm ent, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 6 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investm ent (i) is considered as 12% for calculating NPV -0.090 -0.090 0.175 76.15% 0.090 0.072 0.090 0.006 0.084 0.075 0.018 0.090 0.026 0.064 0.051 0.000 0.090 0.032 0.058 0.041 0.000 0.090 0.032 0.058 0.037 0.000 0.090 0.032 0.058 0.033 0.000 0.090 0.032 0.058 0.029 0.090 0.090 0.090 0.090 0.090 0.090 0.09 0.09 0 1 2 3 4 5 6 Discount R ate (i) 12%
Replace Mercury Vapour Lamps with Metal Halide Lamps in Case Press Shop
Previous Status
In a watch manufacturing unit, lighting survey was carried out throughout the plant area. The plant team has installed energy efficient lamps in many places. They wanted to extend energy efficiency in lighting system in other areas of the plant also. In some of the areas like case press shop, high pressure mercury vapour (HPMV) Lamps were installed. The efficacy and colour property of HPMV lamps are lower than the latest metal halide lamps.
The plant team replaced the 125 watts HPMV lamps with 70 Watts metal halide lamps in Case Press shop. The implementation was carried out in a phased manner.
Benefits
The annual energy savings achieved by replacing HPMV lamps with metal halide lamps was Rs.0.37 millions. This required an investment of Rs. 0.75 millions and paid back in 24 months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Replace Incandescent Lamps (GLS) with Energy Efficient Compact Fluorescent Lamps (CFL) for Task Lighting in Machines
Background
Incandescent lamps are one of the older generation lamps. Their energy consumption is higher and the efficacy levels are very poor. One of the direct replacement of incandescent lamps are the Compact Fluorescent Lamps (CFL). The efficacy (Lumens /Watt) of CFL & GLS of lamps are given below: " Incandescent lamp (GLS) " CFL : : 14 lumens/watt 60 lumens/watt
Previous Status
There were around 200 incandescent lamps of 60 Watts in operation as task lighting in machines. Compact fluorescent lamps are best suited for task lighting application.
Benefits
The annual energy saving achieved by replacing the incandescent lamps with CFL was Rs.0.182 millions. The investment required was Rs.0.07 millions, which paid back in 5 Months.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Renewable Energy
Implementation of the project resulted in a saving of 134 MT of LSHS. The investment required was Rs.15.5 millions and paid back in about 36 months. The depreciation benefit of Rs. 5.5 millions has been taken into account while calculating the economic benefits. Besides economic benefits, environmental benefits have also been derived out of this project. It has resulted in reducing sulphur-dioxide (SO2) emission to the tune of 217 kgs per annum. Environmental benefits ! Reduction in 134 tons of LSHS per year ! Reduction in 217 kgs of SO2 per year Cost benefit analysis Annual Savings Rs. 5.5 millions Investment Rs. 15.5 millions Simple payback 36 months
Renewable Energy Proposal-1: Application of Solar Energy for Generating Preheated Boiler Feed Water Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -15.500 -15.500 9.286 28.51% 15.500 12.400 5.500 -2.475 7.975 7.121 3.100 0.000 5.500 5.500 0.861 1.973 3.698 2.510 0.000 5.500 1.973 2.241 0.000 5.500 1.973 2.001 0.000 5.500 1.973 1.787 0.000 0.000 5.500 5.500 1.973 1.973 1.595 1.424 0.000 5.500 1.973 1.272 0.000 5.500 1.973 1.136 5.500 5.500 5.500 5.500 5.500 5.500 5.500 5.500 5.500 5.500 5.5 15.5 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study 2
System Description
The gasifier, which uses firewood as fuel, is connected with a gas engine that operates on 100% producer gas. The engine is actually meant for natural gas firing, however with a few modifications this could be used for power generation using producer gas. Dried firewood is fed into the hopper of the gasifier through bucket elevators. In order to avoid clogging of firewood, a vibrator is placed alongside of the hopper, which ensures smooth flow of firewood. The produces gas generated through partial combustion under controlled supply of air is fed through various stages of filters and cleaning system. Tar, particulate matter and other impurities are filtered with water scrubbers and micro filters. In order to bring down the gas temperature the cleaned gas is passed through a two stage cooling system with water circulation. The temperature of gas is brought down from 500oC to about 45oC, so as to feed into the engine.
Benefits:
The adoption of biomass gasifier system for power generation has given significant tangible and intangible benefits. The total investment was about Rs 60.0 Lakhs out of which Rs 30.0 Lakhs have been availed through MNES subsidy. The cost of power generation works out to be Rs. 3.0 per unit as against the present electricity charges of Rs 4.50 per unit for HT industries. It gives a direct savings of Rs 1.50 / kWh. The annual savings would be about Rs 1.7 millions for 300 days of system operation. The total investment was paid back within 24 months after considering the subsidy component.
Annual Savings Rs. 1.7 millions Investment Rs. 3.0 millions (after subsidy) Simple payback 24 months
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Case study No 3
Pumping
for
Industrial
Process
A tobacco processing plant has installed solar water pumping system to cater to their process requirements. The system is capable of pumping about 20,000 KL of water per year from the bore wells. All bore wells are located at about 4.0 km distance from the plant, where there is no grid available. Water pumped from the 3 bore wells is stored in the storage tank with 40 KL capacity.
System Description
There are two solar PV systems of 3.8 kWe each and one 3.6 kWe installed for water pumping. The total installed capacity of solar water pumping system is 11.5 kW. In this system, solar panels are connected to a flow optimizer, DC AC inverter and two submersible pumps of 1.8 kW capacities each. The pumps are located at a depth of 80m below ground level. The on / off operation of the pumps is automatically controlled through the flow optimizer panel using a Front side view of solar PV system float switch fixed in the tank. When the output electricity is low due to diminished solar radiation, it switches off one pump so as to ensure maximum water output from the other pump. The specifications of system are given below: ! ! ! ! ! ! ! No of arrays No of pumps Wattage of each module No of modules in 3.6 kW system Voltage output Capacity of pump No of modules in 3.8 kW systems :3 : 6 (2 in each system) : 75 W : 48 : 120 V : 1.8 kW each : 56 in each system
Water pumped to the plant is used for various process applications such as Steam generation, domestic applications and chilling plants. The system requires minimal maintenance of cleaning once in a week of the solar panels and checking of pump output for smooth running of the system.
Benefits
The total investment for this project is Rs 55.0 Lakhs. This project has resulted in substantial power savings for the company which is otherwise would have been used for water pumping.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
The estimated energy generation from solar water heating system is 30,00,000 kcal / day.
System Description
There are 711 solar collectors installed in four rows, which are connected in series. They are connected to 2 storage tanks of 50,000 litres capacity each. One of the storage tanks is kept as stand-by and used during maintenance. Water from DM plant is circulated through solar water heaters by circulation pumps and fed to the boiler. The system has been generating hot water at 80oC almost through out the year. Further, during summer the temperature is set low in order to get maximum quantity of water. The following operation and maintenance practices are being adopted to keep up the thermal performance of the system. " Periodical cleaning of solar collectors " Inlet water to solar water heater should be treated to a level of 5 8 ppm dissolved solids " Periodic checking of flow through drain pipes in each row " End point flanges are being replaced at regular intervals
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
Benefits
The hot water generated by solar water heating system has replaced about 1.5 tons of coal per day. The cost of coal is about Rs 2200 per ton. This system is an operating about 180 days in a year. Total investment of this system was Rs 50.0 lakhs of which Rs 30.0 Lakhs was the net investment after availing MNES subsidy. The annual savings achieved by conserving coal is estimated as Rs 0.6 millions per annum. With the savings achieved, the investment was paid back in less than 5 years.
Besides economic benefits, the system has also resulted in substantial reduction in CO2 and SO2 emissions.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Renewable Energy Proposal-4: Solar Water Heating System for Pre-heating Boiler Feed Water Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -3.000 -3.000 0.114 13.20% 3.000 2.400 0.600 -0.646 1.112 0.600 0.600 0.000 0.478 0.000 0.600 0.215 0.274 0.000 0.600 0.215 0.245 0.000 0.600 0.215 0.218 0.000 0.600 0.215 0.195 0.000 0.600 0.215 0.174 0.000 0.600 0.215 0.155 0.000 0.600 0.215 0.139 0.000 0.600 0.215 0.124 0.600 0.600 0.600 0.600 0.600 0.600 0.600 0.600 0.600 0.600 0.6 3 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Project Description
A biogas plant of 25 m3/day capacity has been installed to cater to the thermal energy requirements of the canteen. It is floating dome type digester connected with two burners of 2 m3 and 3 m3 capacities each. At the initial stage, cow dung was charged to create micro organisms especially bacteria in order to catalyze microbial action in the digester. After stabilization, wastes generated from the canteen that are rich in organic content have been charged. Normally the feedstock charged at 1:1 ratio with water is stirred and homogenous mixture has been prepared and fed into the digester. It helps the methanation process to take place at faster rate. In order to maintain the required output cow dung has been charged at regular interval as an inoculum. The gas production depends on several parameters such as organic content of the feedstock, retention time, pH maintained in the digester, Total dissolved solids in the slurry etc,.It is important to note that no fibrous material like coriander stem, onion skin etc should be fed into the digester. This would ultimately result in lesser gas production. In this plant, they have faced a problem of reduced gas production after one year of operation. It was due to the absence of sufficient micro organisms to digest the organic content and hence the lesser gas production. Subsequently, complete cleaning had been done and recharged with cow dung to initiate the process.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Benefits
The installation of biogas plant has reduced the consumption of LPG which has been used for cooking applications. The cost of LPG used was Rs 450 per cylinder. Use of LPG has resulted in a saving of about 20 cylinders of LPG and cost to the tune of Rs 0.1 million per year. The company has availed 50% subsidy and hence the total cost of the project was about Rs 0.2 millions after subsidy. With the savings incurred the investment has been realized in 24 months period. The operating and maintenance cost of this project has been considerably low. Besides providing a quality fuel, this project has resulted in many other benefits. The environmental implications of disposing the waste generated before installing the biogas plant have been sorted out completely. Another intangible benefit of this system is the generation of rich organic manure which is being utilized for in-house farming. However, due to low pressure and calorific value of biogas this could only be used mainly for water boiling, frying etc.
Renewable Energy Proposal-5: Biogas Generation from Canteen Wastes for Cooking Applications Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -0.200 -0.200 0.225 40.81% 0.200 0.160 0.100 -0.022 0.109 0.040 0.100 0.022 0.063 0.000 0.100 0.036 0.046 0.000 0.100 0.036 0.041 0.000 0.100 0.036 0.036 0.000 0.100 0.036 0.032 0.000 0.100 0.036 0.029 0.000 0.100 0.036 0.026 0.000 0.100 0.036 0.023 0.000 0.100 0.036 0.021 0.100 0.100 0.100 0.100 0.100 0.100 0.100 0.100 0.100 0.100 0.1 0.2 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
Gasifier
Dust collector
Diesel scrubber
Cyclone separator
Water Sprayer
Gas outlet
Project description
The producer gas generated from gasifier is fed through various stages of cleaning as it contains carbon dust, tar etc. The gas which comes out of gasifier is at temperature of about 400oC. It passes through dust collector to remove dust particles which would help improving the quality of gas. In order to further improve the gas quality by removing other impurities and particulates, producer gas is fed through cyclone separator, water spray arrangement and diesel scrubber. This would avoid clogging of burners and hence improve the combustion efficiency. There are a few problem faced during operation of this system, since installation that are, ! Scrubber contamination ! Cooling Tower contamination due to carbon accumulation
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Also, the gasifier system has to be unloaded once in 700 hrs of operation (once a week) for regular maintenance in order to remove tar which is formed along the walls of gasifier. However, the burner requires less maintenance.
Benefits
Use of biomass gasifier system has resulted in tremendous savings on furnace oil to the tune of 60T/month which accounts for 30% savings on furnace oil consumption. The cost of furnace oil and firewood are Rs 15 / liter and Rs 1600 / T respectively @ 35% moisture. The total savings achieved is about 100 Lakhs per annum due to reduction in furnace oil consumption. The cost of firewood used for gasification is about Rs 40.0 Lakhs. Hence the net savings achieved is about Rs 6.0 millions per year. This system required an investment of Rs 4.5 millions which includes for biomass gasifiers, burner, cleaning systems and other accessories. Apart from cost benefits, this project has resulted in reduction of CO2 equivalent to 17 Tons per month.
Renewable Energy Proposal-6: Biomass Gasifier for Industrial Thermal Applications Savings/Year (Rs Million) Investment (Rs Million) Year (n) Inflow Energy saving (A) Out flow Initial Cost (B) Depreciation ( C) Net Income (D)=A-B Tax @ 35.875 % on Income(D) - depreciation ( C ) Cash Inflow after Tax (F) Present Value = F/(1+i)^n NPV (Rs. Million) IRR Basis of Calculation 1. Investment being for energy efficiency equipment, Depreciation of 80% in first year and 20% in second year is allowable as per GoI 2. NPV & IRR are calculated for 10 years 3. Corporate tax is considered @ 35% with 2.5% surcharge (as existing in India presently) 4. Corporate tax is calculated taking into account 80 % depreciation in I year and 20 % depreciation in II year 5. Interest on investment (i) is considered as 12% for calculating NPV -4.500 -4.500 18.650 101.69% 4.500 3.600 6.000 0.861 4.588 0.900 6.000 1.830 3.325 0.000 6.000 2.153 2.739 0.000 6.000 2.153 2.445 0.000 6.000 2.153 2.183 0.000 6.000 2.153 1.949 0.000 6.000 2.153 1.740 0.000 6.000 2.153 1.554 0.000 6.000 2.153 1.387 0.000 6.000 2.153 1.239 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6 4.5 0 1 2 3 4 5 6 7 8 9 10 Discount Rate (i) 12%
628
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AC DRIVES
Allen-Bradley India Ltd. C-11, Ind Area, Site-4, Sahibabad -201 010, Dist. Ghaziabad, Uttar Tel: 11 8771112 Fax: 11 8770822 WWW: www.ab.com/
Cegelec India Ltd. A - 21/24, Sector 16 Noida 201 301 Tel: 011 - 852 5643 Fax: 011 - 852 0405
Mr. Sudhir Naik Vice President - Corporate Mktg. Hi-Rel Electronics Limited B -117 & 118, GIDC, Electronics Zone, Sector-25 Gandhi Nagar 382044 Tel: 02712-21636, 22531 Fax: 02712-24698 Email: mktg.hrcl@hirel.sprintrpg.ems.vsnl.net.in Mr N C Agrawal Managing Director MEDITRON SIRTDO Industrial Estate P O BIT, Mesra Ranchi 835 215 Tel: +91-651-535875 Email: meditron@dte.vsnl.net.in, jyoti@dte.vsnl.net.in Adsorption Dryers. Mr. Rajnish Joshi Exe. Vice President Delair India Pvt. Ltd. 20, Rajpur Road, New Delhi 110054 Tel: 011-2912800 Fax: 011-2915127, 2521754 Email: bryair@nda.vsnl.net.in AFBC Boilers, Mr K Kuppuraju President-Technical CetharVessels Pvt ltd 4,Dindigul road, tiruchirappilly Tel: 0431-482452/53 Fax: 0431-481079 Email: try_cvltry@sanchar.com Air & gas compressors, Mr Andre Schmitz Managing Director Atlas Copco (India) Ltd Mahatma Gandhi Memorial Building Netaji Subhas Road Mumbai 400 002 Tel: +91-22-5596416 / 17 Fax: +91-22-5597928 Email: r.suresh@atlascopco.com Air compressors Mr M Raveendran Director Coimbatore Compressor Engineering Co Pvt Ltd S F No 429, Thanneerpandal Peelamedu Coimbatore 641 004 Tel: +91-422-2570323 Fax: +91-422-2571447 Email: compressor@eth.net
Danfoss Industries Pvt. Ltd. 296, Old Mahabalipuram Road Sholinganallur, Chennai 600 119 Tel: 044 2550 1555 Fax: 044 2550 1444 Email: danfoss.india@danfoss.com Emco Lenze Pvt. Ltd (Registered and Sales Office) 1st Floor, Sita Mauli, Above Bank of Maharashtra, Madanlal Dhingra Road, Panchpakhadi, Thane (West) Mumbai- 400 602. Tel :-+91 - 22 - 2540 5488 / 2540 5490 / 2545 2244 Fax :-+91 - 22 - 2545 2233 Email :- mktg@emcolenze.com Energytek Electronics Pvt. Ltd. A - 31, GIDC Electronics Zone Gandhinagar 382 044 Tel: 02712 - 25562 Fax: 02712 30544 Messung Systems Pvt Ltd S - 615, 6th Floor, Manipal Centre Dickinson Road Bangalore 560042 080 5320480 Email: bco@messung.com Ador Powertron Industries Ltd. Plot 51, Ramnagar Complex D - 11 Block, MIDC, Chinchwad Pune 411 019 Tel: 020 - 5572 532, 5573 778 Fax: 020 - 5575 817 Mr K N Balaji Chief Operating Officer Eurotherm Del India Ltd 152, Developed Plots Estate Perungudi Chennai - 600 096 Tel: 044-24961129 Fax: 044-24961831 Email: sales@eurothermdel.com
Dr Jairam Varadaraj Managing Director ELGI EQUIPMENT LTD Elgi Industrial Complex Trichy Road Singanallur P O Coimbatore 641 005 Tel: +91-422-2589555 Fax: +91-422-2573697 Email: investor@elgi.jet.co.in Mr Amol Parkhe Product manager Kirlosker Copeland (EE) 1202/1,Ghole Road Near Ramchandra Sabhagurha Pune-411004 Tel: 020-5536350 Fax: 020-5534988 Email: amolp@kircop.com Air conditioning systems Ms Sajitha M Nair Marketing executive Presvi Controls Pvt ltd no 8, 2nd street,Venkatram nagar extn Adayar Chennai 600 020 Tel: 91-044-24420977/ 93 Fax: 91-044-24410289 Mr J P Singh Managing Director YOKOGAWA BLUE STAR LTD 40/4, Lavelle Road Bangalore 560 001 Tel: +91-80-2271513 Fax: +91-80-2274270 Email: ybilr@giasbg01.vsnl.net.in Mr. B G Raghupathy Vice Chairman GEA Cooling Tower Technologies (India) PvtLtd 443, Anna Salai, Teynampet Chennai-600018 Tel: 044-24326171 Fax: 044-24360576 Email: gct@vsnl.in Mr Anil K Srivastava Managing Director CARRIER AIRCON LTD Chiller Business Unit 114, Shahpur Jat Near Asian Games Village New Delhi 110 049 Tel: +91-11-6497131 to 34 Fax: +91-11-6497140 K N A Chandrasekar Regional Manager Amtrex Hitachi Appliances Ltd Tulsi Apartments 47,II Main Road, R A Puram Chennai 600 028 Tel: 044 - 24937483 Fax: 044- 24935534 Email : kna.chandrasekar@amtrexhitachi.com Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Mr T Nakamoto Managing Director Daikin-Shriram Air Conditioning Pvt Ltd 12th floor, Surya Kiran Building 19KG Marg New Delhi 110 001 Tel: 011-375-2647 Fax: 011-375-2646
Matsushita Air-conditioning India Pvt Ltd Nungambakkam high raod Nungambakkam Chennai 600 034 Tel: (91)-(44)-28274705
Ambiator Mr. A Vaidyanathan Managing Director HMX - SUMAYA Systems A 422, Peenya Industrial estate !st cross, 1 st stage Bangalore 560058 Tel: 080-3722325, 1065 Fax: 080-3722326 Email: ambiator@hmx.biz Ash handling systems; high alumina Automatic oil fired burners Mr. R. Rawat Partner Burnax India 338, Balmukund Khand, Giri Nagar, Kalkaji, New Delhi 110019 Tel: 011-26215124, 26230498 Fax: 011-26215124 Automatic Power Factor Controller Mr. Vipin SuriI Managing Director Sylvan Electronics A-92/1, Naraina Indl. Area, Phase-I New Delhi 110028 Tel: 011-25791044/2324 Fax: 011-25794617 A Square Incorporation 11 (Old: 7) Subramanyaa 1st Floor, 3rd Street Santhi Nagar,Aadambakkam Chennai 600 088 Tel: 044 2451853 Email: srisuras@satyam.net.in
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Automation Mr P S Sridharan Managing Director MEGATECH CONTROL PVT LTD Alsha Complex 51, 1st Main Road Gandhi Nagar Chennai 600 020 Tel: +91-44-24996733 / 5654 Fax: +91-44-24341668, 4996215 Email: megatech@md2.vsnl.net.in AXIAL FLOW FANS Amalgamated Indl. Composites Pvt. Ltd. Unit No.111/112 Ashok Service Industrial Estate L B S Marg, Bhandup (West) Mumbai 400 078 Tel: 022-5591 3591/04565, 5534 6919 Fax: 022-5591 3611, 55346920 Paru Engineers Private Limited B-56, Durgabai Deshmukh Colony Hyderabad 500 007 Tel: 040 - 2764 4174 Fax: 040 - 2764 4174 Blowers Mr R P Sood Managing Director ENCON FURNANCES PVT LTD 14/6, Mathura Road Faridabad 121 003 Tel: +91-129-274408, 275307 / 607 Fax: +91-129-276448 Mr L Chandrashekar Managing Partner MYSORE ENGINEERING ENTERPRISES No 169, Industrial Suburb II Stage P B No 5859, Peenya Post Bangalore 560 058 Tel: +91-80-8394423 Fax: +91-80-3349746 Email: keeebgl@vsnl.net.in Boilers & Axuliaries Mr. Ashok Tanna Managing Director Vinosha Boilers Pvt. Ltd. And Taurus Heat Systems Baarat House, Ist Floor, 104, Apollo Street, Fort, Mumbai 400001 Tel: 022-2674590, 2676447 Fax: 022-2611515: Mr Michael H W Band Executive Director Mitsui Babcock Energy (India) Pvt Ltd 516-520, International Trade Tower Nehru Place New Delhi 110 019 Tel: +91-11-6436790, 6446118 Mr. Cyrus Engineer Vice President Industrial Boilers Ltd. 701-C, Poonam Chambers, Dr. Annie Besant Road, Worli, Mumbai 400018 Tel: 022-4926629 Fax: 022-4937505 Mr Prakash Kulkarni Managing Director THERMAX BABCOCK & WILCOX LTD Sagar Complex Kasarwadi Pune 411 034 Tel: +91-20-7125745 Fax: +91-20-7125533 Email: kulkarnip@tbwindia.com,
Fax: +91-11-6489793 Email:administrator.del@mitsuibabcock.com Mr J P Singh Managing Director YOKOGAWA BLUE STAR LTD 40/4, Lavelle Road Bangalore 560 001 Tel: +91-80-2271513 Fax: +91-80-2274270 Email: ybilr@giasbg01.vsnl.net.in Mr K C Rana Managing Director AVU ENGINEERING PVT LTD A - 15, APIE Balanagar Hyderabad 500 037 Tel: +91-40-23773235 / 2343 Fax: +91-40-23772343 / 3235 Email: avuhyderabad@rediffmail.com MrC S Radhakrishnan Executive Director Foster Wheeler India Pvt Prakash Presidium 110 Mahatma Gandhi Road, Nungambakkam Chennai 600 034 Tel: 91-44-2822-7341 Fax: 91-44-5822-7340 Email: fwenergy@fwc.com Mr B Pattabhiraman Managing Director GB Engineering Enterprises Pvt Ltd D - 99, Developed Plots Estate Thuvakudi Trichy 620 015 Tel: +91-431-501111 (8 lines) Fax: +91-431-500311 Email: gbengg@tr.dot.net.in Mr Ranjit Puri Chairman & Mg Director INDIAN SUGAR & GENERAL ENGINEERING CORPORATION (THE) A - 4, Sector 24 Noida 201 301 Tel: +91-118-4524071 / 72 Fax: +91-118-4528630, 4529215 Email: rp@isgec.com
Mr. Arun Gandhi Proprietor Crescent Engineering Corporation 49, H-32, Sector - 3, Rohini, New Delhi 110085 Tel: 011-27164109, 27276448 Fax: 011-27274553, 27162490 Mr B S Adishesh Wholetime Director IAEC INDUSTRIES MADRAS LTD Rajamangalam Villivakkam Chennai 600 049 Tel: +91-44-2655725, 26257783 Fax: +91-44-24451537, 24995762 Email: iaec.mds@elnet.ems.vsnl.net.in Calorifiers Mr. Dinesh Harjai Partner Crupp Metals Kh. No. 56/1, Mundka, Rohtak Road, New Delhi 110041 Tel: 011-25189024 Capacitors Mr R G Deshpande Managing Director BC COMPONENTS INDIA PVT LTD Loni - Kalbhor, (Central Railway) Pune 412 201 Tel: +91-20-6913451, 6913285 Fax: +91-20-6913609 Email: ram.deshpande@bccomponents.com Shri. S K Nevatia Hind Rectifiers Ltd Lake Road Bhandup West Mumbai Tel: 22 - 5564 41 22 Fax: 22 - 5564 41 14 Email: hirect@vsnl.com Momaya Capacitors 401, Madhav Apartments Jawahar Road, Opp. Rly. Stn. Ghatkopar (East) Mumbai 400 077 Tel: 022 - 5516 2899/ 1005/ 0745 Fax: 022 - 5516 0758 Shakti Capacitors Pvt Ltd Plot No 104/105 PB No 176 Industrial Estate Sangli 416 416 Tel: 91-233-310-915 Fax: 91-233-310-984 Email: shkcap@pn2.vsnl.net Mr. S. Jayaraman Sr. General Manager-Mktg. Kapsales Electricals Limited Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Khatau House, Plot No. 410-411, Mogul Lane, Mahim, Mumbai 400016 Tel: 022-4461975, 4450050 Fax: 022-4450016 Centrifugal & axial fans Mr J B Kamdar Chief Executive NADI AIRTECHNICS 26, G N T Road Erukkenchery Chennai 600 118 Tel: +91-44-5570264 / 771 Fax: +91-44-5371149 Email: ebmnadi@md2.vsnl.net.in Mr A P Gokhale Director Autowin systems povt ltd Plot no 2, Vedant Nagari Karve nagar Pune-411052 Tel: 020-5431052, 5423358 Fax: 020-5467041 Email: autowin@vsnl.com Centrifugal Pumps Mr BSS Rao/rajiv Sr General manager Beacon Weir ltd no 28, Industrial estate Ambattur chennai-600098 Tel: 044-26250739 Email: bwlmarketing@vsnl.net Mr P U K Menon Executive Director MATHER & PLATT INDIA LTD P B No 7 Chinchwad Pune 411 019 Tel: +91-20-7476196 to 98, 7477434 (D) Fax: +91-20-7462519 Email: matherpn@giaspn01.vsnl.net.in CERAMIC COATING RAVI Thermal Engineers Pvt. Ltd. No.11, 4th Cross, Central Excise Layout Vijaynagar Bangalore 560 047 Tel: 080 - 330 5794 Fax: 080 - 330 3964 CERAMIC FIBRE Minwool Rock Fibres Limited 204, Kings Apartments Juhu Tara Road Juhu Mumbai 400 049 Tel: 022-56154809 Fax: 022-56178921
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Ceramic Fibre products Mr.Mahesh Chavda Sales Manager Murugappa Morgan Thermal Ceramics Ltd Tiam House-Annexe Building-3rd Floor No.28 Rajaji Salai, Chennai-600001 Tel: 044-55224897,55272781 Fax: 044-55213709,55227093 Email: mahesh@ho.mmtcl.co.in CFL Mr Vinay Mahendru A-39, Hosiery Complex Indo Asian fuse gear ltd phase II extn Noida-201305 Tel: 0120-2568471, 2568093-98 Fax: 0120-2568473 Email: ecolite@indoasian.com Chillers Harshlal Suragne Er-Marketing Kirloskar Mcquay pvt ltd PB No 1239,Hadapsar industrial estate pune 411013 Tel: 020 6821502,03-06 Fax: 020-6821509 Email: kmlpune@vsnl.com CLEATED BELT CONVEYOR Kraft Engg. & Projects Ltd 189, Arcot Road, Vadapalani Chennai 600 026 Tel: 044 - 2484 5811 Fax: 044 - 2484 7838 coalesor Siemag Hi tech filters R k Industry house Walbhat Road Goregaon (E) Mumbai 400 063 Tel: 022-26851885, 3231 Fax: 022-26851048 Email: siemag@vsnl.com Cogeneration power plants based on waste heat Mr Pinaki Bhadury Senior Manager Thermax Limited Cogen Division Sai Chambers, 15 Mumbai-Pune Road Wakdewadi Pune 411003 Tel: 020-205511010 Fax: 020-205511042 COMPRESSED AIR SYSTEM MAINTENANCE Orchid Energy Systems 1141 B, Trichy Road Coimbatore 641 045 Tel: 0422 318389 Fax: 0422 312073 Compressed air systems Mr K.S. Natarajan Managing Director Trident Pneumatics Pvt Ltd. 5/232, K.N.G. Pudur Road Somayampalayam Post Coimbatore 641 108 Tel: 0422 2400492 Fax: 0422 2401376 Email: sales@tridentpneumatics.com Condenser Mr M Sreenivasan Chief Executive SUPER ENGINEERING COMPANY B - 1, Industrial Estate Ariamangalam Trichy 620 010 Tel: +91-431-2441131 Fax: +91-431-2441366 Cooling Tower Mr Raviselvan Managing Director Gem Cooling Towers Private Limited SF. No. 100/A Arasur Coimbatore 641407 Tel: 0422-2887059/2880129 Fax: 0422-2888247 Mr Vikram Swarup Managing Director Paharpur Cooling Towers Ltd. Paharpur House 8/1/B Diamond Harbour Road Kolkata 700027 Tel: 91-33-24792050 Fax: 91-33-24792188 Email: pctccu@paharpur.com Mr S Bansal Chief Executive Paltech Cooling Towers & Equipments Ltd. A-502 & 601 ANSAL CHAMBER - I BHIKAJI CAMA PLACE NEW DELHI 110066 Tel: 011-26108114 / 26174250 Fax: 91-11-26174250 Mr Pankaj Bhargava Managing Director Parag Fans & Cooling Systems Limited Plot no. 1/2b & 1b/3a Industrial Area no. 1 A.B. road Dewas 455 001 Tel: 07272-58135 / 58131 Fax: 91 - 7272 - 30273, 58850 Email: paragb@bom2.vsnl.net.in Cooling Tower water treatment Hercules Speciality Chemicals Ltd 5TH FLOOR, VAYUDNOOTH CHAMBERS 15/16, MAHATMA GANDHI ROAD BANGALORE 560001
Cooling water treatment chemicals Mr JayantRajvanshi Director Aqua Chemicals B-237A Road No. 6D V.K.I.Area Jaipur 302013 Tel: 0141-2331542,5061909 Fax: 0141-2331543 Email: JayantRajvanshi@aquachemicals.Com DC DRIVES Siemens Ltd. Motors, Drives & UPS Division Sector - 11, Plot 11 Kharghar Mode Navi Mumbai 410 208 Tel: 022 757 7030/ 31/ 32 Fax: 022 757 7106: DG sets Mr Mohan M Gujrar Managing Director Gurjar Power Engineers Pvt ltd no 18, Ist Floor,Corporation Building Residency Road Bangalore-560025 Tel: 080-2216416, 7469 Fax: 022-2216416 Email: gurjarmohan@yahoo.com Powerica Limited 115 Mittal Court B-Wing Nariman Point Mumbai 400021 Tel: 022-22825949
Mr Anand Kothaneth General Manager BATLIBOI ENGINEERS PVT LTD 99/2 & 99/3, N R Road Bangalore 560 002 Tel: +91-80-2235061 to 63 Fax: +91-80-2235085 Email: blr.batlico@axcess.net.in Diffuser Siemag Hi tech filters R k Industry house Walbhat Road Goregaon (E) Mumbai 400 063 Tel: 022-26851885, 3231 Fax: 022-26851048 Email: siemag@vsnl.com Dryers Mr A D Parekh General Manager HDO PROCESS EQUIPMENT AND SYSTEMS LTD 5/1/2, GIDC Industrial Estate Vatva Ahmedabad 382 445 Tel: +91-79-5830591 to 94 Fax: +91-79-5833286 Email: patfilt@ad1.vsnl.net.in ECONOMISERS Megatherm Engineers & Consultants Pvt.Ltd. 10, Kodambakkam High Road Chennai 600 034 Tel: 044 - 823 3528/ 3707 Fax: 044 - 825 8559 Mr B P Deboo Managing Partner ALBAJ ENGINEERING CORPORATION 340, Clover Centre Moledina Road Pune 411 001 Tel: +91-20-6131511, 6133018, 6121542 Fax: +91-20-6137255 Email: albaj@vsnl.com Eddy current control systems Dr. M. J. Davis Executive Director Eddy Current Controls (India) Limited Eddypuram, Chalakudy, District Thrissur Thrissur 680722 Tel: 0488-842882/716/698 Fax: 0488-842716 Efficiency enhancement coating for pumps Mr Rahul N Amin Chairman & Mg Director JYOTI LTD Industrial Area P O Chemical Industries Vadodara 390 003 Tel: +91-265-380633, 380627 Fax: +91-265-380671, 381871 Email: cmd.jyoti@sm3.sril.in
Mr Pradeep Mallick Managing Director WARTSILA INDIA LTD 76, Free Press House Nariman Point Mumbai 400 021 Tel: +91-22-2815601 / 5598, 28175995 / 5601 Fax: +91-22-2842083 Email: pradeep.mallick@wartsila.com Mr K C Dhingra Managing Director WESTERN INDIA MACHINERY CO PVT LTD Park Plaza North Block, 6E, 6th Floor 71, Park Street Kolkata 700 016 Tel: +91-33-22468913 / 9674 Fax: +91-33-22468914 Mr Sumit Mazumder Managing Director TIL LTD 1, Taratolla Road Garden Reach Kolkata 700 024 Tel: +91-33-24693732 to 36, Fax: +91-33-24692143 / 3731 Email: ug@tilindia.com Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
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Electrical Measuring Instruments Mr R R Dhoot Chairman IMP POWER LTD Advent, 7th Floor 12 - A, General J Bhosale Marg Nariman Point Mumbai 400 021 Tel: +91-22-2021890 / 886 / 697 Fax: +91-22-2026775 Email: contactus@imp-power.com Electronic ballasts Mr Shantilal patel Propreitor Nishan Power converters Krishna Vijay saw mill compound Opp S T stand, Agra Road Bhivandi-421302 Tel: 91-2522-257201 Fax: 91-2522-222032 Email: krishnas@vsnl.com Mr V Ramaraj Managing Partner OPAL NO 5, rajeswari street Mehta nagar chennai 600029 Tel: 044-23742036 / 1218 Fax: 044-23742036 / 1218 Email: opal@md2.vsnl.net.in
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Mr N C Tiwari Assistant General Manager, Product Development & Mangement Kirloskar Brothers Limited Ujjain Road Dewas-455001 Tel: 07272-27315 Fax: 07272-27347 Email: ntiwari@dws.kbl.co.in Energy management & Control systems Mr Lalit Seth Chief Executive HPL-SOCOMEC PVT LTD Atma Ram Mansion, 2nd Floor 1/21, Asaf Ali Road New Delhi 110 002 Tel: +91-11-23236811 / 4811 Fax: +91-11-23232639 Email: hpl@hplindia.com CMS ENERGY Management systems W 324, Rabale MIDC Mumbai 400701 Tel: 91-022-27696720,86 Fax: 91-022-27694585 Energy meters Mr Qimat Rai Gupta Chairman & Mg Director HAVELLS INDIA LTD 1, Raj Narain Marg Civil Lines Delhi 110 054 Tel: +91-11-23935237 to 40 Fax: +91-11-3921500, 3981100 Email: marketing@havells.com Mr Lalit Seth Chief Executive HPL-SOCOMEC PVT LTD Atma Ram Mansion, 2nd Floor 1/21, Asaf Ali Road New Delhi 110 002 Tel: +91-11-23236811 / 4811 Fax: +91-11-23232639 Email: hpl@hplindia.com Energy Recovery Ventilator (ERV), Mr. Rajnish Joshi Exe. Vice President Arctic India Engineering Pvt. Ltd. 20, Rajpur Road, New Delhi 110054 Tel: 011-22912800 Fax: 011-22915127, 2521754 Email: bryair@nda.vsnl.net.in Energy saver for air conditioners Dr V K Koshy Chairman & Mg Director BHARAT ELECTRONICS LTD Shankaranarayan Building, 2nd Floor 25, M G Road Bangalore 560 001 Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Tel: +91-80-5595729 Fax: +91-80-5584911 Email: imd@bel-india.com Energy saver for Lighting Mr R Sekar Chairman & Managing Director ES Electronics (India) Pvt Ltd 438,4th Main Road Nagendra Block,B.S.K.I Stage, Bangalore 560050 Tel: 080-6727836 / 8761 CLIPSAL Lighting India (P) Ltd Bajaj Niwas OpP. C.K.P. Club, 712 , Linking Road, Khar (W) Mumbai Tel: 022-56046483 Energy savers for AC Induction motors Santronix india pvt ltd unit no 12 Electronic sadan III MIDC, Bhosari Pune 411026 Tel: 020-7122758 Fax: 020-7129518 Email: satronix@bom3.vsnl.net.in Energy Saving Lighting Systems. Mr. Praveen Kumar Sood Managing Director Linear Technologies India Pvt. Ltd. K-37, Green Park, Main Basement, New Delhi 110016 Tel: 011-6854395, 6854946 Fax: 011-6854057 Energy Services Consultancy Mr P S Sankaranayaran Director Avant Garde Engineers & Consultants (p) Ltd. 68A Porur Kundarathur High road Porur Chennai 600 116 Tel: 044-24828717,18,19,22 Fax: 91-44-24828531 Email: avantgrade@vsnl.com Mr Nalin Kanshal Business Director Elpro energy Dimensions Pvt ltd 6,7,8 IV N Block Dr RajKumar Road, Rajaji Nagar entrance Bangalore-560010 Tel: 080-3122676,3123238,3132035,3132036 Fax: 080-3487396 Email: support@ecoenergycentre.com
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EVAPORATIVE CONDENSERS Baltimore Aircoil Company Inc. 122, Hema Industrial Estate Sarvodaya Nagar Jogeshwari (E) Mumbai 400 060 Tel: 5524 5714 Fax: 55245713 Email: swapan@bom5.vsnl.net.in Evaporative Cooling Pad (ECP) and Control Panel heat Extractor Mr. Rajnish Joshi Exe. Vice President Arctic India Engineering Pvt. Ltd. 20, Rajpur Road, New Delhi 110054 Tel: 011-2912800 Fax: 011-2915127, 2521754 Email: bryair@nda.vsnl.net.in Fans Mr A M Naik Mg Director & CEO LARSEN & TOUBRO LTD L & T House Ballard Estate Mumbai 400 001 Tel: +91-22-22618181 Fax: +91-22-22620223 Email: amn@lth.ltindia.com filters for Air Compressors Mr. Sanjay Joshi Managing Director Domnick Hunter India Pvt Limited B-214, ANSAL CHAMBER-I 3, BHIKAIJI CAMA PLACE NEW DELHI 110066 Tel: 11 261 92172 Fax: 011-26185279 Fluid Bed Dryer Mr Subodh S Nadkarni President & CEO SULZER INDIA LTD Sulzer House Baner Road, Aundh Pune 411 007 Tel: +91-20-5888991 / 98 Fax: +91-20-5886393 Email:comml.pune@sulzerind.sprintrpg.ems.vs nl.net.in Aerotherm Systems Pvt Ltd Plot no 1517 Phase III GIDC Vatwa Aheemedabad 382445 Tel: 079-5890158 Fax: 079-5834987 Email: vadherad1@sancharnet.in
Mr K C Patel General Manager Gujarat Perfect Engineering Ltd 301, Shailja Complex II, Akota Road Vadodara 390 020 Tel: +91-265-334861, 645786 Fax: +91-265-646880 Email: gperfect@icenet.net.in FRP BLADES Amalgamated Indl. Composites Pvt. Ltd. Unit No.111/112 Ashok Service Industrial Estate L B S Marg, Bhandup (West) Mumbai 400 078 Tel: 022-591 3591/04565, 534 6919 Fax: 022-591 3611, 5346920 Encon (India) 2 - B/17, Shivkripa N C Kelkar Road Dadar (West) Mumbai 400 028 Tel: 022 - 2437 2949, 24306578 Fax: 022 - 2431 0992, 24321929 Furnace Mr Saroj Poddar Chairman ALSTOM LTD 14th Floor, Pragati Devika Tower 6, Nehru Place New Delhi 110 019 Tel: +91-11-26449906, 6449907, 6449902 / 3 Fax: +91-11-26449447 Mr. Arun Gandhi Proprietor Crescent Engineering Corporation 49, H-32, Sector - 3, Rohini, New Delhi 110085 Tel: 011-27164109, 27276448 Fax: 011-27274553, 27162490 Mr Vilas H Patil Managing Director DYNAMIC FURNACES PVT LTD 65, Universal Industrial Estate I B Patel Road Goregaon (E) Mumbai 400 063 Tel: +91-22-58733516 Fax: +91-22-58733021 Email: tarsod@bom3.vsnl.net.in Mr R P Sood Managing Director ENCON FURNANCES PVT LTD 14/6, Mathura Road Faridabad 121 003 Tel: +91-129-274408, 275307 / 607 Fax: +91-129-276448
Mr C P Maheshwari Managing Director HC GIDDINGS PVT LTD 3, Chittaranjan Avenue Kolkata 700 013 Tel: +91-33-272820, 261740 Fax: +91-33-2372820, 2361740 Mr M Gopal Managing Director HIGHTEMP FURNACES LTD I - C, Phase II P B No 5809 Peenya Industrial Area Bangalore 560 058 Tel: +91-80-8395917 / 4076 / 1446 Fax: +91-80-8397798 / 2661 Email: hightemp@vsnl.com Mr M K Sen Managing Director INCORPORATED ENGINEERS LTD D - 400, Gayatri MIDC, Uran Phata Nerul Navi Mumbai 400 706 Tel: +91-22-57619352 Fax: +91-22-57619368 Email: idvl@bol.net.in Mr N Gopinath Managing Director FLUIDTHERM TECHNOLOGY PVT LTD SP - 132, III Main Road Ambattur Industrial Estate Chennai 600 058 Tel: +91-44-26357390, 26357391 Fax: +91-44-26257632 Email: fluidtherm@vsnl.com Harmoic analyser Neptune India ltd Neptune house C 270 SFS Sheikh sarai Phase I New delhi 110017 Tel: 011-26013367-70 Fax: 011-26013371 Email: neptune@del2.vsnl.net.in Mr Dilip Dharmasthal Managing Director Alacrity Electronics Limited Suresh Mahal, 12 - B Valmiki Street T Nagar Chennai 600 017 Tel: 044 - 2823 6620 Fax: 044 - 2825 9406 Avante Global services 225, Prakash Mohalla East of Kailash, New Delhi 110065 Tel: 011-26233259,26443097 Email: avante@eth.net
Mr. P Anil Kumar Managing Director TOWLER ENTERPRISE SOLUTIONS PVT.LTD HARMAN HOUSE 482, 80 FT ROAD, GANGANAGAR BANGALORE 160032 Tel: 080-3530033-36,3432289 Fax: 080-3431548 Mr Lalit Kumar Pahwa Managing Director HARMAN INNOVATIVE TECHNOLOGIES LTD Harman House 482, 80 FT Road Ganganagar Bangalore 560 032 Tel: +91-80-3530036 / 37 Fax: +91-80-3431548 Email: indo@harmanit.net.in harmonic filters Power Linkers 122,Nahar & seth estate chakala Mumbai 400099 Tel: 022-28325565, 28371902 Fax: 022-28386025 Email: powersys@vsnl.com Harmonic measurement and analysis Power Linkers 122,Nahar & seth estate chakala Mumbai 400099 Tel: 022-28325565, 28371902 Fax: 022-28386025 Email: powersys@vsnl.com Harmonic utility Equipments Mr Parag J Pandya CEO Amtech Electronics India ltd E - 6 GIDC Electronics Zone Gandhi Nagar Gandhi Nagar 382 028 Tel: 079 - 3225324/3227294/3227304 Fax: 079 - 3224611 Email: info@amtechelectronics.com Heat exchanger Mr M Sreenivasan Chief Executive SUPER ENGINEERING COMPANY B - 1, Industrial Estate Ariamangalam Trichy 620 010 Tel: +91-431-2441131 Fax: +91-431-2441366
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Mr Mohammed Meeran Proprietor AASIA RADIATORS P S C Bose Road Jawahar Autonagar Vijayawada 520 007 Tel: +91-0866-543881 Fax: +91-0866-545860 Mr Ajit Singh Chief Executive Officer AIRFRIGE INDUSTRIES 10/65, Kirti Nagar Industrial Area New Delhi 110 015 Tel: +91-11-55931909 / 72 Fax: +91-11-55436781 Email: afi@del3.vsnl.net.in Mr B P Deboo Managing Partner ALBAJ ENGINEERING CORPORATION 340, Clover Centre Moledina Road Pune 411 001 Tel: +91-20-6131511, 6133018, 6121542 Fax: +91-20-6137255 Email: albaj@vsnl.com Mr Deepak Singh Executive Director BUILDWORTH PVT LTD G S Road Dispur Guwahati 781 005 Tel: +91-361-560354 Fax: +91-361-561411 Email: bwpl@gwl.vsnl.net.in Mr Sucha Singh Managing Director COIL COMPANY PVT LTD A - 21/24, Naraina Industrial Area New Delhi 110 028 Tel: +91-11-55701967 / 1968 / 9127 Fax: +91-11-55709126 Email: coilco@nda.vsnl.net.in Er Ashok Kumar Gupta Chairman CRANE-BEL INTERNATIONAL Dev - Satya Bhavan C - 23, Lohia Nagar Ghaziabad 201 001 Tel: +91-120-4722994, 4716883, 4713281/82 Fax: +91-120-4712709, 4722995 Email: international@crane-bel.com Mr. Dinesh Harjai Partner Crupp Metals Kh. No. 56/1, Mundka, Rohtak Road, New Delhi 110041 Tel: 011-55189024, 55474133 Fax: 011-55183085 Mr B Pattabhiraman Managing Director GB Engineering Enterprises Pvt Ltd D - 99, Developed Plots Estate
Thuvakudi Trichy 620 015 Tel: +91-431-501111 (8 lines) Fax: +91-431-500311 Email: gbengg@tr.dot.net.in Mr K C Patel General Manager GUJARAT PERFECT ENGINEERING LTD 301, Shailja Complex II Akota Road Vadodara 390 020 Tel: +91-265-334861, 645786 Fax: +91-265-646880 Email: gperfect@icenet.net.in Mr C P Maheshwari Managing Director HC GIDDINGS PVT LTD 3, Chittaranjan Avenue Kolkata 700 013 Tel: +91-33-2272820, Fax: +91-33-22372820 Mr A D Parekh General Manager HDO PROCESS EQUIPMENT AND SYSTEMS LTD 5/1/2, GIDC Industrial Estate Vatva Ahmedabad 382 445 Tel: +91-79-5830591 to 94 Fax: +91-79-5833286 Email: patfilt@ad1.vsnl.net.in Mr B S Adishesh Wholetime Director IAEC INDUSTRIES MADRAS LTD Rajamangalam Villivakkam Chennai 600 049 Tel: +91-44 26257783 Fax: +91-44-24451537 Email: iaec.mds@elnet.ems.vsnl.net.in Mr M K Sen Managing Director INCORPORATED ENGINEERS LTD D - 400, Gayatri MIDC, Uran Phata Nerul Navi Mumbai 400 706 Tel: +91-22-57619352 Fax: +91-22-57619368 Email: idvl@bol.net.in Mr Ranjit Puri Chairman & Mg Director INDIAN SUGAR & GENERAL ENGINEERING CORPORATION (THE) A - 4, Sector 24 Noida 201 301 Tel: +91-118-4524071 / 72 Fax: +91-118-4528630, 4529215, 4542072 Email: rp@isgec.com
Mr S V Mehta Chairman & Director INDUSTRIAL MACHINERY MANUFACTURERS PVT LTD 3607 - 3609, GIDC Estate Phase IV Vatva Ahmedabad 382 445 Tel: +91-79-5831152 / 1449 Fax: +91-79-5832216 Email: sysadmin@immpl.xeeahm.xeemail.com Mr L Chandrashekar Managing Partner MYSORE ENGINEERING ENTERPRISES No 169, Industrial Suburb II Stage P B No 5859, Peenya Post Bangalore 560 058 Tel: +91-80-8394423 Fax: +91-80-3349746 Email: keeebgl@vsnl.net.in Mr V David Selvaraj Vice President (Operations) PARANI STEELS PVT LTD AL - 84, 4th Street 11th Main Road Anna Nagar Chennai 600 040 Tel: +91-44-26286285 / 2246 / 2247 Fax: +91-44-26211265 Mr Ramesh Wadhwani Managing Director UNITOP ENGINEERS PVT LTD 78/1, GIDC Industrial Estate P O Box No 761 Makarpura Vadodara 390 010 Tel: +91-265-642161 / 62 Fax: +91-265-644698 Email: unitop@unitopengrs.com Mr Chakor L Doshi Chairman WALCHANDNAGAR INDUSTRIES LTD 3, Walchand Terraces Opp Air Conditioned Market Tardeo Mumbai 400 034 Tel: +91-22-54939498, 54934800 Fax: +91-22-54936655 Mr Pashupati Nath Kapoor Partner KASHI INDUSTRIES 16/80, B 1 Civil Lines Kanpur 208 001 Tel: +91-512-311395, 319074 Fax: +91-512-319074 Mr Roy Eapen Proprietor HEAT TRANSFER DEVELOPMENT 84 - C, Jeevan Complex 5th Cross, 100 Feet Road Gandhipuram Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Coimbatore 641 012 Tel: +91-422-2858271 / 2 Fax: +91-422-2447341 Mr J Peter Arokiam Managing Director Manikam Radiators Pvt Ltd 11/275 - B, Subramaniapalayam K N G Pundur Road G N Mills Post Coimbatore 641 029 Tel: +91-422-2843311 / 12 Fax: +91-422-2843311 Email: mrad@md4.vsnl.net.in Heat recovery boilers Mr K G Ramachandran Chairman & Mg Director BHARAT HEAVY ELECTRICALS LTD BHEL House Siri Fort New Delhi 110 049 Tel: +91-11-26001010 Fax: +91-11-26493021, 26492534 Heat Recovery Wheel (HRW) Mr. Rajnish Joshi Exe. Vice President Arctic India Engineering Pvt. Ltd. 20, Rajpur Road, New Delhi 110054 Tel: 011-2912800 Fax: 011-2915127, 2521754 Email: bryair@nda.vsnl.net.in Mr R N Bakshi Managing Director UNITHERM ENGINEERS LTD 101, Laxmi Market, 1st Floor Vartak Nagar Junction, Pokhran Road No 1 Mumbai 400 606 Tel: +91-22-55406131 Fax: +91-22-55406569 Email: unitherm@vsnl.com Mr. S. R. Babbar Partner Wellmake Engineering Company A-28,Mangolpuri Indl. Area, Phase-II, New Delhi 110034 Tel: 011-27018199, 27025409 Fax: 011-27019330 Mr. Liakat Ali Proprietor Premier Electric Company Plot No.7, 12/2 Mathura Road, Faridabad 121002 Tel: 0129-270858, 274311 Fax: 0129-270858
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High Efficiency Electric Transformers Mr. Liakat Ali Proprietor Premier Electric Company Plot No.7, 12/2 Mathura Road, Faridabad 121002 Tel: 0129-270858, 274311 Fax: 0129-270858 Mr. T. V. Joseph General Manager Transformers and Electricals Kerela Ltd.(TELK) Angamaly P.O. 683573, Angamaly 683573 Tel: 04856-452251 Fax: 04856-452873 High efficiency power distribution & special Transformers. Mr. Nitin Nayak Director El -Tra Equipment Company (India) Pvt. Ltd. 11th Mile, Old Madras Road, Avalahalli, P.O. Virgonagar, Bangalore 560049 Tel: 080-8510652, 8472229 Fax: 080-8510652 Email: eltrablr@hotmail.com High Efficiency Pumps Sulzer Pumps India Ltd No.9, MIDC, Thane Belapur Road Dingha, Navi Mumbai 400 708 Tel: +91 22 5790 4321 Fax: +91 22 5790 4306 Email: sulpump@vsni.com HT capacitors, Furnace duty capacitors Mr. M.D. Killedar Manager (Works) Goa Capacitors Pvt. Ltd. 14, Corlim Industrial Estate, Corlim, Ilhas, Panaji 403110 Tel: 0832-286176/240 Fax: 0832-286203 Humidifiers Mr S V Mehta Chairman & Director INDUSTRIAL MACHINERY MANUFACTURERS PVT LTD 3607 - 3609, GIDC Estate Phase IV, Vatva Ahmedabad 382 445 Tel: +91-79-5831152 / 1449 Fax: +91-79-5832216 Email:sysadmin@immpl.xeeahm.xeemail.com HVAC Mr. Sandeep Saxena Manager Capital Enterprise 36 Industrial Estate MLN Regional Engineering College Allahabad 211002 Tel: 545362 Fax: 461775 Email: mall@vsnl.com Incinerators Mr S M Jain Vice President ADOR TECHNOLOGIES LTD Plot No 53, 54 & 55 F - II Block, MIDC Area, pimpri Pune 411 018 Tel: +91-20-7470225, 7476009 Fax: +91-20-7470224 / 7358 Email: info@ador-technologies.com Mr U V Rao Director ALLIED CONSULTING ENGINEERS PVT LTD Allied House Road No 1, chembur Mumbai 400 071 Tel: +91-22-55284028 Fax: +91-22-55283805 Email: ace@bom3.vsnl.net.in Mr M K Sen Managing Director INCORPORATED ENGINEERS LTD D - 400, Gayatri MIDC, Uran Phata Nerul Navi Mumbai 400 706 Tel: +91-22-57619352 Fax: +91-22-57619368 Email: idvl@bol.net.in Induction heaters Inventum engineering company P O box 9435 Andheri (E) Mumbai 400093 Tel: 022-26730499/ 590 Fax: 022-26730887 Email: inventun@vsnl.net.in Industrial Ceramics Mr N Anjiah Managing Partner Annapurna Annapurna Technical ceramics 21-118 Kakani Nagar Vizag 534007 Email: atceramics@hotmail.com
Industrial furnaces Mr U V Rao Director Allied Consulting Engineers Pvt Ltd Allied House Road No 1, chembur Mumbai 400 071 Tel: +91-22-55284028 Fax: +91-22-55283805 Email: ace@bom3.vsnl.net.in Mr Anup Dasgupta Director FIRE GASES & KILN (INDIA) PVT LTD 156, Jodhpur Park Kolkata 700 068 Tel: +91-33-4730164 / 1289, 4728391 / 2 Fax: +91-33-4731540 Mr S L Mathur Managing Director STEIN HEURTEY INDIA PROJECTS PVT LTD 8/1, Middleton Row Kolkata 700 071 Tel: +91-33-2260194, 2457484 / 89 Fax: +91-33-2443636, 2476655 Email: shipp@cal.vsnl.net.in Mr R K Agrawal Chief Executive Officer Eastern Equipment & Engineers S - 14, Civil Township Rourkela 769 004 Tel: +91-61-502508, 503898 Fax: +91-61-503898 Email: sanghi@cal2.vsnl.net.in Aero therm systems pvt ltd Plot no 1517 Phase III GIDC Vatwa Aheemedabad 382445 Tel: 079-5890158 Fax: 079-5834987 Email: vadherad1@sancharnet.in Instrumentation control systems Mr M L Anand Chairman ANAND CONTROL SYSTEMS PVT LTD D - 67/68, Sector VI Noida 201 301 Tel: +91-118-4537395, 4554627 Fax: +91-118-4533782 Email: anandpwr@nda.vsnl.net.in Fisher Rosemount (India) Limited D Wing, 2nd Floor Modern Mills Compound Mahalaxmi Mumbai 400 011 Tel: 91 22) 462 0462 Fax: (91 22) 462 0500 Libratherm Instruments 402, Diamond Industrial Estate Ketki pada Road Dahisar East Mumbai 400068 Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Tel: 022-28960659 Fax: 022-28963823 Email: libratherm@vsnl.com Mr. Prem Dua Director Puneet Industrial Controls Pvt. Ltd. 45 Community Centre, East of Kailash, New Delhi 110065 Tel: 011-26423328, 26419479 Fax: 011-26423328 Mr P S Sridharan Managing Director MEGATECH CONTROL PVT LTD Alsha Complex 51, 1st Main Road Gandhi Nagar Chennai 600 020 Tel: +91-44-24996733 / 5654 Fax: +91-44-24341668, 4996215 Email: megatech@md2.vsnl.net.in Mr A N Sen Managing Director AN INSTRUMENTS PVT LTD 59 - B, Chowringhee Road 5th Floor Kolkata 700 020 Tel: +91-33-2402222, 2472509 Fax: +91-33-2806684 Email: ani@cal.vsnl.net.in Insulation Lloyds Insulation 386, Veer Savarkar Marg Mumbai 400 025 Tel: 022-54340876 Fax: 022-54376858 Intermediate controller for compressed air Mr Kiran C pande Manager-Compressed air management solutions Godrej & boyce manufacturing company ltd Pirojshanagar, Vikhroli Mumbai-400079 Tel: 022-55962251-56 Fax: 022-55961525 Email: hnd@godrej.com Inverter welding Tejas Enterprises C/5/72 Sahyadri Nagar Charakop, Kandivili West Mumbai 200067 Tel: 022-2867869 Email: sillweld@yahoo.co.in
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OIL FIRED THERMOPAC/AQUATHERM SYSTEM Thermax Limited Thermal Engg. Division Chinchwad Pune 411 019 Tel: 020 - 775 941 to 49 Fax: 020 - 775 907 Oil/gas burners,
Power control equipments, Mr A Sarkar Vice President SCHNEIDER ELECTRIC INDIA LTD 58, MIDC Area, Satpur Nashik 422 007 Tel: +91-253-350394 / 95 / 96 Fax: +91-253-350771 Email: asarkar@pobox.com Power factor compensation
Mr. Dinesh Harjai Partner Crupp Metals Kh. No. 56/1, Mundka, Rohtak Road, New Delhi 110041 Tel: 011-5189024, 5474133 Fax: 011-5183085 Ovens Mr N Gopinath Managing Director FLUIDTHERM TECHNOLOGY PVT LTD SP - 132, III Main Road Ambattur Industrial Estate Chennai 600 058 Tel: +91-44-26357390, 26357391 Fax: +91-44-26257632 Email: fluidtherm@vsnl.com Mr M Gopal Managing Director HIGHTEMP FURNACES LTD I - C, Phase II, P B No 5809 Peenya Industrial Area Bangalore 560 058 Tel: +91-80-8395917 / 4076 / 1446 Fax: +91-80-8397798 / 2661 Email: hightemp@vsnl.com Plate & spiral heat exchangers,dryers & evaporators Mr Satish Tandon Managing Director ALFA LAVAL (INDIA) LTD Mumbai Pune Road Dapodi Pune 411 012 Tel: +91-0212-27127721 Fax: +91-02121-2797711 Email: satish.tandon@alfalaval.com Power Consultants Mr D B Arora Managing Director Acon Power consultants 45, Satyanand Vihar Rampur Jabalpur-482008 Tel: 91-0761-2667261, 9826246688 Fax: 91-0761-2664207 Email: acon@sancharnetin
Neptune India ltd Neptune house C 270 SFS Sheikh sarai, Phase I New Delhi 110017 Tel: 011-6013367-70 Fax: 011-6013371 Email: neptune@del2.vsnl.net.in Power Factor controller CMS ENERGY Management systems W 324, Rabale MIDC Mumbai 400701 Tel: 91-022-27696720,86 Fax: 91-022-27694585 Mr. R. K. Iyer Vice President Saha Sprague Limited No.805, North Rear Wing, 8th Floor, Manipal Centre, 47, Dickenson Road, Bangalore 560042 Tel: 080-5595463, 5595266 Fax: 080-5595463 Pumps Mr D K Hohenstein Chief Executive Officer KSB PUMPS LTD Mumbai Pune Road P O Pimpri Pune 411 018 Tel: +91-20-7472006, 7473684 Fax: +91-20-7476120 Email: hohensteindk@ksb.co.in Mr K C Dhingra Managing Director Western India machinery co pvt Ltd Park Plaza North Block, 6E, 6th Floor 71, Park Street Kolkata 700 016 Tel: +91-33-2468913 / 9674 Fax: +91-33-2468914 Radiant heater Mr. Ashok Tanna Managing Director Vinosha Boilers Pvt. Ltd. And Taurus Heat Systems Baarat House, Ist Floor, 104, Apollo Street, Fort, Mumbai 400001 Tel: 022-22674590 Fax: 022-22611515
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
List of Suppliers
RADIANT TUBE RECUPERATIVE HEATER Mr U V Rao Director ALLIED CONSULTING ENGINEERS PVT LTD Allied House Road No 1, chembur Mumbai 400 071 Tel: +91-22-55284028 Fax: +91-22-5283805 Email: ace@bom3.vsnl.net.in Reactive compensator Emco Electronics 106, Industrial area Sion (East) Mumbai 400022 Tel: 022-224096731/782 Fax: 022-24096039 Reactive power compensation Equipment and systems Mr. S. M. Subba Rao Adviser Meher Capacitors (P) Ltd. 52/1, Basappa Road, Shantinagar, Bangalore 560027 Tel: 080-2236879, 2241272 Fax: 080-2225325 Reactors Mr Ranjit Puri Chairman & Mg Director INDIAN SUGAR & GENERAL ENGINEERING CORPORATION (THE) A - 4, Sector 24 Noida 201 301 Tel: +91-118-4524071 / 72 Fax: +91-118-4528630, 4529215, 4542072 Email: rp@isgec.com Reciprocating & centrifugal pumps Mr Hemant Didwania Director INDIAN COMPRESSORS LTD 33, Okhla Industrial Estate New Delhi 110 020 Tel: +91-11-6839440 / 9, 635030 Fax: +91-11-6840020 Recuperators Mr R K Agrawal Chief Executive Officer EASTERN EQUIPMENT & ENGINEERS S - 14, Civil Township Rourkela 769 004 Tel: +91-61-502508, 503898 Fax: +91-61-503898 Email: sanghi@cal2.vsnl.net.in AQUAMEAS (Danfoss) Commerce avenue, 3rd floor, Mahaganesh SOC., Paud Road Pune 411 038 Tel: +020 544 9767, 544 9757 Fax: +020 542 0401 Email: aquameas@vsnl.net Eureka Industrial Equipments Pvt. Ltd. Royal Chambers, Paud Road, Pune 411038 Tel: 91 20 5443079 / 4004535/ 4004554 Fax: 91 20 5441323 Fitzer Instruments (India) Pvt. Ltd. Near Ambivli Station (W) P.O. Mohone Thane 421 102 Tel: 0251 2271321 Fax: 0251 2271336 Email: fitzer@bom7.vsnl.net.in Mr Madhukar Sinha Managing Director Associated Plates & Vessels Pvt Ltd 1/A 14, 15 & C - 17, Industrial Area Bokaro Steel City, Bokaro 827 104 Tel: +91-6542-51034, 51434 Fax: +91-6542-51334 Email: apvpl@dte.vsnl.net.in, msinha32@hotmail.com Rotometers Refractories TATANAGAR REFRACTORIES & MINERALS CO LTD Chamber Bhawan Bistupur Jamshedpur 831 001 Tel: +91-657-427187, 435039, 428044 Fax: +91-657-428044 Mr K S Swaminathan Mg Director & Vice Chairman Tata Refractories Ltd P O Belapur Jharsuguda 768 218 Tel: +91-6645-50260 Fax: +91-6645-50243 Daka Monolitics Pvt. Ltd. 32-B, Samachar Marg Opp. Allahabad Bank Mumbai 400 023 Tel: 044 - 2265 4837 Refrigeration Dryers. Mr. Rajnish Joshi Exe. Vice President Delair India Pvt. Ltd. 20, Rajpur Road, New Delhi 110054 Tel: 011-22912800 Fax: 011-22915127 Email: bryair@nda.vsnl.net.in Rotary kilns
Separator and other oil & gas processing equipments Mr A D Parekh General Manager Hdo Process Equipment And Systems Ltd 5/1/2, GIDC Industrial Estate Vatva Ahmedabad 382 445 Tel: +91-79-5830591 to 94 Fax: +91-79-5833286 Email: patfilt@ad1.vsnl.net.in Servo voltage stabiliser Green Dot electric corporation G 9, Hem Kunt Tower 98, Nehru Place, New delhi 100019 Tel: 011-26416395 Fax: 011-26222088 Email: greendotindia@hotmail.com Soft starter Excellent Industrial Instruments 1/63, Type E Sidco Nagar Villivakkam Chennai 600049 Tel: 044-26172977 Fax: 044-26172531 Mr. K. W. Kekane Director Sales Minilec Marketing Services Pvt. Ltd. S.No. 1073/1-2-3, At. Post. Pirancoot, Tal. Mulshi, Pune 412111 Tel: 02139-22162, 22354 to 57 Fax: 02139-22134, 22180 Mr Ranjan Kumar De Country Manager ALLEN BRADLEY INDIA LTD C - 11, Industrial Area Site IV,shahiabad Ghaziabad 201 010 Tel: +91-120-471112 / 0103 / 0105 / 0164 Fax: +91-120-4770822 Email: msseshadri@ra.rockwell.com, rnm@raabil.com Soot Blower with Industrial Boilers Mr. R. Rajshekhar Managing Director R R Techno Mechanicals (P) Ltd. 94, Thiru Vi Ka Industrial Estate, Guindy, Chennai 600032 Tel: 044-22346693 Fax: 044-24918183, 22333204 Sound proof gensets Mr R N Khanna Managing Director CONTROLS & SWITCHGEAR CO LTD 222, Okhla Industtrial Estate New Delhi 110 020 Tel: +91-11-6918834 to 37, 6836170 / 020 Fax: +91-11-6848241 / 7342 / 8245 Email: cs222@giasdl01.vsnl.net.in Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Speciality Refrigerants/Propellants K.Ganesh Marketing manager (South Asia) Regional Segment Manager Dupont Flurochemicals E.I.DuPont India Ltd Arihant Nitco Park,^th Floor 90,Dr.Radha Krishnan Road Mylapore chennai 600004 Tel: 044-28472800,28473752(D) Fax: 044-28473800 Email: k.ganesh@ind.dupont.com Split air conditioner Mr Brij Raj Punj Chairman Lloyd Electric & Engineering Ltd M - 13A, Punj House Connaught Place New Delhi 110 001 Tel: +91-11-23329091 to 98 Fax: +91-11-23326107 Email: lloyd@giasdl01.vsnl.net.in Star -delta-star converter Mr M Vijayasarathy Managing Director Vijay Energy Products Pvt Ltd S P - 75, Ambattur Industrial Estate Chennai 600 058 Tel: +91-44-26254326, 26256883 Fax: +91-44-28282906, 26255185 Email: vijayenergy@eth.net Ambetronics 4B Pushotam Girgaon Near Dream Land Cinema Mumbai 400004 Tel: 022-28371143 Excellent Industrial Instruments 1/63, Type E, Sidco Nagar Villivakkam Chennai 600049 Tel: 044-26172977 Fax: 044-26172531 Steam jet ejectors Forbes Marshall PB No 29, Mumbai-Pune road Kasarwadi Pune 411034 Tel: 91-0212-21279445 Fax: 91-0212-797413 Mazda Controls Ltd MAZDA HOUSE ANCHWATI 2ND LANE, AMBAWADI AHMEDABAD 380006 Tel: 79 6431151 Fax: 79 6565605 STEAM TRAP MONITOR Spirax Marshall Limited P B No.29, Mumbai-Pune Road Kasarwadi,Pune 411 034 Tel: 020 - 794 495 Fax: 020 - 797 593/ 413
List of Suppliers
Steel tubes for boilers Tube Products of India Post Box No. 4, Avadi Chennai 600 054 Tel: 91 44 26384040 Fax: 91 44 26384051 Email: SatianathP@murugappa.co.in Superheater & Economiser Mr Ranjit Puri Chairman & Mg Director INDIAN SUGAR & GENERAL ENGINEERING CORPORATION (THE) A - 4, Sector 24 Noida 201 301 Tel: +91-118-4524071 / 72 Fax: +91-118-4528630, 4529215, 4542072 Email: rp@isgec.com SYNTHETIC FLAT BELTS Elgi Ultra Industries Ltd. Elgi House, Trichy Road Ramanathapuram Coimbatore 641 045 Tel: 0422 2304141 Fax: 0422 - 2311 740 Habasit Iakoka Pvt. Ltd. C - 207, Kailas Esplanade Opp. Shreyas Cinema L B S Marg, Ghatkopar Mumbai 400 086 Tel: 022 - 5500 2464 Fax: 022 - 5500 2466 NTB group NTB House, A-302 Road No.32, Wagle Estate, Thane 400 604 Tel: (091)-22-55822118,55821582 Fax: 55810056, 55823778 NTB International ltd A 302, Road no 32 Wagle estate Thane 400604 Tel: 022-25821582, 25822118 Fax: 022-25810056 Email: ntbgroup@vsnl.com Systems engineering for captive power Generation Mr D R Dhingra Managing Director Continental Generators Pvt Ltd 3869, Behind Primary School, G B Road Delhi 110 006 Tel: +91-11-7535566 to 68, 525632 Fax: +91-11-7516598, 528510 Vaccum Pumps Kakati Karshak Industries Pvt. Ltd Nacharam Industrial Area Hyderabad 500 076 Tel: 91-40-7153104/05 Fax: 91-040-7171980 Email: cvrao@hd1.vsnl.net.in Nash vaccum pumps 67 UPS, Kaggadaspura Extension Guru Layout Bangalore Tel: (+91) 80 - 521 49 38 Fax: (+91) 80 - 528 43 37 Email: nashwater@mantraonline.com PPI PUMPS PVT LTD 4/2 PHASE 1 G I D C VATWA AHMEDABAD 382445 Tel: 079-5832273/4 / 5835698 Fax: 079-5830578 Variable Drives, Mr. Liakat Ali Proprietor Premier Electric Company Plot No.7, 12/2 Mathura Road, Faridabad 121002 Tel: 0129-270858, 274311 Fax: 0129-270858 Variable fluid couplings Mr Praveen Sachdev Mg Director & CEO GREAVES LTD 1, Dr V B Gandhi Marg P O Box 91 Mumbai 400 001 Tel: +91-22-2671524 / 4913 Fax: +91-22-2677850, 2652853 Variable Frequency Drive Mr Ramnath S Mani Managing Director Control Techniques India Limited 117/B, Developed Plot Industrial Estate Perungudi Chennai 600 096 Tel: 044-24961123 / 1130 / 1083 Mr. Balagopal Managing Director Dynaspede Integrated Systems (P) Limited 136-A Sipcot Industrial Complex Hosur 635126 Tel: 91-4344 - 2276915, 2276813 Fax: 91-4344 - 2276841 TEMPERATURE INDICATOR CONTROLLER (TIC) Ensave Systems Private Limited 3, Anand Shopping Center Second Floor, Bhattha, Paldi Ahmedabad 380 007 Tel: . 079 662 1116 Fax: 079 663 7907
List of Energy Auditors V. Shanmugavel & Associates, [Indian Institute Of Research], 63, Rangnathan St.,T-Nagar, Chennai-17. Ph.044-24342756, 24336529, 24327447. Fax.044-24327447. E-Mail:shan@giasmd01.vsnl.net.in U V Krishna Mohan Rao Associates (UVKA) 62 Muthuvel Naicker Street, Kodambakkam Chennai 600 024 Telephone : 044 2483 2859 Telefax : 044 2484 4172 email : uvkrao@vsnl.net TV Sddeutschland India Private Limited, 321, Solitaire Corporate Park, Bldg. NO. 3 2ND Floor, Chakala, Andheri (EAST), Mumbai - 400 093 Tel.: 022 - 5692 3415 / 16 Fax: 022-5692 3418 E-mail: tuvbombay@tuvindia.com Website www.tuvindia.com The Energy and Resources Institute (TERI), Darbari Seth Block, India Habitat Centre, Lodhi Road, New Delhi - 110 003 Tel: 91-11-24682100/2111 Fax: 91-11-24682144/2145 Email: mailbox@teri.res.in Thapar Centre for Industrial Research & Development Bhadson Road Patialal 147004 Fax: 01752364012/2365522 Tel: 0175-2365510/2393605 director@thaparesearch.org roy@thaparresearch.org Tensor Consulting Engineers (Chennai) Pvt.Ltd., Flat No.20, Mahalaxmi Apartments, #1, 4th Street,Nandanam Extension, Chennai 600 035. Ph.: 044-24320426, TeleFax : 044-24320596 E-mail : tce@md4.vsnl.net.in SEE-Tech Solutions Pvt. Ltd., 11/5, Letsconserve, MIDC Infotech Park, Behind Infotech Tower, South Ambazari Road, Nagpur - 440022. Tel: 0712-2222177 Fax: 2225293
Building, Cement, Ceramics, Chemicals, Confectinery, Dairy, Engineering, Food & Beverages, Paperboards, Printing & Packaging, Pulp & Paper, Sugar, Textile,Tyres & Rubber products
Agro & Food, Buildings, Cement, Engineering, Automobile, Leather, Steel, Oil & Gas, Paper, Chemical, Pharmaceutical, Rubber, Textile, Sugar & Glass
Alluminium; Fertilizers; Iron & Steel; Cement; Chemicals, Pulp & paper; Sugar; Textile; Chlor Alkali; Petro Chemicals; Power plants; Port Trust, Buildings & Hotels; Engineering, Electrical Distribution Companies
Pump & Paper, Textile, Transport Sectors (Industries & Services), Chemical, Iron & Steel
Iron & Steel, Aluminium, Cement, Petrochemical, Textile, Pulp & Paper, Chemical, Buildings, Fertilizer, ChlorAlkali,
Email: seemil_ngp@sancharnet.in Synergy Management Services BD-62, SEC - I, Salt Lake City Kolkata - 700 064 PH : 033- 23342663 FAX : 033- 23376290 EMAIL : mm_ghosh@hotmail.com Saket Projects Limited Saket House, Panchsheel, Usmanpura, Ahmedabad - 380 013. Tel. No. : 079-27551817, 27551931, 27552873 Fax No. : 079-27550452 E-mail : mail@saketprojects.com M/S Rayon Applied Engineers 117/1,Gupta Compound, Pipliapala A.B. Road Indore-450017 (M.P.) PH- 0731-2440637FAX NO.-07312475281 E-MAIL- rayon_engg@rediffmail.com National Thermal Power Corporation Ltd. Scope Complex, Institutional Area, Lodhi Road New Delhi.
a) Iron & Steel b) Metallurgical c) Chemical d) Thermal Power Station e) Textile f) Cable manufacturing g) Tea Industry
Gas & Petrolium, Chemicals, Fertilizers, Textiles, Dairy, Infrastructures, Soap & Detergent, Commercials
1. Cement Industries 2. Automobile Industries 3. Textile Industries 4. Fertilizers Industries 5. Engineering Industries 6. Steel Industries 7. Food Products Industries 8. Oil Industries
Sectors- Power Generation (Coal fired & Gas fired combined cycle Power Plants)
Kirloskar Consultants Limited 13-A, Kirloskar Kisan Compound Karve Road, Kothrud PUNE - 411 038
Iron and Steel, Cement, Chlor Alkali, Textile, Chemicals, Port Trust, Commercial Buildings and Establishments, Engineering Units, Foundry, Pharmaceuticals, Automobile, Pumping Systems, Oil & Vegetable Manufacturing, Pump Manufacturing, Compressor Manufacturing, Software Units, Co-generation Textiles, Fertilizers,Engineering, Chemical, Aluminium, Forging, Food, Steel, Hospitals, Commecial Buildings, Pumping Stations, Automobiles.
Northern India Textile Research Association Sector 23, Raj Nagar Ghaziabad (UP)- 201 002 PH: 0120-2783586, 2783592, 2783638 FAX: 0120-2783596 E-Mail: nitra@nde.vsnl.net.in M K Raju Consultants Private Limited 16, Srinagar Colony Temple Avenue, Chennai - 15 Tele No. 2235 1151 Fax No. 2235 1070 Email: admin@mkrajuconsultants.com Mitcon Consultancy Services Ltd. Kubera Chambers, Shivajinagar, Pune - 411 005, Maharashtra Ph: 91-020 - 2553 3309 / 2553 4322 Fax : 020 - 2553 3206 E-mail:
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
All
1) Textile 2) Chemicals / Pharmaceuticals / Petrochemicals 3) Foundry 4) Engineering 5) Plastics 6) Hotels & Commercial Establishments 7) Paper 8) Water Works 9) Food 10) Rubber & Tyre 11) Plywood 12)Explosives Refinery
List of Energy Auditors deepakzade@indiatimes.com deepakzade2003@yahoo.com Homepage: www.mitconindia.com Maruti Consultants 195, O.U.Teacher's colony, Sainikpuri, Hyderabad 500094, Tel:040-27111021, 040-27110755, FaxNo: 040-27111021, e-mail:ivrkumar_hyd@dataone.in Mecon Limited, P.O. Doranda, Ranchi 834002, Jharkhand Ernst & Young Pvt., Ltd., Ernst & Young Tower, B-26, Qutab, Institutional Area, New Delhi 110 016 Escon Tech 611, Milstone Building, Drive In Road, Nr. Drive In Cinema, Ahmedabad 380054 Ph No. : 079-27495745 Fax No. 079-25454945 E-mail : rkescon@yahoo.com ESCO Electronics Pvt. Ltd. 1030 A, 20th Main, 5th Block, Rajajinagar, Bangalore - 560010 Ph : 91 - 80 - 23352485, Fax.91-80-23352488 email : escoelc@vsnl.net escoelec@yahoo.com
Process, Textiles, Engineering, Vegetable Oils, Ceramics,Cement, Food Products and Consumer Goods, PlasticsPaper Chemicals
I) Iron & Steel ii) Non-ferrous iii) Mining iv) Power v) Energy vi) Refinery Chemical, Fertilizers,Cement, Process, Distillery, Glass, Ceramics, Polyester Film, Steel, Building, Water Utility (Municipal Development Authority), Refractories
1) Utility Distribution System 2) Forging & Auto ancillaries 3) Sugar Mills 4) General Industries & Software park 5) Building Complexes, Hotels ,hospitals and large buildings. (Govt buildings). (i) Iron & steel (ii) Textiles (iii) Synthetics & chemicals (iv) Captive Power Plant (v) Heavy Engg. Industries (vi) Commercial Buildings (vii) Food Products (viii) Mining (ix) Distillery (x) Sugar. (xi) Refractory (xii) Auto Mobiles (xiii) Glass Industries Pharmaceutical, Petroleum and petrochemicals, Battery, Power Plant, Foundry, Sugar, Cement, Iron and steel, Power generation and distribution, Tobacco, Electroplating, Municipal water pumping and street lighting. Thermal Power Plants Milk Plants Textile Industries Auto & Paint Industries
Energy Audit Services 1116, Sector, - 17, Faridabad 121002. Tel: (0129)-2282132, 2284125 Mobile: 9811229516, 9811627972. Fax: (0129) 2262576 E- mail: <sinhaeas@ndb.vsnl.net.in>
Energy Economy & Environmental Consultants 506, 15th Cross, Indiranagar 2nd Stage, Bangalore-560038 Tel: (080) 25213986-89 Fax: 91-80-25259172 e-m: eeec@vsnl.com Energo Engineering Projects Pvt. Ltd. A-57/4, Okhla Industrial Area, PhaseII, New Delhi 110 020
Tel : 91-11-2638 5323 / 28 / 29 / 38 Fax : 91-11-2638 5333 E-Mail : energo@del3.vsnl.net.in Elpro Energy Dimensions Pvt Ltd 6,7,8 Dr. Rajkumar Road, Rajajinagar IV N Block, Rajajinagar Entrance, Bangalore - 560 010 Ph:08023123238,23122676 Fax:080-23487396 Email:support@ecoenergycentre.com Electrical Research And Development Association ERDA Road, Makarpura Industrial Estate Vadodara-390 010, Gujarat Ph: 2642 942/2642 964/2642 377/2642 557 Fax: 0265-2638 382 E-mail: erda@erda.org Website: http//www.erda.org Energetic Consulting Pvt. Ltd. (Earlier Concept Consultants) 3, Vishwagiri, Vishnunagar, Baji Prabhu Deshpande Rd, Naupada, Thane (W) 400 602 Telephone : +91 22 2544 7011 Telefax : +91 22 2537 0444 email : rucc@vsnl.net DSCL Energy Services Company Ltd, II Floor, Kanchenjunga, 18, Barakhambha Road, New Delhi 110 001 Tel: 0091 11 23316801 Fax: 0091 11 23319062 e-mail:dscpower@vsnl.com M/s Dinesh Rathi & Associates, 6, Tatya Tope Nagar, West High Court Road, Nagpur - 440 015 [M.S.] Ph. : 0712-2225566, 2241911/21-22, Fax : 0712-2241912, mail : drathi_ngp@sancharnet.in; drangp_ngp@sancharnet.in : dranagpur@yahoo.co.in Descon Limited, Centre for Excellence Block - EP, Plot - X1,2 & 3, Sector - V, Salt Lake City, Kolkata - 700091, Ph No -033 - 23577015, 23574308 10, Fax No. -033 23573578, E - mail - info@desconsoft.com Devki Energy Consultancy Pvt. Ltd. 405, Ivory Terrace, R.C. Dutt Road, Vadodara-390007 Tel: 0265-2354813/2330636
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Aluminium Fertilizer Iron & Steel Pulp & Paper Chloro-Alkali Textile Chemicals Petrochemicals Gas Cracker Thermal Power Stations Commercial Buildings
Paper, Sugar, Tea,Cement,Textile,Chemical,Distelleries, Glass,Dairy, steel, rice mills, Automobiles, edible oil, food processing, engineering, hospitals and Commercial Buildings
1] Cement, 2] Alluminium, 3] Iron & Steel, 4] Chemical, 5] Water, 6] Foods, 7] Textile & 8] Municipal Street Lighting etc
1. 2. 3. 4.
List of Energy Auditors Fax: 0265-2354813 Email: devkienergy@sify.com 5. Textiles 6. Dairy 7. Paper 8. Plastics 9. Rubber 10) Commercial Buildings Thermal Power Plant, Pulp and Paper, Sugar, Steel, Transport, Rubber, Chemicals, Cement, Textile, BOPP, Engineering, Food Processing, Chlor Alkali, Wire Drawing, Starch, Pharmaseuticals, Fertiliser, Hotels, Hospitals, Rice Mills, Institutes, Commercial Buildings, Aluminium, Dairy Chemical & Petrochemical, Fertilizer, Cement, Tyre, Sugar, Pulp & Paper, Automobile, Textile & Textile Processing, Foundry, Ministeel, Engineering, Ceramic, Synthetic Fibres, Hotels & Commercial Buildings, Food, power plants, Metals, etc
Conzerv Systems Pvt Ltd 44 P Electronic City, Phase II, Hosur Road Bangalore 560 100 Phone:- +91 80 5118 9700 Fax:- +91 80 5118 9729 email:- contact@conzerv.com
Central Electricity Authority Conservation and Environment Division Room No 315, Sewa Bhawan R.K.Puram, New Delhi-66 Central Power Research Institute, Energy Research Centre, P.B.No. 3506, Sreekariyam, Thiruvananthapuram - 695 017, Ph No. 0471-2596004,2599687, cprit@vsnl.net Centre of Energy Studies and Research Devi Ahilya University Khandwa Road Campus Indore 452 017 Phone: 0731-2462366 Telefax: 0731-2467378 Central Pulp & Paper Research Institute, Post Box No. 174, Paper Mill Road, Himmat Nagar, Saharanpur 247 001 Tel. No. (0132) 2725317, 2722756, Fax No. 0132 2727387, 2721367, E-mail:- rmm_cppri@rediffmail.com Central Fuel Research Institute PO FRI,Dhanbad , Jahrkhand -828 108 Tel No. 0326-2381001-10 Fax:- 0.326-2381113 E-Mail:-dnb_dcfri@sancharnet.in Academy for Conservation of Energy 820, Siddharth Complex, R C. Dutt Road, Alkapuri, Baroda. Ph No. (91)(265) 2325024 , Fax. No(91)(265)2325034 Email : info@syguruace.com &
Power Stations (Coal, Hydro, Oil and Atomic), Port Trust, Process Industries, Building & Establishments
Fertiliser, Iron & Steel, Cement, Pulp & Paper, Chloral kali, Textile, Chemicals, Commercial Buildings, Cold Storages
Transport Sector , Mining Sector, Dairy /Food Sector , Power Sector ,Iron & Steel, Textile Sector 1.) Chlor Alkalis ( GACL) 2.) Cement ( Gujarat Siddhi Cement) 3.) Petrochemicals ( IOCL) 4.) Chemicals & Pharmaceuticals ( BASF, Alembic, RPG Life Science, Wockhardt, Rubamin ) 5.) Food Processing ( Vadilal Ltd. Sharaf Food , Charotar Animal Feed)
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
sii2k@rediffmail.com
6.) Engineering (Steelage, Spaco carburetors Ltd., Gujarat Mahendra Tractors ) 7.) Steel Casting ( Manglam Alloy Ltd., Rajhans metals) 8.) Textile ( Kiran Industries Ltd., Niranjan Mills, Marudhar Spg. Mills)
Central Pulp & Paper Research Institute, Post Box No. 174, Paper Mill Road, Himmat Nagar, Saharanpur 247 001 (UP) Tel. No. (0132) 2725317, 2722756, Fax No. 0132 2727387, 2721367, E-mail:- rmm_cppri@rediffmail.com Central Technical Center, Aditya Birla Management Corporation Limited , ARIES House , Old Padra Road, Vadodara - 390007 Phone No. : 0265 - 2323546 / 2323561 Fax No. : 0265 - 2323521 E mail : ctcbaroda@adityabirla.com Central Scientific Instruments Organisation CSIR Madras Complex Taramani P.O. Chennai, Tamil Nadu - 600 113 Tel - 044 2541061 Fax - 044 2541026 Email: csiom@vsnl.com BICON Consultants Pvt. Ltd., 59/A, Puddapukur Road, Kolkata - 700 020. Phone: 033 2485 2293, Fax: 033 2859 0079 E-mail: bicon@vsnl.net Balmer Lawrie & Co. Ltd. 21, Netaji Subhas Road, Kolkata 700001 Telephone : (033) 22225620 Fax : (033)22105585, 22105662 Email venkataraman.r@balmerlawire.com Bharat Sanchar Nigam Limited. O/o Sr. DDG (Electrical), 10th Floor, Chanderlok Bldg., 36 Janpath, New Delhi - 110001. Avant-Garde Engineers and Consultants (P) Ltd., 68A, Porur Kundrathur High Road,Porur, Chennai - 600 116
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
Fertilizer, Cement,Chlor Alkali,Textile, Chemicals, Fiber & Insulator, NonFerrous Metals, Diesel Generators, Thermal Power Plants, Gas Turbine Generators.
1. Automobile Industry, 2. Chemical, 3. Engineering. 4. Commercial Buildings, 5. Iron & Steel-Foundry, 6. Metallurgy, 7. Hospitals, 8. Rubber Beltings
Chemical, Engineering, Thermal, Power Plants, Steel Plants, Paper Mills, Breweries, Food Processing, Sugar Factories, Refineries, Tobacco, Tea, Jute Mills etc
Captive Power Plant, Biomass Power Plant, Cogeneration Plant, Sugar Plant'Iron & Steel
List of Energy Auditors Tel: 044-24828717- 23 Fax:044-24828531 E-mail:avantgarde@vsnl.com Textile Industry Paper & Straw Boards Industry Cement Industry Chemicals & Pharma Industry Sugar Industry Glass Industry Food & Dairy Industry Tobacco Industry Metallurgical Industry Engineering Industry Rubber & Leather Industry Polymers / PVC/ Plastic Industry Hotels & Hospitals
APITCO Ltd. 8th Floor, Parisrama Bhavanam, Basheerbagh, Hyderabad-500004 Email: hyd1_Apitco@sancharnet.in; Ph: +91-4023237333,23237981,23243611 web: www.apitco.org
Andhra Pradesh Productivity Council "Productivity House" Plot No.87 Road No.2, Banjara Hiills Hyderabad 500 033 Tel: 040-23545102 /23545103 & 23545232 Tel.Fax:040-23542827 E-Mail: appchyd@yahoo.co.in
Paper, Cement, Pharmaceuticals, Fertilizers, Glass And Petro Chemicals, Electrical And Thermal Parameters
Financial Mechanism
Counseling young entrepreneurs Organizing short-term Entrepreneurial Management Programmes Development and Industrial
Techno economic feasibility reports; project appraisals; short market survey Techno managerial studies of individual firms for enhancing their competitiveness in key areas like marketing, costing and pricing, MIS and corporate delivery systems.
Technology Upgradation As an extension of its Management Consultancy Services and for supporting client's efforts for modernization, the bank has set up an Industrial Technology Group engaged in the following tasks:
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Enhancing technology awareness among industrialists ! Catalyzing a step-up in quality, productivity and cost effectiveness ! Disseminating technological/market information Financial Package To help liquidity in the units undergoing modernization programmes and as an incentive, a special financial package is extended for the Bank's clients.
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Liberalised terms of margin (15-20%) Extension of the Bank's Equity Fund Scheme (EFS : interest-free loan to a maximum of RS 100,000, matching the proprietor's contribution) Holiday period of three years for the EFS loan and eighteen months for the Term Loan Easy repayment, aligned to profit accruals Need based Working capital
Financial Mechanism
Canara Bank
Scheme for Energy Savings for Small & Medium Enterprises (SME) Sector A novel scheme devised for SMEs for acquiring / adopting energy conservation / savings equipments / measures. Purpose : For acquiring / adopting energy conservation / savings equipments / measures by SMEs. Eligibility : (a) (b) (c) (d) (e) Units under Small Scale Sector & Medium Enterprises Cost of energy for the unit should constitute not less than 20% of the total cost of production Unit should possess energy audit report issued by an approved energy Consultant/Auditor. Borrowal A/Cs-ASCC code S1 or S2 during previous review. Current account holders having dealings exclusively with us satisfactorily for a period of last one year.
Loan Amount : Maximum Rs 100 lakhs Margin : 10% of Project Cost Rate of Interest : 1% less than the prevailing rate applicable for loans of similar tenure. Security : Prime- Assets created out of the credit facility. Collateral- NIL up to Rs 5 lakhs. For loans over Rs 5 lakhs as determined by Bank on merits. Repayment : Maximum 5-7 years including moratorium of 6 months Guarantee Cover: For loans up to Rs 25 lakhs Cover under Credit Guarantee Fund for Small Industries of CGFTI would be available. Grants : Bank provides 25% of the cost of Energy Audit / Consultancy charges with a maximum of Rs 25000/- to the first 100 units on a first come first served basis which is in addition to the grant of Rs 25000/- being provided by IREDA(First 100 units)
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
INDIAN RENEWABLE ENERGY DEVELOPMENT AGENCY (IREDA) SCHEMES APPLICABLE IREDA provides loan for Energy Efficiency/Conservation sector under following categories Maximum repayment Rate of Max. Minimum Maximum period Interest(%) Moratorium Promoters IREDA including p.a. (Years) Contribution(%) loan(%) moratorium (Years)
SCHEME
11.00
10
30
30
B. EQUIPMENT FINANCING: Energy Conservation / Efficiency Systems and Equipments ( including DSM )
11.50
10
20
9.50
20
equipment cost
9.00
20
Maximum Loan Amount : Rs. 80 Lakhs per project under Equipment Financing .
Financial Mechanism
Bank of Baroda
Small Scale Industries and Ancillary Units (SSI Units) A Small Scale Industrial Unit, is one which is engaged in the manufacture, processing or preservation of goods or is a servicing and repair workshop undertaking repairs of machinery used for production, mining or quarrying or custom service unit (except water service units), having investments in plant and machinery (original cost) not exceeding Rs. 1 Crore. Bank of Baroda has special Loans and Advances for the purpose of fixed capital investment and also for working capital requirement. Key Benefits The loans and advances offered by Bank of Baroda for SSI Units can be used for the basic needs of:
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Acquisition of factory, land and construction of building spaces. Purchase of plant and machinery including lab equipment, testing equipment, etc. Meeting working capital requirements, like raw materials, stock-in-progress, finished goods and for purchase or discounting of bills. Temporary additional assistance for meeting the urgent needs of raw material. Additional monitory assistance for any eligible purpose.
Making available timely and adequate financial resources for the sector at competitive rates i.e. 2% below the PLR of SIDBI i.e. @ 9.5% p.a. Proper and dedicated coverage for "Medium Sector" in India for financial assistance, especially for small scale sector units graduating to the medium scale.
For the present, Term Loans and Bill discounting facility are covered under the Fund. Definition of Medium Sector
A unit having investment in plant and machinery upto Rs.10 crore would be considered as Medium Sector Enterprise. There is no change in the present definition of SSI unit.
Investors Manual for Energy Efficiency for Small & Medium Scale Enterprises
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
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 5 th July, 1989 and registered under the Societies Registration Act, 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
21 of 1860
(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.
ex officio member;
ex officio member;
ex officio member;
ex officio member;
ex officio member;
ex officio member;
(h) Chairman of the Central Electricity Authority established under the Electricity (Supply) Act, 1948 (i) Director-General of the Central Power Research Institute registered under the Karnataka Societies Act, 1960
XXI of 1860
(j) Executive Director of the Petroleum Conservation ex officio member; Research Association, a society registered under the Societies Registration Act, 1860 (k) Chairman-cum-Managing Director of the Central ex officio member; Mine Planning and Design Institute Limited, a company incorporated under the Companies Act, 1956
1 of 1956
(l) Director-General of the Bureau of Indian Standards ex officio member; established under the Bureau of Indian Standards Act, 1986 (m) Director-General of the National Test House, ex officio member; Department of Supply, Ministry of Commerce and Industry, Kolkata (n) Managing Director of the Indian Renewable Energy ex officio member; Development Agency Limited, a company incorporated under the Companies act, 1956 (o) one member each from five power regions members; representing the States of the region to be appointed by the Central Government (p) such number of persons, not exceeding four as may be members; 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 (q) such number of persons, not exceeding two as may be members; nominated by the Governing Council as members 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 Meetings of Governing Council
63 of 1986
1 of 1956
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. (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 (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.
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;
(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. (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 (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. (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 Officers and employees of Bureau Director-General of Bureau Constitution of Advisory Committees and other committees
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; (c) all the rights and liabilities of the Energy Management Centre shall be transferred to, and be the right and liabilities of, the Bureau;
Transfer of assets, liabilities and employees of Energy Management Centre
(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 C entre 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
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;
(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; 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;
Power of Central Government to enforce efficient use of energy and its conservation
(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
Power of State Government to enforce certain provisions for efficient use of energy and its conservation
15. The State Government may, by notification, in consultation with the Bureau (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;
(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. (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. (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;
Power of inspection Establishment of Fund by State Government
(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.
Power of Central Government or State Government to issue directions
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 (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.
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 (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 subsection (5) or section 4; (d) expenses on objects and for purposes authorised by this Act
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).
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. 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. 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. 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. (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.
Budget
677
Annual report
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.
Factors to be taken into account by adjudicating officer
28. While adjudicating the quantum of penalty under section 26, the adjudicating officer shall have due regard to the following factors, namely:(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.
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.
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. 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.
(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, (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 (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
679
(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.
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. 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.
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. (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. (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. 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. (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
5 of 1908
5 of 1908
(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.
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. 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. 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. 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.
Decision to be by majority
Right to appellant to take assistance of legal practitioner or accredited auditor and of Government to appoint presenting officers
(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. 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
Power of Central Government to issue directions to Bureau
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 B ureau shall, as far as practicable, be given an opportunity to express his views before any direction is given under this sub-section. (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 (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
(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. (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 Default by companies
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; (b) the existing Energy Management Centre from the date of its constitution to the date of establishment of the Bureau,
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. 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 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. 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.
Delegation
Power to exempt
Chairperson, Members, officers and employees of the Appellate Tribunal, Members of State Commission, DirectorGeneral, Secretary, members, officers and employees to be public servants. Power of Central Government to issue directions. Power of Central Government to make rules.
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
55. The Central Government may give directions to a State Gover nment or the Bureau as to carrying out into execution of this Act in the State 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;
(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. (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.
Power of State Government to make rules
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.
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.
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.
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. 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.
List of Energy Intensive Industries and other establishments specified as designated consumers
1. 2. 3. 4. 5. 6. 7. 8. 9. Aluminium; Fertilizers; Iron and Steel; Cement; Pulp and paper; Chlor Akali; Sugar; Textile; 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;
689
References
References
REFERENCES
! Detailed Energy Audit reports
CII Godrej GBC has carried out detailed energy audits in over 550 Industries in India, comprising of various sectors such as cement, paper, sugar, ceramics, engineering, power plants, leather, pharmaceutical, tea, synthetic fibre, etc. The feedback from the audited units indicated a saving of Rs 1,500 million based on the implementation of proposals suggested in the detailed energy audit. The energy consumption details and savings possible in each of these sectors have been compiled 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 Godrej GBC under the ADB Energy Efficiency support project. This manual includes all the energy saving aspects that can be incorporated at design stage for achieving energy efficiency. ! Case Study booklets on energy efficiency prepared by CII on Energy Intensive Sectors Six case study booklets in six energy intensive sectors covering actual implemented case studies were brought out under the project. This project involved extensive travel by CII team to over 30 industries to study the energy saving 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
Internet
Data & Statistics Ministry 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 Database - www.Eco-web.com SIDI - www.sidbi.com Ministry of Chemicals - www.chemicals.nic.in Chemical Manufacturers Association - www.icmaindia.com Chemical Technology - www.chemicals-technology.com Equipment Suppliers Bharat Heavy Electricals Limited www.bhel.com Thermax www.thermax.com Asea Brown Boveri www.abb.com Siemens - www.siemens.com Suzlon Energy www.suzlon.com Financial Institutions Indian Renewable Energy Development Agency www.iredaltd.com World Bank www.worldbank.org The Energy & Resources Institute www.teriin.org Export import bank of India www.eximbankindia.com Canara bank www.canarabankindia.com Small Industries Development Bank of India www.sidbi.com State Bank of India www.statebankindia.com Bank of Baroda www.bankofbaroda.com USAID www.usaid.gov
References
P K Arunachalam, Manager - State Bank of India, Chennai FLSmidth India Limited, Chennai Mr R Prabha, General Manager (Priority Credit Wing), Canara Bank
Visits made
Financial Institutions Canara Bank, Bangalore Indian Renewable Energy Development Agency (IREDA), New Delhi State Bank of India (SBI) Energy Business Division, Chennai Visit to companies Aurobindo Pharma Ltd G S B Forge Ltd. Granules India Ltd Dr. Reddy's Laboratories Ltd. Rane Engine Valves Limited TKH Plastics Pvt Ltd Godrej Agrovet Ltd Hindustan Coca-cola Ltd Nicholas Piramal India Limited N R B Bearings TI Diamond Chain Ltd Priyadarshini Spinning Mills Ltd. GTN Textiles Ltd (Medak Unit) Shantha Biotechnics Pvt. Ltd. Ravi Foods Pvt. Ltd., Tecumseh Products India Ltd. VST Industies Ltd. Dr. Reddy's Laboratories Ltd. - Generics Dr. Reddy's Laboratories Ltd. Eveready Industries ITW Signode Ltd.
Conclusion
Small & Medium Enterprises (SMEs) in India are playing a very major role in the overall development of the countrys economy. SMEs constitute one of the vibrant sectors of the Indian economy in terms of employment generation, the strong entrepreneurial base it helps to create and its share in industrial production and exports. DEFINING SME ? The definition of a Small & Medium Enterprise various widely Small Industries Development Bank of India (SIDBI), a nodal agency for small industries defines Medium sector enterprises as units having investment in plant and machinery upto Rs.10 crore. However, as defined by State Bank of India (SBI), companies having turnover of less than 25 crores per annum is considered as SME. About Investors Manual Under the `India: Second Renewable Energy Project, Indian Renewable Energy Development Agency (IREDA) is operating a World Bank Line of credit (WBLOC) to finance projects in energy efficiency/ conservation sector. As a part of the above project, Technical assistance Plan (TAP) is envisaged for (i) institutional development and technical support to IREDA,(ii) improving the marketing of the energy efficiency and demand-side management investments (iii) Promoting private sector participation in end-use efficiency. As a part of the project, CII Godrej GBC has been assigned the task of Preparation of Investors Manual for Energy Efficiency/ Conservation in Small and Medium Scale Sector for the use of Bankers Objective of this Manual: The objective of this Investors Manual for Energy Efficiency in Small & Medium Enterprises for the use of Bankers is a step in highlighting & bringing in investment opportunities for energy efficiency equipment. This manual covers various topics like energy saving potential for various industries, technologies available to improve energy efficiency, equipment suppliers, government policies / incentives available for the sector, terms of IREDA and other financial institutions extending support to such projects etc. The end objective of the activity is market development for energy efficiency / conservation products & services for SMEs. CII Godrej GBC adopted the following methodology in preparing this manual: 1. Classifying the SME sector/equipment under energy intensive category 2. Identifying different energy intensive SME sectors which are likely to invest in EE technologies
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
3. Identify available technologies and relate each of them to SME sector application. 4. Identifying energy saving potential for each of the energy intensive industry and list the major energy saving measures, which could be undertaken in each of the industry/equipment 5. Develop model financial structures for energy efficiency investments and its payback 6. A brief technical detail including schematics and cost benefit analysis for each of the proposed energy saving measures. 7. Providing the list of equipment suppliers (both Indian as well as international), EPC contractors, Energy service companies etc. who can take up this energy saving measures 8. Giving the list of consultants / energy auditors etc, who can be approached for conducting energy audit, preparation of DPR etc. 9. A brief detail of government policy / incentives / concessions available etc. for identified energy saving projects / equipments. 10. Giving a brief detail of finance available for taking up energy efficiency projects from IREDA as well as from other financial institutions All the projects are all proven projects, which have been implemented successfully in Indian industry. The objective of highlighting these projects is to facilitate the potential investors & bankers, in having a quick reference of the various energy saving measures and also enable them make decisions on investment. Summary of this report This report focuses on energy conservation methodologies & case studies in 10 major sectors and 8 commonly used equipment in the Indian Small & Medium Enterprises (SMEs) Sectors covered under this manual 1. Leather 2. Cement 3. Pharmaceutical 4. Ceramics 5. Tea 6. Food processing 7. Paper 8. Textile 9. Sugar 10. Foundry
Major equipment covered under this manual 1. 2. 3. 4. 5. 6. 7. 8. Air compressors Centrifugal pumps Centrifugal fans Boilers & steam system Refrigeration & air conditioning system Electrical distribution Electrical motors Lighting
According to estimates, the total energy consumed in the SMEs is in the order of about 8000 MW. The various sectors highlighted in this report offer an annual energy saving potential of about 1000 MW which is equivalent to Rs. 28000 Million This, in turn, creates an investment opportunity of Rs 42000 million, to achieve the projected energy savings. This report will serve the objective of its preparation, in promoting / development of market for energy efficient equipment & suppliers in Indian industry.