Investor Manual For Energy Efficiency

Confederation of Indian Industry
Energy Management Cell

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CONTENTS
Page No.
Executive Summary
1. Introduction 1
2. Energy Saving Opportunities in Various Sectors
Cement 5
Caustic Chlorine 58
Aluminium 89
Glass 121
Ceramics 161
Copper 199
Paper 229
Fertilizer 310
Foundry 400
Textiles 448
Engineering 484
Sugar 530
Power Plant 596
3. List of Suppliers Address 628
4. List of Energy Auditors 650
5. List of Energy Service Companies 654
6. Financial Mechanism 655
7. Government incentives 667
8. Reference 689
9. Conclusion 693
521
EXECUTIVE SUMMARY
The Republic of India (India), the world’s sixth largest energy consumer, plans major energy
infrastructure investments to keep up with increasing demand—particularly for electric power.
India also is the world’s third largest producer of coal, and relies on coal for more than half
of its total energy needs.
Indian Renewable Energy Development Agency Limited is a Public Limited Government

Company established in 1987, under the administrative control of Ministry of Non-Conventional
Energy Sources (MNES) to promote, develop and extend financial assistance for renewable
energy and energy efficiency/conservation projects with the motto: “ENERGY FOR EVER”
About Investors’ Manual

Indian Renewable Energy Development Agency (IREDA) has received a line of credit from the
International Bank for Reconstruction and Development (IBRD) / Global Environmental Facility
(GEF) towards the cost of “India: Second Renewable Energy Project”.
As a part of this line of credit, technical assistance plan (TAP) is envisaged for institutional
development and technical support to IREDA. Preparation of this investors’ manual for
energy efficiency sector – industrial sub sector, as a guide to intending entrepreneurs, is one
of these TAP activities.
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
based on inputs from various stakeholders in energy efficiency sector.
Confederation of Indian Industry (CII) – Energy Management Cell (EMC) was awarded the
task of preparing this manual by IREDA.
CII – EMC adopted the following methodology in preparing this manual:
1. Analyze the existing data available with CII and develop a detailed action plan for execution
2. Identify industries under energy intensive and non-intensive categories
3. Review the detailed energy audits carried out by CII in various sectors and estimate
energy saving potential possible in identified energy intensive and non-intensive sectors
4. Analyze literature available with CII
5. Discuss with industry experts / Consultants
6. Identify list of energy saving measures to be undertaken in each industry
7. Evaluate technical details for each of the proposed energy saving measures in various
industries
Confederation of Indian Industry - Energy Management Cell

Introduction
522
8. Prepare / identify the list of equipment suppliers (National & International), EPS Contractors,
Energy Service Companies, etc., who can take up these energy saving measures
9. Review the collected data with experts in each of the energy intensive and non-intensive
industries
10. Prepare / identify the list of consultants / energy auditors etc., who can be approached
for conducting energy audit, preparation of DPR, etc.
11. Interacting with IREDA and other financial institutions
12. Preparation of a brief note of finance mechanism available for taking up energy efficiency
projects from IREDA and other financial institutions
13. Preparation of a brief description of government policy / incentives / concessions available

for identified energy saving projects / equipment identified in various energy intensive and
non-intensive sectors
industries
The various sectors identified under this project, and the share of energy in the manufacturing
cost, is as under:
Sector Power & Fuel cost as

% of Production cost
1 Cement 43.7
2 Caustic Chlor 40.7
3 Aluminium 33.4
4 Glass 30.9
5 Ceramic 25.3
6 Copper 24.0
7 Paper 23.7
8 Fertiliser 18.4
9 Foundry 13.7
10 Steel 13.3
11 Sponge Iron 12.8
12 Synthetic Textiles 11.3
13 Textile 10.3
14 Engineering 6.0
15 Tyre 7.7
16 Drugs & Pharma 4.6
17 Dairy 4.2
18 Sugar 2.0*
19 Petro Chemical 2.0
20 Refinery 2.0
* cost equivalent of bagassee consumed
Investors Manual for Energy Efficiency

Introduction
524
These 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, 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 in 16 major sectors of Indian
industry.
The energy intensive sectors not included in this report are:

• Steel & sponge iron
• Petrochemcial
• Refinery
The reason for exclusion of these sectors is:
• These sectors are technology specific
• The players in this sector are very few in number
• The players in these sectors are cash-rich and may not approach financial institutions for
funding energy saving projets. Alternately, they may approach for technology upgradatioon
projects, but these companies are well aware of these projects they need to take up in
future.
S.No Sector Annual saving Investment opportunity

Potential Rs. Million, Rs. Million,
(US $, Million) (US $, Million)
1 Cement 3500 (70) 7000 (140)

2 Caustic Chlor 8600 (172) 30000 (600)
3 Aluminium 500 (10) 1000 (20)
4 Glass 550 (11) 800 (16)
5 Ceramic 350 (7) 725 (14.5)
6 Paper 3000 (60) 5000 (100)
7 Fertiliser 2000 (40) 6000 (120)
8 Foundry 1800 (36) 3500 (70)
9 Sythetic Fibre 1300 (26) 2500 (50)
10 Textile
11 Tyre 860 (17) 1750 (35)
12 Drugs & Pharma 1100 (22) 1800 (36)
13 Sugar 4200 (84) 6000 (120)
14 Engineering 5000 (100) 10.000 (200)
15 Copper 750 (15) 1500 (30)
16 Power Plants 3000 (60) 5000 (100)
Total 37,510 (730) 82,575 (1651.5)

525
The various sectors highlighted in this report offer an annual saving potential of Rs 37510.
million. This, in turn, creates an investment opportunity of Rs82575 million, to achieve 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.

1
Introduction
India’s Energy scenario
Background
India’s economic growth is currently recovering from a mild slowdown in 2002, which was
mainly attributable to weak demand for manufactured exports and the effects of a drought on
agricultural output. Real growth in the country’s gross domestic product (GDP) was 4.8% for
2002, and is projected to rise to 5.7% in 2003. The economic effects of recent political
tensions in the region have been quite modest.
Oil
Oil accounts for about 30% of India’s total energy consumption. The majority of India’s roughly
5.4 billion barrels in oil reserves are located in the Bombay High, Upper Assam, Cambay,
Krisha-Godavari, and Cauvery basins.
Future oil consumption in India is expected to grow rapidly, to 3.2 million bbl/d by 2010, from
2.0 million bbl/d in 2002.
Natural Gas
Indian consumption of natural gas has risen faster than any other fuel in recent years. From
only 0.6 trillion cubic feet (Tcf) per year in 1995, natural gas use was nearly 0.8 Tcf in 2000
and is projected to reach 1.2 Tcf in 2005 and 1.6 Tcf in 2010.
Coal
Coal is the dominant commercial fuel in India, satisfying more than half of India’s energy
demand. Power generation accounts for about 70% of India’s coal consumption, followed by
heavy industry. Coal consumption is projected in the International Energy Annual 2002 to
increase to 450 million short tons (Mmst) in 2010, up from 369 million short tons in 2000.
India is the world’s third largest coal producer (after China and the United States), so most
of the country’s coal demand is satisfied by domestic supplies.
ELECTRICITY
As per recent estimate, total installed Indian power generating capacity is about 112,000 MW.
The government had targeted capacity increases of 100,000 megawatts (MW) over the next
ten years.
Per-Capita Consumption
Per capita energy consumption in India is only 350 kWh (277 Kg of oil equivalent (KOE)),
which is just 3.5 per cent of that in the USA, 6.8 per cent of Japan, 37 percent of Asia and
18.7 per cent of the world average.

Introduction
2
But, energy intensity, which is energy consumption per unit of GDP, is one of the highest in
comparison to other developed and developing countries. For example, it is 3.7 times that of
Japan, 1.55 times of the USA, 1.47 times of Asia and 1.5 times of the World average.
The industrial sector is the highest consumer of electricity (34 percent) followed by agricultural
(30 per cent) and domestic (18 per cent) sector.
The importance of energy as a driver for economic growth in India Is greater than in most
countries. The world development report ranks India sixth in its list of countries requiring
energy for GDP growth.
Energy Consumed in kJ per $ of GDP

70000
60000
50000
40000
30000
20000
10000
0
Poland
India
China
Indonesia
US
UK
Germany
Japan
Russia
Turkey
S Africa
Switzerland
a. Huge gap between supply & demand b. Massive T & D losses
Capacity Addition in last 5 yr Plan (MW) T & D Losses

35%
30000
16000
10%
Target Actual
India Benchmark
c. Average cost of supply exceeds d. Increasing losses of SEBs

average tariff
Price (Rs./kWh) Avg. SEB Rate of Return

3.4
2.42 1992-93 1998-99
1.92
1.41
0.22
-12%
Industry Domestic Agriculture Avg Price Cost
-18%

3
Energy conservation is one of the prime areas of focus to overcome the supply – demand gap.
Whilst the generation increase has been steady, the consumption pattern has also been
steady.
Electricity consumption in India
Electricity Consumption - Profile
50
40
Percentage
30 1996-97
20 2001-02
10
0
DOMESTIC IRRIGATION OTHERS
The electricity consumption profile in India has, by and large, been the same in the last five
years. There has been a small drop in the irrigation / agriculture based consumers, which
has been equated by a small increase in the consumption profile of domestic consumers. The
commercial & miscellaneous users and the industrial consumers have not varied a lot.
This has been the profile in spite of the increase in GDP & per capita power consumption.
The per capita power consumption in 1996 – 97 has been 334.26 kWh compared to 350 kWh
in 2001-02.
The per capita national income has increased from 10149 in 1996-97 to 17736 in 2001-02.

Introduction
4
Energy Saving Opportunities in

Various Sectors

5
Cement
Per Capita Consumption 100 kg
Growth percentage 8%
Energy Intensity 45% of manufacturing cost
Energy Costs Rs 70,000 million (US $1400 million)
Energy saving potential Rs.3500 m (US $ 70 million)
Investment potential on energy

saving projects Rs.7000 m (US $140 million)

Energy Conservation in Cement Industry
6
1.0 Introduction
Cement is one of the core industries, which plays a vital role in the growth of the nation. India
ranks third among cement producing countries in the world behind China and USA and has
come a long way, since the installation of the first cement plant at Porbandar in 1914. The
present per capita consumption is around 100 kg, which is much lower than the per capita
consumption of 255 kg in the developed countries.
The per capita consumption is expected to increase to about 120 kg in the next 2 years.
India has the requisite quantity of cement grade limestone deposits, backed by adequate
reserves of Coal. The technical expertise and managerial skills of the personnel have grown
tremendously resulting in efficient operation of the plant. The latest cement plants that are
being installed in the country are comparable with the best in the world. India therefore has
a major role to play in the future global cement market.
A large quantity of cement and clinker are being exported particularly from the state of Gujarat
are being exported to other Asian & African countries.
2.0 Present Capacity & Capacity Utilisation

There are 124 major cement plants with an installed capacity of 135 million tonnes as on 31
March 2002. The Indian cement plants are a blend of a few high energy consumption old wet
process plants with a capacity of 300 TPD and modern dry pre-calciner plants with capacities
upto about 7500 TPD.
The annual production of cement by the major cement plants in the year 2001- 02 was around
102.4 million tonnes with a capacity utilisation of nearly 80%. (Source CMA data)
3.0 Growth Potential

The cement demand has been growing at about 8% in the country. However, there has been
substantial increase in capacity of the plants in the recent past through plant upgradation and
slack capacity is available in the industry.
The strategy of the Indian cement industry is to meet the additional demand in the industry
through production of blended cement and utilising the slack capacity available in existing
plants.
Additionally, there are 300 mini cement plants with an installed capacity of 11.10 million tons
producing about 6.0 million tons (2001-02 data)
The major types of cement produced in India include – Ordinary Portland Cement (OPC) –
33, 43 & 53 grader and blended cements such as Portland Pozzolana Cement (PPC) and
Portland Slag Cement (PSC).
The OPC varieties account for about 70% of the production, while the blended cements PPC
& PSC account for 18% and 10% of the production respectively. There has been a recent
trend to produce more quantities of blended cement varieties.

7
4.0 Cement Manufacturing – technologies

Limestone is the raw material used in the manufacture of cement. In India, three types of
processes are being used for cement manufacture and are given below:
• Wet process < 5% of the production
• Dry Suspension (SP) process < 8% of the production
• Dry Precalciner (PC) process > 85% of the production
The detailed description of the different processes is given below.
4.1 Wet Process

The oldest plants in the country are wet process plants. These plants are characterised by
low technology, low capacity, high man-power and higher energy consumption. The maximum
capacity of the wet plants operating in India is only 300 TPD.
With the current trend towards higher capacity, lower energy consumption and better quality
the wet plants are being gradually converted or phased out. The main feature of the wet
process is that the limestone is ground in wet condition and fed to the kiln as slurry. Majority
of the wet process plants have been stopped or converted and less than 5% of the cement
is produced through this process
4.2 Dry SP Process

The Dry SP (Suspension Pre-heater) plants are comparatively modern plants and of moderate
capacity (upto 1500 TPD). In comparison to the wet plants, the dry SP plants are energy
efficient.
The characteristic feature of the dry SP plants is that the limestone is ground in dry condition
and then fed to the kiln system through the pre-heaters.
4.3 Dry Precalciner Process

The Dry precalciner process is the latest process and characterised by high capacity (more
than 3000 TPD) and energy efficiency. More than 90% of the cement is produced through
this process and the detailed process description is as under:
Cement is manufactured from Limestone and involves the following main steps:
• Mining
• Crushing
• Raw meal grinding
• Pyro-processing
• Cement grinding

8
Block Diagram – Cement Industry – Dry Process Precalciner Process
Additives
Fine
Mines Crushing Pre- Raw Mill Blending
blending & Storage
Purchased
coal Raw Meal
Fine
Coal Coal Coal Pyro

storage Crusher Mill processing
Gypsum
Clinker Cement Packing &

storage mill Despatch
Slag or Fly-ash
Mining
The major raw material for cement manufacture is limestone. The limestone is mined in open
cast mines in the quarry and then transported to the crusher through dumpers / ropeways.
Conventionally, the limestone was being mined by the usual methods of drilling and blasting.
The latest trend is to install miners which have the advantage of lower operating cost in
addition to being environment friendly.
Crushing
The mined limestone is conveyed to the crusher through dumpers or ropeways. The material
is then crushed in the crusher to a size of about 25 – 75 mm. The crushing is done in two
stages in the older plants while in the modern plants normally single stage crushing is done.
The typical crushers used are jaw crusher and hammer crusher.
Raw meal grinding

The crushed limestone is ground into a fine powder in the dry condition. Generally, the ball
mill is used for grinding in a dry SP plant, while a Vertical Roller Mill (VRM) is used in a dry
PC plant. The VRM is comparatively more energy efficient consuming only 65% of the energy
consumption of the ball mill. The ball mill along with a pre-grinding system such as roll press
is also used in some of the plants with very hard and abrasive limestone.
Pyro-processing
This is the most important step in the manufacture of cement. This takes place in the kiln
system. The kiln is a major consumer of electrical energy and the only consumer of thermal
energy in a cement plant.

9
The ground raw meal after getting preheated in the pre-heater system enters the calciner.
The calciner is a vessel provided between the preheater and calciner. The calcination of
limestone and the conversion into clinker takes place in the precalciner and kiln respectively.
Cement grinding
The clinker produced in the kiln stored in the silo / stock-pile is ground along with Gypsum
(about 5%) to produce Ordinary Portland Cement (OPC). The generally used grinding
equipment is the ball mill in various cement plants in India. In some of the recently installed
plants the VRM has been installed with satisfactory results. The other types of cement such
as PPC (Portland Pozzolana Cement) and PSC (Portland Slag Cement) are also produced by
grinding clinker with fly-ash and blast furnace slag respectively.
5.0 Energy Intensity of Cement Industry

The production of cement is highly energy intensive with more than 45% of the manufacturing
cost being contributed by energy (electrical & thermal). The Indian cement industry is next
only to the Iron & Steel industry in terms of the overall value of the energy consumption in
the country.
The total value of energy consumed in the Indian cement industry amounts to nearly about
Rs 70,000 millions (USD 1400 millions).
Energy consumed in cement industry - Rs 70,000 million (USD 1400 million)
6.0 Specific Energy Consumption – Average and Targets

The average specific energy consumption of various Indian cement plants in 2001 - 02 is
about 98 units / ton of cement (OPC – 43 grade). There are about 10 numbers of cement
plants who have done extremely well and are operating with a specific energy consumption
less than 85 units / ton.
The thermal energy consumption average is about 760 kcal/kg of clinker. Based on the study
of the latest cement plants, the target energy consumption for a new cement plant could be
as below:
Specific Electrical Energy consumption : 75 units/ton of OPC – 43
Specific Thermal Energy Consumption : 715 kCal/kg of clinker
7.0 Energy Saving potential and Investment potential

The various studies of Indian cement industry indicates an energy saving potential of about
5%, which amounts to Rs 3500 millions (USD 70 millions). The investment potential for these
projects is about 7000 millions (USD 140 millions).

10
8.0 List of Energy Saving Projects

The list of energy saving projects, which can be implemented in different sections of a cement
plant are listed below:
Mines and Crusher

Short-term
• Increase operating capacity of primary & secondary crusher
• Reduce idle run of crushers and belts
• Reduce idle operation of dust collection equipment
Long-term
• Install bulk analyser for crushed limestone
Raw mill grinding & storage

Short-term
• Avoid idle running of raw mill conveyor system (Auxillaries)
• Avoid idle operation of raw mill lubrication system
• Optimise starting & stopping sequence of raw mill (to minimise idle running of fans)
• Minimise false air entry in raw mill system
Medium-term
• Install variable louvre system for roller mill
• Install high efficiency dynamic separator for roller mills
Long-term
• Use vertical roller mill instead of ball mill
• Control raw meal feed size by installation of tertiary crusher
• Install belt and bucket elevator in place of pneumatic conveying
• Installation of efficient mill intervals – diaphragm and liners
• Install online X-Ray analyser for raw meal
• Install slip power recovery system / VFD for raw mill fan / ESP fan
• Install external mechanical recirculation system for roller mills and optimise air flow
• Kiln, Pre-heater & cooler
Short-term
• Install CO and O2 analyser at kiln inlet and preheating outlet
• Maintain proper kiln seal (inlet and outlet) to avoid false air infiltration
• Reduce leakages in the preheater system

11
• Minimise primary air to kiln
• Utilise the cooler waste heat for flyash / slag / coal
• Install soft starters for clinker breaker
Medium-term
• Install VFD for cooler fans and cooler ID fans
• Opptimise the cooler exhaust chimney height to reduce the exhaust fan power consumption
• Install water spray in cooler to minimise fan power consumption
Long-term
• Install system for firing waste tyre, bark, rice husk, groundnut shell and urban waste in
precalciner
• Conversion from pneumatic conveying of kilnfeed to mechanical mode
• Conversion from single channel to multichannel burners
• Replace planetary cooler with grate cooler
• Replace conventional coolers (planetary / grate) with high efficiency coolers
Coal yard & coal mill
• Elimination of spontaneous combustion, by proper stacking
• Avoid idle running of coal conveyor & crusher
• Optimise starting & stopping sequence of coal mill to reduce idle operation of fans
• Maintain higher residue for precalciner firing
• Increase residue of coal mix, if possible
Cement Grinding, Storage & Packing
Short-term
• Water spraying on the clinker at cooler outlet (Temp above 90oC, consumes more grinding
energy)
• Reduce cement mil vents and recirculate to reduce cement loss
• Avoid idle running clinker conveyor – dust collector fan
• Avoid idle running of cement silo exhaust fans
• Optimise starting & stopping sequence of cement mill to avoid idle running
• Increase production of blended cement (PPC and PSC)
• Use of grinding aids
• Optimise water spray compressor capacity

12
Long-term
• Optimise cement grinding fineness – Install particle size analyser and optimise the particle
size distribution
• Install belt conveyor / screw conveyor / bucket elevator system instead of pneumatic
conveying
• Installation of roller press / impact crusher / VRM as a pregrinder before the ball mill
Compressors & Compressed Air System

Short-term
• Eliminate compressor air leakages by a vigorous maintenance programme
• Maintain compressed air filters in good condition
• Install compressed air traps for receivers
• Optimise compressor discharge pressure
Medium-term
• Install screw compressors with VFD in place of old compressors
• Replace multiple small units with single larger units
• Install intermediate control system for compressed air systems
Electrical System
Short-term
• Avoid unnecessary lighting during day time
• Use energy efficient lighting
• Distribute load on transformer network in an optimum manner
• Improve power factor
– Individual compensation
– Group compensation
– Centralised compensation
• Replace over sized motors
• Replace with energy efficient motors
• Use VFD for low / partial loads
• Convert delta to star connection for motors loaded below 50% of full load (for occasional
peak load provide automatic-star-delta-convertor)
• Install energy saver in fluorescent lighting circuit
• Fixing of light fixtures at optimum height

13
• Operate lighting system at lower voltage (say 360 V in 3 phase)
• Use servo stabliser in lighting circuits
• Replace conventional fluorescent tubes (40 W) with slim tubes (36 W)
• Optimise system operating voltage level
Medium-term
• Install demand controller for maximum utilisation of demand
• Use of electronic ballast in place of conventional chokes
DG Sets
Short-term
• Increase loading on DG sets
• Install VFD for cooling tower pumps and fans
• Convert electrical heating furnace to thermal heating
Long-term
• Install WHR system in DG set for preheating furnace oil
• Install vapour absorption refrigeration systems utilising DG jacket with heat or exhaust heat
Newer technologies (Long-term)
• Install high efficiency cooler – CFG / CIS / SF across bar / Pygostep / IKN pendulam –
cooler
• Install low pressure drop cyclones for preheater
• Install latest high-level control systems for kiln, raw mill and cement mills
• Install WHR systems to recover heat from preheater and cooler exhaust
9.0 Long-term case studies

11 actual case studies, which have been implemented successfully in the Indian cement
plants, have been included.
Each of the individual case studies presented in this chapter includes:
• A brief description of the equipment / section, where the project is implemented
• Description of the energy saving project
• Implementation, methodology, time frame and problems faced during implementation (if
any)
• Benefits of energy saving projects
• Financial analysis of projects and
• Replication potential

14
• Diagram of the system or photograph of the project is also included, wherever applicable.
The data collected from the plant is presented in its entirety. However, the name of the plant
is not revealed to protect the identity of the plant. Similar projects can be implemented by
other units also to achieve the benefits.
A word of caution here. Each plant is unique in its own way and what is applicable in one
plant may not be entirely applicable in another identical unit. Hence, these case studies could
be used as a basis and fine-tuned according to the individual plant requirement before taking
up for implementation.

15
Case Study - 1
Installation of High Efficiency Dynamic Separator for Raw Mill
Background
The Raw Mill is one of the important equipment in the Cement industry used for grinding
Limestone into fine raw meal powder. The older plants had Ball Mills
for this operation. Consequently the energy efficient Vertical Roller
Mills (VRM) came into being. The VRMs have comparatively 30 – 35
% lower energy consumption than the Ball Mills. In the older Cement
plants the VRMs had a simple static separator installed for separation
of the coarse and fine material. The separator was an integral part
of the VRM.
In the conventional separators, the ground material is lifted to the

separator by high velocity hot air at the louvres. The separator
separates the coarse and fine particles and fine particles are carried
away by the airflow to the dust collectors. The coarse material subsides
through the raising freshly ground material. This creates additional
pressure drop in the VRM and also leads to increased circulation
inside the Mill. The particle size distribution is also wider with both
very fine and coarse particles present.
The latest trend has been to install cage type high efficiency separator.
In these separators, the material enters radially through a cage type
separator. The coarse material after separation is collected in a cone just below the separator
and is dropped on to the grinding table through a gravity air lock. In this manner the contact
between the freshly ground material and the coarse is avoided.
The advantages of these separators are as below.
• Closer particle size distribution
• Less pressure drop across the VRM
• Higher output at the same fineness as before or finer product

at the same output rate
Previous status
In a million tonne dry process pre-calciner plant, a Vertical Roller
Mill (VRM) was being used for grinding raw meal. The VRM had
a conventional static separator.
Energy saving project

The existing static separator was replaced with a new cage type dynamic high efficiency
separator.

16
Implementation methodology & time frame

The new separator could not be accommodated in the Mill body. So the Mill casings were
modified to accommodate the new separator. Hence, to save on time the drawings were
prepared and the new separator assembled outside and kept ready for installation.
With all these preparations, the actual installation needed only 21 days of Mill stoppage.
However in majority of the cases, the new separator can be fitted into the existing mill casing
itself.
Benefits of the project

There was an increase in the output of the Mill, finer product and reduction in the specific
power consumption of the Mill. Additionally, the Mill vibration also got reduced resulting in
trouble free operation.
The power saving amounted to 2.5 units / ton of Raw meal or 3.0 units / ton of Cement which
annually amounted to 18 lakh units / year.
Financial analysis
This amounted to an annual monetary saving (@ Rs 3.0 /unit) of Rs 270 million (Rs.5.4
million) (US$ 0.11 million). The investment made was around Rs 300 million (Rs.6.0 million)
(US$ 0.12 million) period for this project was 13 months.
Replication potential
There are about 150 vertical roller mills in Indian cement industry. The application of the high
efficiency separator is possible in about 50 installations. The investment potential is therefore
Rs 300 millions (USD 6 million)
Cost benefit analysis

• Annual Savings – Rs 270 million
• Investment – Rs 300 million
• Simple payback - 13 months

17

18
Case Study - 2
Replacement of the Air-lift with Bucket Elevator for Raw-meal

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.

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

The installation of the Bucket elevator took about 6 months. There was no stoppage of the
plant, and the installation of the Bucket elevator was done parallely. The system was hooked
on during a planned stoppage of the raw mill.

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

19
The total benefits amounted to a monetary annual savings of Rs. 2.24 millions. The investment
made was around Rs. 5.4 millions. The simple payback period for this project was 29 months.
Benefits of mechanical conveying

• Low energy consumption (25 - 30% of Pneumatic conveying)
• Reduction in power consumption of silo top dedusting system
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)

• Annual Savings – Rs 2.24 millions
• Investment – Rs 5.4 millions

20

21
Case Study - 3
Replacement of Existing Cyclones with Low Pressure Drop

(LP) Cyclones
Background
The Pre-heaters comprising of 4/5/6 stages of cyclones is an important part of the Kiln section
in a Cement Plant. In the pre-heaters the waste gas coming out of
the Kiln system is used for pre-heating the kiln feed material. With
increased focus towards more heat recovery from the waste gas, the
number of pre heater stages have been increased from 4 to 5 / 6.
The increase in the number of stages however led to increase in the
pressure drop across the system and hence higher fan power. This
led to the development of cyclones, which have a lower pressure
drop. The low pressure drop (LP) cyclones have the advantage of
• Low pressure drop. Hence, lower Pre-heater fan power

consumption.
• Higher output rate with the same Pre-heater fan
• Reduction in thermal energy consumption
Previous status
In a million tonne dry process pre-calciner plant, there were 4 stages
of conventional cyclones with a twin cyclone at the top. The pressure
drop across the top twin cyclone was about 100 – 125 mmWg.

The existing top stage twin cyclone was replaced with a
low pressure drop cyclone.
The top cyclone was at a height of nearly 106 metres.

The implementation of this project involved removal of
the existing cyclone and fixing of the new LP cyclone.
The normal procedure involves the following steps:
• Removal of the bricks inside the existing top cyclone
• Removal of the old cyclone
• Installation of the new cyclone
• Refractory lining of the new cyclones
This procedure however needs a stoppage of the plant of more than 90 days. The plant could
not afford such a long stoppage and the consequent loss of production.

22
Hence, the procedure was improvised to reduce the plant stoppage time. The improvised
procedure adopted by the plant is as below:
• The entire cyclone was assembled at the ground floor
• The inside brick lining was also done at the ground floor only
• The plant was then stopped and the existing cyclones removed
• The entire twin cyclone along with brick lining was lifted to the top and fixed. A special
crane was used for lifting the cyclones of about 150 MT to a height of about 106 metres.
In this manner, the project could be implemented with a stoppage of only 20 days.

There was an increase in the output of the Kiln, reduction in pressure drop of the pre-heater,
reduction in Kiln section power consumption and reduction in Kiln specific thermal energy
consumption. The comparison of the conditions and the energy consumption before and after
installation of the LP cyclones are as below:
Parameter Before Implementation After Implementation
Clinker Production 2650 TPD 2850 TPD
DP across Top Cyclone 100 – 125 mmWg 70 – 90 mmWg
Kiln section Power 30 kWh /ton 28.5 kWh / ton
Heat Consumption 830 kCal / kg 810 kCal / kg
The implementation of this project resulted in a power saving of 1.5 units / ton of Clinker,
which annually amounted to 14 lakh units / year. Additionally there was also the thermal
energy reduction of about 20 kCal / kg. The increased output of 200 TPD of clinker also aided
in reducing the fixed cost component.
Financial analysis
The total benefits amounted to a monetary annual savings of Rs 2.4 millions. The investment
made was around Rs 2.2 millions. The simple payback period for this project was 11 months.
Benefits of low pressure drop cyclone Cost benefit analysis

• Lower pressure drop across P.H. • Annual Savings - Rs.2.4 millions
• Reduction in P.H. fan power consumption • Investment - Rs.2.2 millions
• Increase in clinker production • Simple payback - 11 months
• Reduction in thermal energy consumption.

24
The replacement with LP cyclones has been implemented only in about 25% of the plants and
that too only in majority of the cases for the top cyclones.
The potential for replacement with LP cyclones exists
in atleast about 100 cyclones (50 plants x 2 cyclones
per plant). The investment potential is about Rs 1000
millions (USD 20 millions)
LP cyclones for preheater

23

25
Case Study - 4
Install a high level control system for kiln operation
Background
The Kiln is an important equipment in a Cement plant. The steady and continuous operation
of the Kiln is essential for producing good quality Clinker,
higher level of output and lower energy consumption. The
older Kilns are operated more based on manual control of
various process parameters.
In the next level of operation systems, rule based PID

controls were introduced such as – changing the coal
quantity based on temperature, varying fan speed with
drought etc., were introduced.
The recently installed high level control systems are based

on an “adaptive-predictive” methodology. Based on the
several operational parameters, the results are predicted
and action taken accordingly.
The actual results are also measured periodically and given as inputs to the system. This
helps in refining the prediction mechanism and improving the overall efficiency of the control
systems.
In the latest plants high level control systems have been installed and the control is more
automated. The system operates the plant much the same way, as the best operator would
do, on a continuous basis.
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.

A new high level control system was introduced to operate the Kiln.

The Kiln was initially started in the manual method and after reaching the steady operation
the Kiln was put in the high level control system.

There was a marginal increase in the output of the Kiln, reduction in pre-heater exhaust
temperatures, Cooler Exhaust temperature and steady operation of the Kiln.

26
The benefits achieved are as below.
• Reduction in Pre-heater exhaust temperature by 5°C.
• Reduction in Cooler exhaust temperature by 5°C.
• Variation in exhaust temperatures reduced from ± 10°C to ± 5 °C.
• Variation in clinker litre weight reduced.
• Reduction in thermal energy consumption by 10 kCal / kg of clinker
• Additionally there was also an improvement in the outlet of the kiln by about 3%
Financial 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.
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)


27

28
Case Study - 5
Usage of Cheaper Fuels for Calciner Firing
Background
The Kiln and the Calciner are major consumers of fuel in a Cement plant. The fuel cost
amounts to nearly 20 % of the manufacturing cost.
The increasing cost of fuel and the competition
among the units have made the Cement units to
take up many thermal energy saving projects. The
plants are also looking for avenues for reducing
the cost by replacing the costly fuels with cheaper
fuels. The possible fuels that have been tried by
the Cement units include Lignite, Rice husk and
Ground-nut shell.
Previous status
In a million tonne dry process pre-calciner plant, Coal was being used as fuel for firing in both
the Kiln and Calciner. The Coal was having a Calorific value of about 5900 kCal / kg with a
cost of about Rs. 2000 / MT.

A provision was made to utilise Rice husk in the Calciner. With the new system it was possible
to replace part of the coal fired in the Calciner with Rice husk.

A hopper was installed by the side of the pre-heater building for storing the Rice husk. The
rice husk was fed to this hopper with the help of front end loaders. The Rice husk was
conveyed to the Calciner with the help of a Rotary blower of 32 m3 / hour capacity. The whole
system was fabricated with the waste material available in the plant. The system was hooked
up with the main system during a brief stoppage of the plant. The system could be operated
for about 8 months of non- rainy dry season.

The implementation of the project resulted in the reduction of the cost of fuel used in the
Calciner. The cost comparison of Coal and Rice husk are as below;
Parameter Coal Rice husk
Cost Rs.2000 / MT Rs. 750 / MT
Calorific value 5900 kCal / kg 2900 kCal / kg
Energy cost Rs. 340 / MMkcal Rs. 260 / MMkcal

29
The rice husk was used for replacing about 10% of the total coal used for firing in the
calciners. This resulted in reduction of the total thermal energy cost, with the other conditions
such as output, temperature, pressure etc. remaining the same. There was also a marginal
reduction of the power consumption in the coal mill, as the rice husk was used directly without
grinding. The rice husk becomes wet and handling becomes difficult during the rainy season.
Hence, the usage of rice husk was restricted to the non-rainy and dry season (about 8 months
in a year).
Financial analysis
The annual benefits (in the form of reduction in thermal energy cost) was about Rs. 3.5
millions. The equipment required for conveying and firing in the pre-heater was fabricated in-
house with available material and hence the investment was negligible.
Benefits of using cheaper fuel

• Reduction in thermal energy cost
• Marginal reduction in coal mill power consumption
Replication Potential
Several systems are operating in plants abroad with waste materials such as used tyres,
municipal waste etc., This is an excellent project with good replication potential.
The discussions with various consultants and experts indicates that there is tremendous
potential for installing such systems. There is a need to initiate a demonstration project – a
comprehensive one with mechanisms for collection of waste, processing & firing in the kiln.
With the successful installation of a system in one / two installations can lead to a high
replication effect.
The benefits of implementing this project is two-fold - Reduction of fuel cost in the cement
plant and waste disposal.

• Annual Savings - Rs. 3.5 millions
• Investment – Negligible

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31
Case Study - 6
Variable Speed Fluid Coupling for Cooler ID Fan and

Replacement with Lower Capacity Motor
Background
The fans in a Cement Plant are major consumers of power. One of the important fans in a
Cement plant is the Cooler vent fan. The hot clinker produced in the Kiln is cooled in the
Cooler with the help of air. The air after exchanging heat with the hot clinker is partly used
in the Kiln as secondary air & tertiary air and the remaining air is vented through the Cooler
exhaust fan.
The exhaust air quantity keeps varying according to the operation of the Kiln, clinker production,
coal quality, clinker quality etc,. The Cooler ID fan therefore has to be designed with excess
capacity to meet the extreme requirements. Also, the Cooler ID fan has to be continuously
controlled so that the Kiln hood draught is maintained at – 1mmWg to – 4 mmWg.
Typically, the control of the Cooler ID fan is through the damper. The damper is put on closed
loop with the Kiln hood draught. The control of a centrifugal fan by damper is an energy in-
efficient method as part of the energy supplied to the fan is lost across the damper. The 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 a Cement plant,
the Cooler ID fan offered a good scope for saving energy. The details are as below.
Previous status
In a million tonne dry process pre-calciner plant, the Kiln had a conventional grate Cooler and
the Cooler ID fan was being controlled by damper. The fan was driven by a HT motor
(6.6 kV) of 315 kW and the consumption was around 123 kW. The observations on the system
are as below:
• The operation of a centrifugal fan by throttling the damper is energy inefficient, as part of
the energy supplied to the fan is lost across the damper. The energy efficient method is
to vary the speed to meet the process requirements.

32
• Also, the loading of the motor is only 39 %, leading to in-efficient operation of the motor.
In this system, there was a good potential to incorporate a variable speed mechanism and also
derating the motor to reduce the energy consumption.

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

After installation of the VFC, the speed of the fan was reduced manually in a gradual manner
from 750 rpm. The control of the hood draught was still done through the damper. The other
conditions remained the same as before. Consequent to the satisfactory operation of the VFC
in manual fashion, it was put in closed loop with the hood draught.
The project took about 2 week for installation. This was taken up along with the annual Kiln
shut down and hence the additional stoppage of the Kiln was avoided. The implementation
was done in a phased manner and the closed loop operation of the VFC was put into effect
in about a months time. As the VFC usage is well established and reliable, no problems were
faced during implementation of the project.

There was a drastic reduction in the power consumed by the Cooler ID fan. The comparison of
the conditions and the power consumption before and after installation of the VFC are as below:
Power consumption with damper control - 123 kWh
Power consumption with VFC - 76 kWh
The installation of VFC resulted in power saving of 47 kW. The total annual power saving was
about 3.84 lakh units.
Financial analysis
This amounted to an annual monetary savings (@ Rs 3.30 / unit) of Rs. 1.15 million. The
investment made was around Rs 0.5 millions. The simple payback period for this project was
5 months.
Benefits of variable fluid coupling & lower capacity motor

• Damper loss avoided
• Higher PF and motor efficiency
• Lower power consumption
• Investment - Rs. 0.5 millions

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34
Case Study - 7
Variable Frequency Drives for Cooler Fans
Background
The fans are major consumers of power in cement plant. The Cooler
fans are some of the important fans in the Cement plant. The hot
clinker produced in the Kiln is cooled in the Cooler with the help of
cool atmospheric air.
The cool atmospheric air supplied to the Cooler through multiple

number of Cooler fans. The Cooler air quantity is dictated by the
clinker production, condition of the Kiln & Cooler and other process
parameters.
The clinker bed through which the cooler air is to be pushed, also
varies from time to time. This alters the system resistance and hence
the fan flow. In the older Coolers, the fans are controlled by throttling
of inlet dampers / controlling the inlet guide vanes.
In both these controls, a part of the energy supplied to the fan is lost
across the damper / guide vane. The capacity control is also slow
and not very accurate. The latest method of control is to vary the
speed of the fans to control the capacity.
Many plants have adopted this control and achieved substantial benefits both in the form of
lower energy consumption & better control. The details of the implementation of this project
in a Cement plant is detailed below.
Previous status
In a million tonne dry process pre-calciner plant, the Kiln had a conventional grate Cooler and
7 numbers of Cooler fans were being operated for supplying the Cooling air. The first four fans
were regularly throttled to meet the varying requirements. The observations made on the
system are as below:
• The operation of a centrifugal fan by throttling the damper is energy inefficient, as part of
the energy supplied to the fan is lost across the damper.
• Also, the loading of the motor is varying between 50 % to 60 %, leading to in-efficient

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

The first four fans were installed with Variable Frequency Drives (VFDs).

35

After installation of the VFDs, the varying requirement of the process was met by varying the
speed, thus avoiding the damper pressure drop. The fans were operated with damper fully
open. The VFDs were put in closed loop with the volume flow to ensure constant flow of air
to the Cooler.
The project took about 2 week for installation. This was taken up along with the annual Kiln
shut down and hence the additional stoppage of the Kiln was avoided. As the VFD usage is
well established and reliable, no problems were faced during implementation of the project.

There was a drastic reduction in the power consumed by the Cooler fans. The power saving
in the fans is on account of
• Saving in the energy lost across the dampers
• Increase in the operating efficiency of the motor. The efficiency of the motor depends on
the V/f ratio. In the case of the VFD, the voltage is varied to maintain the V/f ratio at the
designed value. Hence, the efficiency of the motor is maintained at a higher level even at
lower loading of the motor.
The comparison of the conditions and the power consumption before and after installation of
the VFDs are as below:
Drive Rating (kW) Power Power Saving

consumption consumption through
before VFD after VFD VFD
Fan – IA 75 Kw 45 kW 32 Kw 13kW
Fan – IB 75 kW 44 kW 30 kW 14 kW
Fan – IC 110 kW 68 kW 54 kW 14 kW
Fan – IC 110 kW 59 kW 44 kW 15 kW
Total Saving - 57 kW
The installation of VFD resulted in power saving of 57 kW. The total annual power saving was
about 4.57 lakh units.
Financial analysis
This amounted to an annual monetary saving (@ Rs 3.30 / unit) of Rs 1.50 million. The
investment made was around Rs 2.50 million. The simple payback period for this project was
20 months.

36
Benefits of variable frequency drive

• Damper loss avoided
• Constant V/f ratio - hence higher motor efficiency
• Excellent control of capacity
A cement plant has got about 30 – 35 numbers of fans driven by LT (415 Volts) motors. The
application for VFD for cooler fans is a proven project. Majority of the plants have already
implemented the high potential VFD projects in the cement plant.
The potential for installing VFD exists in atleast another 5 fans in say about 100 plants. The
investment potential is therefore (500 VFDs each with an average investment of Rs 200,000)
- Rs 100 millions (USD 2 millions)

• Annual Savings - Rs. 1.50 million
• Investment - Rs. 2.50 millioin
Note
Though the company has utilised in-house resources, the investment equivalent for the project
is Rs.1.0 million. This has been taken for financial calculations.

37

38
Case Study - 8
Replacement of Existing Cooler I Grate with High Efficiency

Cooler System
Background
The Cooler is an important equipment in the Kiln section of Cement plant. The clinker cooler
performs the important function of cooling the hot clinker produced in the Kiln thereby
recuperating the heat back to the Kiln in the form of
hot secondary air. The operation of the Cooler is
therefore important for producing good quality clinker
and operating the plant in an efficient manner.
The older Cement plants had conventional grate

coolers for cooling the Clinker. These Coolers have
a maximum recuperation efficiency of 65 – 70 %.
The present trend has been to replace part of these
Coolers with a high efficiency system with higher
recuperation. Two such systems are popularly being
adopted in many Cement plants in our country. The
adoption of these systems have resulted in a saving of 35 – 50 kCal / kg of clinker in many
plants.
Previous status
In a 2500 TPD dry process pre-calciner plant operating at a capacity of about 2800 TPD, the
plant had a conventional Grate Cooler. The plant wanted to increase the capacity of the plant
to about 3000 TPD and also improve the energy efficiency.

The plant replaced the I grate with high efficiency cooler system. This was done to increase
the capacity of the Cooler and also improve the thermal efficiency of the system.
Additionally the following capacity upgradation measures were also implemented simultaneously.
• Increasing the height of the Calciner
• Installation of high efficiency classifier for both Raw mill and Coal Mill
• Conversion of the existing two fan system to three fan system
• Installation of high efficiency nozzles for GCT

The installation of the high efficiency Cooler was taken up simultaneously with the other
upgradation plans. The first grate comprising of nine rows of conventional plates was replaced
with high efficiency grate plates. The Kiln was stopped for about a month for the installation
of the high efficiency Cooler. The stabilisation time was around 5 days.

39

On account of the capacity upgradation projects the capacity of the Kiln increased from 2800
TPD to 3000 TPD. The installation of the high efficiency Cooler resulted in reduction in the
Cooler air quantity and cooler exhaust air quantity. There was also an improvement in the
steady operation of the Kiln, better quality and lower temperature Clinker. The over-all benefits
achieved are as below.
Parameter Before Implementation After Implementation
Clinker Production 2800 TPD 3000 TPD

Cooler air 2.6 Nm3 / kg 2.1 Nm3/ kg
PH outlet air 1.475 Nm3/ kg 1.444 Nm3/ kg
Clinker Temperature 180. C 120. C
PH outlet Temperature 370. C 336. C
PH loss 217 kcal / kg 191 kcal / kg
Cooler & Clinker loss 131 kcal / kg 120 kcal / kg
Radiation loss 69 kcal / kg 65 kcal / kg
Heat Consumption 780 kcal / kg 745 kcal / kg
Apart from the above quantified benefits the installation of the high efficiency Cooler also
resulted in
• Stabilised Cooler operation
• Avoiding of snow-man formation
Financial analysis
The implementation of this project resulted in an annual saving of Rs. 12 millions (only the
thermal energy saving). The investment made was around Rs. 29 millions. The simple payback
period was 24 months.
Benefits of high efficiency cooler

• Less cooler air
• Lower cooler exhaust and clinker temperature
• Annual Savings - Rs. 12 millions
• Compact - hence less radiation losses
• Investment - Rs. 29 millions
• Thermal energy saving - 30 to 40 kCal/kg of clinker
The above project is a potential replacement of the existing cooler with high efficiency
components. The potential for replacement exists is about 30 plants in India. The total
investment potential is Rs 900 millions (USD 14 millions).

41
Three types of high efficiency coolers are currently available and operating in Indian cement
industry. They are namely – CFG / CIS from Fuller / FLS, Pendulam cooler from IKN and
Pyrostep cooler from Krupp Industries. All the three have tremendous benefits for energy
saving.
Long-term options
A long term option exists particularly for the older
plants (kilns of age say more than 25 years) to entirely
throw out the existing cooler and replace it with a
entirely new high efficiency cooler.
The benefits are 3 fold – Higher energy efficiency

(80-90 kCal/kg of clinker ie., three times that of this
project), better product quality and ease of operation.
The energy saving alone would be about Rs 40

millions. The investment required for total
replacement would vary from Rs 300 millions to Rs
500 millions. Therefore the energy saving alone
cannot justify the replacement. The capacity
augmentation benefits also if included can make the
project more attractive.
IKN – Pendulum Cooler
SF Cross bar cooler

40

42
Case Study - 9
Installation of Low Primary Air Burner in Place of Existing

Conventional Burners
Background
The primary air is used for conveying and distributing the fuel into the Kiln. Conventionally
single channel tubular burners were being used for this purpose. The quantity of primary air
had a major bearing on the thermal efficiency of the system as ambient cold air was being
used as primary air. Hence, efforts have been taken up by various suppliers of equipment to
reduce the quantity of primary air by improvising the burners. Thus, the dual channel burners
and multi-channel burners came into being. The installation of these low primary air burners
resulted in reducing the primary air quantity from about 20 – 22 % to 11 – 12 % in the case
of dual channel burners and 5 – 7 % in the case of the multi-channel burners.
Previous status
In one of the cement plants, the Dual channel burner was being used for Kiln firing. The
primary air quantity was around 12 %.

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

The project was implemented over a period of 9 months. The new Multi channel burner along
with the new coal conveying system was procured and erected. The hooking up with the Kiln
was done during the annual maintenance stoppage. There was no problem during the
implementation of the project.

43
Benefits
The implementation of this project resulted in the following benefits:
• Reduction in Specific thermal energy consumption from 750 Kcal / Kg to 743 Kcal / Kg,
thus saving about 7 Kcal / Kg .
• The flame had become sharper and shorter.
• There was also a marginal reduction in the quantity of Cooler vent air.
Financial analysis
The total annual benefits amounted to Rs 3.2 millions. The investment made was around
Rs 8.5 millions. The simple payback period for this project was 32 months.
Benefits of high efficiency burner

• Reduction in thermal energy consumption - 7 kcal/kg of clinker
• Marginal reduction in cooler vent air
• Sharper and shorter flame
The potential for installing low air burner exists is about 40 installations. The potential investment
for this is about Rs 350 millions (USD 7 millions)


44

45
Case Study - 10
Usage of High Efficiency Crusher as a Pre-grinder Before the

Cement Mill
Background
The final process in a Cement plant is the operation of grinding of cement from clinker in a
Cement Mill. The Cement mills are generally Ball Mills. The Ball Mills can be either open-
circuit or closed circuit mills. The evaluation of the Ball Mills indicate that the Ball Mill is not
energy efficient in the coarse size reduction. The present trend is to install a Roll press or
Impact Crusher as a pre-grinder before the Mill for the initial size reduction. The installation
of the pre-grinder has the following advantages.
• Increase in capacity
• Reduction in specific energy consumption
Hence, all the Cement plants which have open circuit mills can install a pre-grinder system
and achieve substantial energy saving.
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 upgradation 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.

The plant installed a Horizontal Impact Crusher (HIC) of 300 TPH capacity (including
recirculation). The HIC was to act as a pre-grinder and perform the initial size reduction before
the Mill. The HIC had a three deck-vibrating screen to separate and return the coarse material
back to the HIC. The coarse was sent to the HIC back by gravity while the fines were
conveyed to the hopper through a belt conveyor. The fines from the hopper can be later fed
to the Mill through a belt conveyor. Thus the HIC and the Mill were made independent so that
the operation of one does not affect the other. The modified system is schematically shown
in the figure.

The HIC was installed separately and then hooked up to the system. The hooking up of the
HIC took about 5 days. The installation of the HIC increased the capacity of the Cement mill
from 125 TPH to 140 TPH. Consequently some more modifications were taken up to further
increase the capacity of the Mill.
The modifications that were done are as below;
• The three deck screen originally installed were of 12 X 37 mm, 8 X 20 mm and 3 X 8 mm

sizes. Consequently, after operating the plant the last screen size was modified to 5 X 12
mm.
• The diaphragm was shifted by 0.7 M towards the inlet
• The mill ventilation was improved by cutting open some of the dummy side diaphragm
plates.
• The grinding media sizes were gradually changed and were converted ultimately as below.
Identification Earlier Modified
I Chamber 90 – 60 mm 60 – 30 mm
II Chamber 15 mm Balls & 15 X 12 mm Balls &

12 X 12 mm Cylpebs 12 X 12 mm Cylpebs
The stabilisation of the system with all the modifications as mentioned above took nearly an
year.
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 upgradation.
The replication potential exists in 30 cement plants and the investment potential for this
project is Rs 1200 millions (USD 24 millions)

• Simple payback – 32 months

48

49
Case Study - 11
Conversion of Open Circuit Cement Mills to Closed Circuit by

Installing High Efficiency Separator
Background
The final process in a cement plant is the operation of grinding of cement from clinker in a
Cement Mill. The cement mills are generally Ball Mills. The Ball Mills can be either open-circuit
or closed circuit mills. In the case of open-circuit Ball Mills, the coarse material passes once
through the system and hence the grinding is not uniform.
The particle-size distribution is also broader with the presence of particles of different size
ranges. In view of this the recently installed Cement Mills are all closed circuit mills.
In the closed circuit mills the material at the outlet of the mill is fed to the separator. In the
separator the coarse and fines are separated and the coarse is fed back to the mill for further
grinding.
The installation of the closed circuit mills have the following advantages.
• Increase in capacity
• Avoiding of over & under grinding
• Reduction in specific energy consumption
Hence, all the old cement plants can convert their open circuit mills to closed circuit mills and
achieve substantial energy saving.

Previous status
In one of the older cement plants, the raw mill and the kiln sections were modernised by
installing Vertical Roller Mill and a new dry process pre-calciner Kiln. The Cement Mill section
was retained as it is, with the old long tube mills with high-energy consumption. There were
two Cement Mills namely C/M – 2 & C/M – 3 which were being operated continuously. The
capacity and other details of the mills are shown below.
The total production of the two Cement Mills was 70.8 TPH at a specific power consumption
of 35.9 units per ton. The specific energy consumption is comparatively higher with a good
potential for energy saving. Additionally, there was also a requirement for capacity increase
in the Cement Mill.

The two Cement Mills were close circuited by installing a common O-sepa type separator. As
installing individual separator was more expensive, a common separator was installed. The
separator was slightly of higher capacity to take care of additional capacity requirement in
future with Roll Press.
Details Cement Mill – 2 Cement Mill – 3
Size 2.6 M F X 12 M long 3.2 M F X 11.4 M long
Compartments 3 3
Mill Drive 1300 HP 2000 HP
Output 25.2 TPH 45.6 TPH
Fineness 280 m2 / Kg 280 m2 / Kg
Specific Power consumption 38 units / ton 34.8 units / ton

The separator and the Bag filter were located above the mills by constructing two floors over
the mills, as space was not available. As the operation of the Cement Mills was critical from
the production point of view, the implementation was taken up in a phased manner. The
building construction, erection of Bag house, Air separator etc. were all done with minimal
stoppage. The over all stoppage was only 35 days for one mill.
The other modifications that were done are as below;
• The Mills were converted to two chamber mills.
• The ordinary liners were converted to Stepped liners in the I chamber and Drag-peb liners
in the II chamber.
• The II chamber grinding media were converted to cylpebs.
• The air balancing was done by both the suppliers and the Plant team
Benefits
• Increase in capacity from 70.8 TPH to 81.0 TPH (both mills together) ie. 22% increase over
the existing capacity.
• Reduction in specific power consumption from 35.9 units / ton to 32.0 units / ton.
• Better, Cement cooling due to larger amount of air flow through the air separator.
• Avoidance of over grinding (particulate under 3 microns size came down from 4.8% to
2.7%).
• Increase in Cement strength by 10 % over open circuit Mill for same quality of clinker.
Financial analysis
The total annual benefits (energy saving and increased production) amounted to
Rs 120 millions. The investment made was around Rs 350 millions. The simple payback
period for this project was 36 months.
Presently many high efficiency separators from all the motor manufacturers are available and
operating in India. All are equally good and help in reducing the energy consumption and
increasing the overall output of the mill.
The introduction of the high efficiency separator and close circuiting of the mill is possible in
about 30 mills with an investment potential of Rs 1500 millions.


Case Study - 12
Install A Co-Generation System For Recovering Heat From

Kiln Pre heater And Cooler Exhaust
Background
The cement kiln is a major consumer of heat with heat consumption ranges from 685 kCal/
kg in the modern plant to about 800 kCal/kg in the older plants. Out of this heat, nearly about
25% of the heat energy is vented from the preheater and cooler. The heat is vented at lower
temperatures of 300 – 350°C from the preheater and 250- 300°C from the cooler exhaust. A
small part of this heat is utilised for coal drying and limestone drying depends on the requirement
of the plant.
170 kCal/kg Thermal Energy Balance - Typical
330oC
Kiln – Theoretical –
requirement – 420 kCal/kg
Preheater
750 Kcal/kg
Coal firing
300°C
140 kCal/kg
Radiation loss (Recoverable)
70 Kcal/kg
Cooler
The heat can be utilised for generating power and partly meets the power demands of the
plant. The cooler exhaust is generally clean and dust free, while the preheater air is dust
laden with a particle concentration of about 250 gms/m3.
Previous Status
In a one million tonnes per year cement plant with a 4 stage preheater system, the exhaust
heat loss from the system (preheater and cooler) was about 40%
54
Energy saving projects

Install a steam based waste heat recovery system for recovering heat from preheater and
cooler exhaust and generating power.
Implementation methodology and problems faced The project is currently under implementation.
The stoppage expected for this project is about 2 months. The overall time target for
implementation of this project is about 9 months

The benefits of the projects are:
The power plant based on waste heat is expected to generate 7.6 MW with a net exportable
power of 7 MW
This will generate about 1,68,000 units/ day which otherwise would have been bought from
the state grid.
Financial Analysis
The annual benefit expected on account of the power generated from the WHR plant is
Rs. 200 millons. The total investment made is about Rs.900 millions, which has payback
period 54 months
The implementation of WHR in Indian cement industry has not been taken up in a big way.
Out of total 130 cement plants only 3 units have tried the system and that too not very
successfully. There is a need to initiate and install a few demonstration sites, which can
convince the industry to go forward.
Two immediately proven systems – steam based waste heat recovery system (supplied by
many WHR system suppliers) and organic liquid based WHR systems (supplied by Ormat,
Israel) are already operating in several plants abroad satisfactorily and have a good
implementation potential in India.
The only obstacles in the way of implementing this project is – dust removal from preheater
air and high investments (payback period always more than 5 years) On a conservative
estimate the WHR potential in Indian cement industry is about 150 MW.


55

56
Supplier Address Opp Paras Cinema

New Delhi 110019
High-efficiency separator Tel: 011 26426031/5037/26416578
Mr V C Rao Fax: 011 26443175
Managing Director Email: wildelhi@vsnl.net
LNV Technology Private Limited
I-E, Alsa Regency (1 floor) Mr Rakesh Sharma
165, Eldams Road VP - Mktg & Business Dev
Chennai - 600 018 Fuller India Limited
Tel: 2431 4259/69/79 Capital Towers
Fax: 2431 4289 180, Kodambakkam High Road
lnvt@hathway.com Chennai 600034
Tel: +91 (44) 28253182 (D) / 8276030 / 8276343 /
AUMUND ENGINEERING PVT. LTD. 8279569
LAKSHMI NEELA RITE CHOICE CHAMBERS Fax: +91 (44) 28279393
5, BAZULLAH ROAD, T. NAGAR, Email: rakesh.sharma@flsmidth.com
CHENNAI - 600017
Tel. No. : 91-44-28222048/49 Mr R. K Sharma
Fax : 91-44-28222046 Head Marketing
Larsen & Toubro Limited
Material Handling Equipment
Cement & Allied Machinery
Mr K.J.Puetz
G4 Building, 2nd Floor
Chairman & Managing Director
Powai Works, Saki-Vihar Road
Mr. Rajiv Manchanda
Mumbai 400 072, India
Sr. Vice President - Corporate
Tel:+91-22-28581401/11 Extn:2423 / Direct line:
Enexco Teknologies India Limited
+91-22-2858 1752
B-17, Geetanjali Enclave
Fax: +91-22-28581633 / 28581126
New Delhi -110017
e-mail: rks@epc.ltindia.com
Phone: +91-11-2669 2847- 50 (4 lines) / 2669
1524 / 2669 2425(2 lines) Automation Systems
Fax: +91-11-2669 1543 Mr. Arjun Gupta
Email: enexco@vsnl.com Techfab Systems
507 Eros Apartments, 56 Nehru Place
Bharat Heavy Plate &Vessels Limited New Dehli - 110 019
(Ministry of Industry, Department of Heavy Tel.:+91.129.527 29 95
Industry) email: arjung@vsnl.com
B.H.P.V Post
Visakhapatnam –12 Prof Mathai Joseph
Andhra Pradesh Executive Director
Phone : 0891-517381 - 91 (10 lines) Tata Consultancy Service
Fax : 0891 – 517626 1, Mangaldas Road,
Pune - 411 001
Mr. R G Kumar Phone: +91 20 612 2809
Director Fax: 91 20 612 3713
BHP ENGINEERS LTD. Email: mathai@pune.tcs.co.in
F-42A,1st Main Road,
Annanagar East Mr Jayant Kulkarni
Chennai-600102 Manager – MktgSystems
Tel: +91(044) 26208176 Tata Honeywell Limited
Fax: +91(044) 26203328 55-A/8 & 9, Hadapsar Industrial Estate
Email: rgkumar@bhpengineers.com / Pune 411 013
bhpchn@bhpengineers.com/ Tel: +91 (020) 2675531 / 672612
bhpchn@md4.vsnl.net.in Fax: +91 (020) 2679404 / 672205
Email: JayantK@tatahoneywell.co.in
All cement plant machinery
Mr. A K Dembla
Mr Debashish Ghosh
President - Marketing
Manager Commercial Marketing
Humboldt Wedag India Ltd.
Allen-Bradley India Ltd
C-29, Ground Floor, Nehru Enclave
C-11, Industrial Area

57
Site 4 New Delhi-110 024

Sahibabad Telf:91 11 2464 76 70
Ghaziabad 201010 Fax:91 11 2464 76 74
Tel; +91 (120) 2895247 – 52 sharma@loescheindia.com
Email: dghosh@ra.rockwell.com
Waste Heat Recovery Systems
Mr K S Krishna Kumar
Product Executive Mr Edward J. Loring
Ramco Systems Limited Sales & Marketing Manager
SBU Head - Enterprise Process Solutions Exergy Incorporated
No 64, Sardar Patel Road Post Office Box 209
Taramani Hanson, MA 02341
Chennai 600113 Tel: (781) 294-8838
Tel; +91 (44) 2354510 Fax: (781) 294-8144
Fax: +91 (44) 2352884 eloring@Exergyinc.com
Email: hr@rsi.ramco.com
Mr Yehuda Lucien Bronitzcky
Fly-ash conveying system Chairman
MICAW BEEKAY LTD Ormat Industries Limited
Beekay House, L-8, PO Box 68, 81100 Yavne
Green Park Extension Israel
New Delhi -110016 Tel: 972 8 943 3777
Fax: 972 8 943 9901
Consultants info@ormat.com
Mr. Vasudeva
Unit Director Dr J M Chawla
National Council for Cement and Building Managing Director
Materials Caldyn Thermowir Pvt. Ltd.
A-135, Defence Colony A-102 Satya Apartments
New Delhi-110 024 Masab Tank
Tel:0129- 5241963,5310909,5312423 Hyderabad 500028
Fax: 91-129-5242100
Email: info@cementresearch.com Mr Tadashi Nishimura
Executive Vice President - Marketing
Mr A K Pathak Kawasaki Heavy Industries Ltd.
President & Chief Executive 8, Niijima, Harima-cho, Kako-gun,
Research and Consultancy Directorate Hyogo 675-0155, Japan
ACC-RCD Phone : 81-794-35-2131
ACC Campus Fax : 81-794-35-2132
LBS MARG
Thane 400 604 Mr A K Sundararajan
Tel: 022 25823631 Dy General Manager
Bharat Heavy Electricals Limited
Mr Kapil Wadhawa Tiruchirapalli-620014
Deputy Manager Phone - 91(431) 2520713, 2520642
Holtec Engineers Pvt Ltd Fax - 91(431) 2520306
Holtec Center,
A Block, Sushant Lok Mr S V Pendse
Gurgoan-122001 Sr Manager – Sales & Marketing
Phone: (91) 124-638-5095 Thermax Ltd
Fax: (91) 124-638-5114 Energy systems Division
E-mail: kw@holtec.com D-1, MIDC Industrial Area
Chinchwad,
Vertical Roller Mills Pune 411 019
Mr. K B Sharma Tel : (020) 4126349
Vice President - Marketing Fax : (020) 7474640
LOESCHE INDIA Ltd. Email : svpendse@thermaxindia.com
E-2, First Floor, Defence Colony

Energy Conservation in Caustic Chlorine Industry
58
Caustic Chlorine
Per Capita Consumption 1.5 kg
Growth percentage 5.5%
Energy Costs Rs 17900 million (US $360 million)
Energy saving potential Rs.650 m (US $ 13 million)

saving projects Rs.1300 m (US $26 million)

59
Introduction
Electrolysis of salt results three products - caustic soda, chlorine and hydrogen in the proportion
of 1:0.88:0.025. The first two form the major products whereas hydrogen comes in the negligible
proportion.
Caustic soda is produced by electrolysis of salt

(NaCl). Power and salt form the key inputs. More
than 75% of the production and sales is in the
lye form because caustic soda is generated in
liquid form. This liquid form called ‘lye’ is then
evaporated to obtain solids or flakes. Most of the
end users use aqueous solution of caustic soda.
Thus, it makes economic sense to keep it in lye
form. Transportation of lye is cumbersome
whereas solid form is easy to transport. It is
primarily for this reason that lye is converted into solid form.
In India, caustic soda is more in demand than chlorine. However, in global markets it is the
demand for chlorine, which drives the demand-supply of caustic soda.
Paper & pulp, manmade fibers, and soaps form the major user industries of caustic soda in
the domestic market. Paper & pulp industry is the largest single user sector of caustic soda
in India.
For caustic soda manufacturers balancing the prices of caustic soda and chlorine becomes
critical to get maximum returns on an ECU.
However as caustic soda and chlorine are used
in different kinds of industries, the demand for
them is rarely balanced. This creates problems
for manufacturers in marketing these two
products.
The units are mainly located on the west coast

of India, due to two reasons, namely abundant
availability of salt, one of the key inputs required
for the production of caustic soda and proximity
to user industries. Power and salt form the key
inputs in the manufacturing of caustic soda. Power is a major cost item as it accounts for
almost 65% of the total cost of production.
The capacities in the domestic sector have outstripped demand growth.
Thus, only those producers who have access to cheap power and use latest technology will
be able to survive in the long-term.
The growth profile of caustic chlor industry in India is about 4%.

60
Demand & Consumption (Indian Scenario)

Demand growth for caustic soda depends on growth in the user sectors. Demand is further
affected by the substitution of caustic soda with other alkalis.
Paper & pulp, man-made fibers, soaps and alumina are the major user sectors of caustic soda
and they account for more than 80% of the domestic demand.
Paper and pulp sector has been growing at the rate of around 6% pa, in volume terms. Soap
industry is expected to grow at the rate of around 9-10% pa. The demand for caustic soda
is growing from this industry. Caustic soda is used in the conversion of bauxite into alumina.
The demand from this sector is however sluggish. Demand from man made fiber industry, has
slowed down as the sector itself, is growing at a sluggish pace of less than 6% pa. Thus
overall the demand is expected to grow at a moderate rate of around 6-7% pa.
Apart from these industries, caustic soda and chlorine find use in other industries such as,
chemical, water treatment, etc.,
Demand spread over various user sectors insulates caustic soda from the downtrend in any
one sector. Conversely, spurt in demand in any one of the user sectors does not translate into
equivalent growth in demand for caustic.
Demand also suffers from substitution effect to some extent. Based on the considerations
such as price, availability and the final application, it is substituted by other alkalis such as
soda ash. Though the extent of substitution is small, its effect gets magnified during recession
when demand from user sector falls.
Most of the capacity additions in India were planned in early 90’s when the domestic caustic
soda sector was doing well.
Demand & Consumption

(Global Scenario) Domestic Consumption Pattern of Caustic Soda in Various Sectors
Globally the chlor-alkali industry 35%

30%
is driven by the demand-supply 30%
25%
of chlorine unlike in India and 25%
Percentage
20%
therefore globally, caustic soda is 15% 12%
14%
considered as a byproduct. 10%

9% 8%
Demand for chlorine is higher than 5% 2%
that of caustic and many a times 0%

es
na
l
try
lp
rs
ica
a part of caustic produced in the

en
Pu
ibr
mi
he
us
em
tm
Alu
eF
Ot
Ind
r&
ea
process is wasted.
Ch
ad
pe
Tr
ap
nm
Pa
ter
So
Ma
Wa

61
Global consumption pattern of caustic soda also differs from that of Indian consumption.
Globally chemicals account for 40% of the total consumption followed by paper & pulp, etc.
The major manufacturers of caustic soda/ chlorine are located in USA, China and Saudi
Arabia. USA is the largest consumer and is also a net importer whereas the China and Saudi
Arabia are the net exporters. Exports from China affect the domestic industry in a major way.
World production of caustic is estimated to be around 40 million ton per year. India accounts
for about 4% of the world production.
Cost of power in caustic soda producing regions (FY97)

Country Power tariff (Rs)
USA 1.8
China 1.0
Saudi Arabia 0.8
India 2.8 (4.2 in FY98)
The Process
Caustic Soda (NaOH), is manufactured commercially by the electrolytic process based on the
Faraday’s law of electrochemistry.
The basic equation depicting the process for manufacture of caustic soda commercially is :
NaCl + H2O —————> NaOH + ½ Cl2 + ½ H2
The above reaction is initiated by passage DC current through an aqueous solution of sodium
chloride (Brine). Chlorine gas is liberated at the anode and hydrogen as by product is
liberated at the cathode of the electrochemical cell.
The electrolyte leaving the electrolyte cells is saturated with chlorine. Most of the chlorine is
removed by adding acid (HOCl + HCl -> Cl2 + H2O), then the remaining chlorine is converted
to chloride by adding caustic soda and sulphite (NaOH + HCl -> NaCl + H2O), (2NaOH +
NA2SO3 + Cl2 -> Na2SO4 + 2NaCl + H2O). Some of the chlorine from the dechlorination
process and from other streams on the plant, is reacted with caustic soda to produce sodium
hypochlorite (2NaOH + Cl2 -> NaOCl + NaCl + H2O). Sodium hypochlorite is sold to make
bleach products.
Chlorine gas formed at the anode of the electrical cell is cooled and dried of any moisture.
It is then compressed and cooled to -36 degrees celcius so that it forms a liquid.The liquid
form of chlorine is less bulky and easier to transport.
Some of the chlorine gas formed in the electrical cell is burned in hydrogen, which is formed
at the cathode of the electrical cell. This reaction produces hydrogen chloride gas (Cl2 + H2
-> 2HCl). This gas is dissolved in water to form a 32 per cent hydrochloric acid solution.

62
Domestic Consumption Pattern of Caustic Soda in Various Sectors
35%
30%
30%
25%
25%
Percentage
20%
14%
15% 12%
9% 8%
10%
5% 2%
0%
res
na
l
lp
try
rs
t
ica
en
Pu
mi
he
Fib
us
em
tm
Alu
Ot
Ind
r&
rea
Ch
e
ad
pe
ap
T
nm
Pa
ter
So
Ma
Wa
Domestic over capacity and cheaper imports resulted in a glut of caustic soda in domestic
market in the last few years. This can be seen from the fall in capacity utilisation over the
years.
The average capacity of the domestic caustic soda plants is 150 tpd as against the global size
of 450 tpd. This indicates very low economies of scale.
The latest production figures for the last three years is depicted in the form of a graph below:
YearwiseProductionfor CausticSoda
1481.3 1480
1500
1400 1343.8
000'Metric
Tonne 1300
1200
1999-2000 2000-2001 2001-2002
Series1 1343.8 1481.3 1480
Year

63
Conventional processes
Diaphragm Cell
Diaphragm cell contains a diaphragm, usually made of asbestos fibers. This separates the
anode from the cathode and allows ions to pass through electrical migration simultaneously
reducing the diffusion of products. The diaphragm permits a flow of brine from anode to
cathode and prevents side reaction. Sodium ions along with sodium chloride are discharged
into the cathode chamber. Thus sodium chloride is separated in evaporators when caustic
soda is obtained in the form of aqueous solution. The recycled salt is combined with fresh salt
for further use.
This process is now obsolete and is not being used in any commercial manufacturing process
in India.
Mercury Cell
This process is one of the older processes being used in India and accounts for nearly 30%
of the caustic production in the country.‘
In this, anode (made up of graphite or titanium) remains fixed and a moving pool of mercury
acts as cathode. Free sodium from the sodium chloride solution (salt water) forms a sodium
mercury amalgam. The amalgam is decomposed using in a separate vessel with soft water
producing 50% caustic solution and hydrogen gas. The depleted salt water is cleansed of
chlorine, re-saturated with salt, purified and recycled.
This is an older process and has the advantage of relatively lower capital costs. However, it
has two significant disadvantages:
• Power consumption is high at around 3,200 kwh per ton of caustic soda (100%) compared
to low power consumption in diaphragm cell and membrane cell.
• Mercury cell plants are pollution hazards since mercury is a major pollutant and also
evaporates in small quantities at the operating temperature.
Because of the high specific energy consumption and pollution hazards, the process is now
being phased out. The process is depicted schematically below:

64
Mercury Cell
Raw Salt
Diluted Brine
Brine Raw Brine

Saturation
Caustic Precipitants
Solution
Dechlorination Precipitation Residue
Purified Brine
Filtration
Hydrochloric Hydrochloric Acid
Acid
Heat
Exchangers
Anolyte
Electrolysis
Amalgam Mercury Cooling

Water
Amalgam
Caustic Decompositio Drying
Solution
(47.5%) Hydrogen
Cooling Cooling Compression
Mercury Mercury Liquefaction

Removal Removal
Bottling
Storage
Dispatch/ Flaking Unit Hydrogen Dispatch

Bottling/ Boiler
Flaking Unit

65
Membrane Cell
This is the most modern process and accounts for about 70% of caustic chlor production in
India.
This cell uses a semi-permeable membrane to separate the anode and cathode compartments.
Membrane cells separate the compartments with porous chemically active plastic sheets that
allow sodium ions to pass, but reject hydroxyl ions.
Sodium ions diffuse to the cathode area where they react with de-mineralized water to produce
30-35 % caustic soda and hydrogen gas (The caustic soda is subsequently concentrated to
50 % levels). The salt water is dechlorinated, purified, and recycled in the process. The
schematic diagram of a typical membrane cell is shown below:
Lean brine, Cl2 H2, NaOH (32%)
Anode Cathode
Weak
Na+Æ NaOH
H2OÆ Soln
Feed Brine Dilute caustic soln (28%)
This process has been gaining importance in the country because of number of advantages
over the mercury cell process which are as follows;
It has lower power consumption of 2,400-2,500 kwh per ton of caustic soda as compared to
around 3,200 kwh per ton in the mercury cell process. When a mercury unit is converted to
membrane cell, it is able to increase its capacity by nearly 20% because the available power
can now produce more quantities of caustic soda.
It has lower maintenance cost than the mercury cell

process and simpler plant operations.
Caustic soda produced has high purity and thus finds

more market like in pharmaceuticals, semiconductor,
biotech etc.
The disadvantages of this process are:
• Itis more capital intensive
• It requires dependence on imports for technology.
• The selectively permeable membrane is manufactured under patent by only a select

companies in the world. The three major names in this business are Dupont, ICI Chemicals
and Asahi Chemical Co under different brand names.

66
• The technology for the cells for the reaction is also available with a select few companies
like Di Nora of Italy, ICI of UK and Asahi of Japan.
• It requires high quality of salt solution.
• The major impurities in the raw salt (NaCl) are sodium sulphate, Calcium chloride and
magnesium chloride which needs to be removed to the traces level (parts per billion) as
they directly affect the membrane operation and life.
• Membranes need to be replaced once in every three years.
• Power consumption of the membrane cells increase by 40-50 KWh/Ton of caustic per year
because of the contamination of the membranes.
• After 3-4 years time it becomes economically viable to replace the membranes with new
ones.
For ease of transportation and requirement at the user end, a small percentage of caustic
soda is converted to flakes. The flaking proces is detailed below:
350-370o C
To Vacuum
Salt
Caustic Molten
(47.5 %) Pre Final Salt
Heater
concentration concentration (400-

450 o C)
66 % 98 %
Flaking
D rum
Vacuum
Caustic Flakes
Power is the most important input in the production of caustic soda. It accounts for about 65%
of the total cost of production.
The cost of power from co-generation is half the purchased power. The producers with the
co-generation plant therefore benefit from low variable cost. However the initial capital cost
for setting up these power plants is very high.
Caustic soda can be manufactured in any of the following types of cells - mercury cell,
membrane cell and diaphragm cell. Power consumption by membrane cell is the least of all
the three cells.

67
Energy requirement (For 1 ton of caustic) by Electrolytic processes
Energy kwh/ton Mercury Diaphragm Membrane
Electricity 2800-3200 2500-2600 2300-2500
Steam (equivalent) 0 700-900 90-180
Total 2800-3200 3200-3500 2390-2680
Relative energy cost % 92 100 75
Cost of setting up a green field plant based on membrane cell comes to around Rs 1.0 billion
for 100 TPD plant whereas that of converting the mercury cell to membrane cell comes to
around Rs 0.8 billion for 100 TPD plant.
Total energy consumption in caustic chlor is Rs 17900 million (USD 360 million).
Energy Consumption Pattern

Industries in India thereby assuring a regular and cheap source of power. The data regarding
the captive power plants for caustic chlorine industry is attached as Annexure-1.
From the total power consumed in the process, almost 90% is utilised in the electrolytic cells
in form of DC. Rectifiers are used to convert AC current to DC current.
Diode based rectifiers are slightly less efficient (96-96.5 %) than the more advanced thyristor
based rectifiers which have an efficiency advantage of 0.5-1%.
Specific energy consumption for various steps of the process is as follows for the membrane
process. In a caustic chlorine process, all the energy consumption is measured on 100%
caustic output basis.
1) Cell house:
Two kinds of cell configurations are preferred in the manufacturing process. Depending on the
configuration the SEC of the cell house changes. The Typical average figures of these two
configurations are:
a) Monopolar arrangement : 2300 KWh/Ton caustic (App.)
b) Bipolar arrangement : 2250 KWh/Ton Caustic. (App)
The lowest initial consumption recorded for cell house globally is 2150 KWh/Ton caustic. As
entioned the power consumption increases every year because of the membrane contamination.
The feed parameters to the cell also play an important part in the specific energy consumption
of the cell. The feed brine concentration and temperature should be properly monitored. A
decrease of 1 Deg C of temperature of feed brine or caustic can increase the energy
consumption of a cell by 5-6 KWh/Ton. Also an increase of dilute caustic concentration by 1%
can increase the specific energy consumption by around 13-14Units.
All these parameters are required to be monitored online continuously and close loop controls
are employed for maintaining the parameters. Good and advanced Instrumentation and controls
form the backbone of any caustic chlorine industry.

68
2) Chlorine Liquefaction:
The chlorine produced on the anode side of the cell is
wet and slightly impure. This chlorine is treated in the
chlorine house where it is cooled, dried and filtered
and finally liquefied.
This whole process is quite energy intensive as a lot

of cooling water and chilled water load is there. As a
thumb rule the chlorine compression and cooling
requires 204-205 KWh/MT Cl2 and another 50-55 KWh/
MT Cl2 is required for refrigeration. This takes the total
in a chlorine house to 250-255 KWh/ton of Chlorine
liquefied.
View of membrane cell house

Any reduction in the specific energy consumption of the chiller or chlorine compressor will
have a marked effect on the SEC of chlorine house.
3) Evaporator House :
The caustic solution obtained from the cells is of 32% concentration and needs to be
concentrated further for use as 47.5 % lye (aqueous soln.) or as dry flakes. Typically, a 3-
effect evaporator is used for concentrating to about 47.5% and steam at 11 - 12 kg/cm2 is
used for this purpose.
4) Flaking Unit :
Caustic soda is also sold as flakes which is 99%
pure. This is obtained by further concentration of
47.5 % caustic from the evaporator house in the
flaking unit.
In flaking unit there is a pre concentrator which

concentrates 47.5 % caustic lye to 61%. The
heat for this is provided by the vapours of the
final concentrator (at around 360-370 Deg C) in
a shell and tube type heat exchangers. This is
further concentrated to 98% in the final
Brine Distribution arrangement in cell
concentrator unit. The energy consumption in the
house
flaking section is both fuel and electrical.
The specific energy consumption is 100 KWh/Ton flakes as electrical energy and 100
Litre/Ton of furnace oil.
Use of hydrogen in place of furnace oil makes economic sense if hydrogen is excess (assuming
it is also used in the main boiler) and is not sold separately in a more profitable manner.
1 NM3 of hydrogen gas is equivalent to 0.29 Ltr of furnace oil in terms of heat value.

69
In some cases prilling of caustic is also done to supply caustic as prills just like Urea.
Caustic Prilling Unit

Caustic prilling units have been employed by some major players, one of them being Gujarat
Alkalies and Chemicals limited.

70
CASE STUDY 1
Avoid Valve Throttling at the Identified Pumps of Brine Section

by Providing VFD With Close Feedback Control
Background
The caustic soda plant consumes substantial power for pumping brines due to feed variation,
fine capacity control of the pumps. Pumps therefore are essential for operation of plant at
lower energy consumption. A case study involving the VFD control of the pumps in a caustic
soda plant is described below.
Present Status
System is designed for 250 TPD caustic production
The plant team observed that almost all brine pumps have control valve in re-circulation on
main line. Control valve on these re-circulation not open more than 30 – 40%. Heavy
throttling on the re-circulation valves indicates high capacity and rating for the pumps.
Valve control is an energy inefficient way of capacity control
The best energy efficient method of capacity control for a pump (or for that matter any
centrifugal equipment) having varying capacity requirements is to vary its RPM, which can be
best achieved with a variable frequency drive (VFD).
Energy Saving Project

The plant team installed Variable Frequency Drives (VFD) for all identified pumps with discharge
pressure of the main header as feedback control from the main header .
The VFD can be provided with a closed loop pressure sensor control. This pressure sensor
will continuously sense the pump discharge header pressure and give a signal to the VFD,
to either increase or decrease the RPM of the pump, thereby matching the varying capacity
requirements.
Benefits
Installation of VFDs has resulted in an annual energy saving potential is Rs.1.34 million. This
called for an investment of Rs.1.23 million, which had a simple payback period of
11 months.
Potential for Replication

Cost benefit analysis Typically in caustic soda unit, there are about 30 pumps
(brine and water) in operation and tthere is a potential
for application of VFD in atleast about 25 pumps. Only
• Investment - Rs. 1.23 millions about a quarter of this potential has been tapped. The
potential for replication is therefore very high for this
project.

71

72
CASE STUDY 2
Replace Steam Ejector with Water Ring Vacuum Pump for

Brine Dechlorination
Background
Brine dechlorination of the return brine is an essential process requirement of any caustic
chlorine plant. This dechlorination is done by using vacuum of the order of 400-450 mm HG
on the hot return brine thereby sucking the excess free chlorine.
Present Status
Steam ejectors are normally installed to meet the vacuum requirements of the return brine
dechlorination section. The vacuum required in the section is to the tune of 400-450 mmHg.
200-250 Kg of steam per hour at 8-10 Kg/cm2 pressure is utilised in this ejector system.
The plant team of a 250 TPD caustic chlor unit in India observed good potential to reduce the
cost of operation, by installing water ring vacuum pump in place of steam ejector. The
operation of cost of an ejector is more than the water ring vacuum pump.
The team knew that this is a proven project and has been implemented in many other plants.
A vacuum of 600-650 mm Hg is easily achievable with a water ring vacuum pump. This will
meet the requirement of vacuum conditions to be maintained in the brine de-chlorniation
section.

The plant team installed a water ring vacuum pump in place of steam ejector for the brine
dechlorinating condenser. The capacity of the vacuum pump was the same as that of the
existing ejector.
This step has resulted in reduction of atleast 50% of steam requirement.
Benefits
The annual energy saving achieved by replacing steam ejector with water ring vacuum pump
is Rs. 0.3 million (at a steam cost of Rs 350/Ton) This called for an investment of Rs. 0.2
million, which had a simple payback period of 8 months.


73

74
CASE STUDY 3
Provide VFD For One Chlorine Compressor And Avoid Bypass

Control During Load Variation
Background
Acid ring centrifugal chlorine compressors are normally employed for chlorine compression
before liquifaction in any caustic plant (using any process). In a typical 250 TPD plant, five
chlorine compressors were available in the plant (4 X 70 TPD and 1 X 40 TPD). The suction
pressure of the chlorine header is to be maintained at –45 mm WC.
Present Status
It was observed by the plant team that the suction pressure of chlorine header is very crucial
for the plant operation (maintaining differential pressure across membranes between hydrogen
and chlorine compartments). This is maintained by regulating the bypass control valve of one
of the chlorine compressors.
In a 250 TPD plant in India, there were four compressors running (3 x 70 TPD and 1 x 40
TPD). Three compressors were operated with full valves opening and header suction pressure
was controlled by controlling the bypass valve of one compressor.
Bypass control is one of the most energy efficient methods of capacity or head control as
there is no reduction in the energy consumption with process load. This poses a good saving
potential in the compressor.
Moist Chlorine from Cell

house
- 45 mm WC
CWS CWR
35 % Open
VF D 112 kW
Chlorine
Compressor
Acid Separator
Sulphuric Acid Return

75
Energy Saving project

The plant team observed that after initial startup of the compressor the bypass valve need not
be used and a VFD may be installed in one of the compressors.
Any variation in load can be taken care of by giving a closed feedback control to the VFD from
the suction header pressure and keeping the set point as –45 mm WC. This ensures optimum
supply of chlorine, as per requirement
Benefits
The annual energy saving achieved by installing a VFD to one of the chlorine compressors
in a 250 TPD plant is Rs. 0.57 million. This called for an investment of Rs 0.75 million. This
investment will be paid back in 16 months.
This project has been implemented only in one or two units. The potential for replication is
extremely high.


76

77
CASE STUDY 4
Install Thermocompressor And Utilise Flash Steam in the

I- Effect Heat Exchanger
Present Status
Caustic at 130oC is entering the flash vessel and comes out at a temperature of 80 – 90 oC.
In the process of flashing, the caustic concentration increases by upto 3% in the flash tank
and the temperature falls from 130oC to 80 – 90 oC. The temperature of caustic has to be
maintained in the vertical heat exchanger of about 130oC. To maintain the temperature of
130oC, the typical ∆T of maximum 30oC is required, which needs a steam of condensing
temperature of 160oC, This is eqivalent to a steam pressure of 8 ksc.
The flash vessel is at a temperature of 80oC, which is equivalent to a steam saturation

pressure of 0.5 ksc(a). Since the vapors from flash vessel contain some caustic vapors also,
the pressure has to be maintained lower say about 0.3 ksc, to get the equivalent temperature.
Recommendation
There is an excellent potential to recover heat by installing a thermocompresor and using live
steam at a pressure of 12 ksc as a motive steam. The flash generated in the vessel can be
recovered and reused in the plant. Care has to be taken of material of construction of Heat
exchanger and ejector. Installation of a thermocompressor( ejector) has been succesfully
implemented in many plants and resulted in good savings.
Benefits
A 250 TPD caustic chlor unit in India has implemented
this proposal and has achieved an annual savings of
• Investment - Rs. 4.50 millions Rs. 3.20 million. This required an investment of
Rs. 4.50 million and got paid back in 17 months.

78

79
CASE STUDY 5
Replace Existing Reciprocating Refrigeration Compressors by
Background
Refrigeration load is the major power consumer in caustic chlorine plant. It is required for
Chlorine Liquification. The process is quite energy intensive as a lot of cooling water and
chilled water load is there. Any reduction in the energy consumption in the compressor will
result in very high saving.
Present Status
In a caustic chlor unit in India, reciprocating
compressors (450 TR) were operating in the
refrigeration system and meeting the demand of
the entire plant.
The compressors were in continuous oepration

as there was very low load variation in the
system. The load variation occurs only when
demanded by production schedules or during
peak load hours. The specific energy consumption
for producing chilled water at 10 Deg C was
1.0 - 1.2 KW/ TR

The plant team compare the performances of Reciprocating and Centrifugal / Screw
compressors, based on plant visits to other installations and discussions with industry experts.
It was observed that the Centrifugal / Screw compressors operate with specific power
consumption of 0.60 - 0.65 KW/ TR.
The plant team replaced the existing reciprocating compressor with screw/centrifugal
compressors. For the same operating conditions, the power consumption of the compressors
reduced by around 40%.

80
On a load of 450 TR the existing power consumption in the reciprocating compressors is

480 KW. The new centrifugal/screw compressors have a power consumption of 290 KW.
Benefits
The annual savings achieved by this replacement of compressors is Rs 5.60 million with
investment of Rs. 7.0 million (including civil work and controls), which had a simple payback
period of 15 Months.


81

82
Case study 6
Install commercial Co-generation system for Caustic Chlorine

Industry
Background
The power from state electricity boards of India apart from being costly at an average rate
of Rs 4.0/Unit also lacks quality and reliability. Generating power through captive power plant
can be a solution in terms of quality and cost. A co-generation plant can be used for efficient
utilisation of energy in various processes.
Power quality plays an important role in a caustic chlorine plant. Refrigeration and steam
requirement also contribute to a significant figure to total energy cost. Considering the above
factors Co-generation is best solution for a caustic chlorine plant in terms of low specific
energy consumption and quality of power. The following case study involves setting up of a
co-generation plant in a typical caustic chlorine plant of 200 TPD involving membrane cell
technology.
Present Status
The power requirement for a caustic chlorine plant of 200 TPD is around 2600 kWh/Ton
Caustic which comes to around 23 MW so a captive plant based on furnace oil/naptha of 25
MW capacity will be sufficient to support the plant power needs.
Apart from generating power of 24-25 MW, steam can be generated from flue gases. The flue
gas temperature from the DG is around 380–400 Deg C. Steam can be generated at 10 kg/
cm2 using waste heat recovery boiler at the rate of 0.5 TPH per MW of generation. For 25
MW DG sets about 12.5 TPH steam can be generated by installing waste heat recovery
boilers. The steam requirement is around 11 TPH for a 200 TPD plant in various processes
the breakup of which is as follows (the consumption pattern may vary slightly depending on
technology used and product mix):
1. Evaporator house : 0.7 Ton/ Ton of caustic soda

(Caustic concentration unit)
2. Brine House : 0.4 Ton/ Ton of caustic soda
3. Flaking Plant : 0.2 Ton/ Ton of caustic soda
About 1.5 TPH steam left out of total generation after fulfilling the requirement in various
processes. This steam can be use for refrigeration of capacity 300 TR at the rate of 220 TR
per TPH of steam. The refrigeration can be use to cool air, which can be supply to DG room
for cooling. Supply cold air at about 24-25 Deg C to DG room. This will increase the efficiency
of DG set by 1-1.5 %.

83
Schematic flow diagram for a typical co-generation plant for 200 TPD plant
Flue gas
180-200o C
Flue gas
380-400oC
Waste heat
recovery boilers
DG Set 25 MW
Steam for evaporator (12 KSC)
Jacket Jacket 5.8 TPH

water water
50 C-55oC
o
75oC-80 oC
Steam for brine house
VAM 3.3 TPH (5-6 Ksc)
Chilled water 8-
10 Deg C Steam for flaking unit
1.7 TPH (12 Ksc)
Chlorine
liquefaction
Steam for VAM for DG room air
cooling (8-9 Ksc)
1.5 TPH
Refrigeration contributes a significant role in a caustic chlorine industry. Refrigeration is required

for chlorine liquefaction. For a 200 TPD plant the refrigeration load is about 600 TR, considering
80 % of chlorine is liquefied (rest goes in the production of hydrochloric acid). The return
jacket cooling water from the DG set jacket is at 75-80 Deg C and offers an excellent
opprotunity to produce refrigeration through a Vapor Absorption System based on hot water
@ 40 TR/MW of generation. This will result in drastic reduction of refrigeration cost as
refrigeration power consumption is around 55 Kwh/Ton of chlorine liquefied. This alone will
result in a savings of App. Rs 1.30 Crores/Year.
As VAM is considered as green refrigeration the add on benefit is the clean and green image
of the plant and product.
The following are the benefits of co-generation in a caustic power plant.
• The cost of power generation is Rs 2.5 to Rs 2.7 per unit for furnace oil based DG plant,
as compare to an average of Rs 4.00 per unit from SEBs.
• Refrigeration is free of cost resulting from waste heat.
• Steam required for various processes can be generated from flue gas and thus free.
• VAM is pollution free and reflects a clean and green image of the company products.
• Overall by installing the waste heat recovery systems from flue gases and jacket cooling
water, the efficiency of the DG set is also enhanced by 10-12 % thus bringing down the
cost of power.

84
• Cooling the DG room by cool air at 24-25 Deg C will increase the efficiency of DG by 1-
1.5 % as for every 6 Deg C reduction in room temperature there is a increase in efficiency
by 1 %. This itself results in a savings of Rs 8-10 Crores per annum.
Cost Benefit Analysis

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


85

86
CASE STUDY
Convert existing mercury cell based plant to membrane cell

based plant.
Background
The latest technology for manufacturing caustic chlorine is membrane cell. The power
consumption in a caustic chlorine plant is a major issue since it shares 70% of the total cost
of production. Any reduction in power consumption may lead to high profitability. The case
study involving using selectively permeable synthetic polymeric membrane instead of
conventional high energy intensive mercury cells fro electrolytic manufacturing of caustic soda
and chlorine.
Present Status
Caustic soda is still produced by conventional mercury cell technology in some cases. It is an
old technology and has only advantage of low capital cost. The specific energy consumption
of mercury cell house is around 3100 kwh per ton of caustic soda (including utilities) compare
to 2600 kwh per ton of caustic soda for a membrane cell based plant. Also carry over of
mercury from mercury cell house leads to pollution hazards, as mercury is a major pollutant.This
makes the product un acceptable to the high end users like phrma, biotech and electronic
industry. In mercury cell technology caustic comes out at 47-48 % concentration and in
membrane cell caustic comes out at 32 % concentration, so a caustic concentrator is required
to concentrate the caustic to required percentage. The specific energy consumption of
membrane cell house and the membrane life is highly affected by the impurities in brine. The
major impurities in raw salt are sodium sulphate, calcium chloride and magnesium chloride.
The impurity level should be in ppb instead of ppm.
To convert from the existing mercury cell to membrane cell, the cell house has to be completely
changed and replaced with the new electrolysers. Rectifiers also need replacement as the
cells are in parallel instead of series in mercury cell.
The other major revamp is needed in the brine purification section. Since ultrapure brine
quality is needed for membranes, a brine filtration and polishing system is required. The
vendors list is enclosed in the annexure.
A caustic concentration unit also needs to be added to concentrate caustic from 32% to
47.5% (rayon grade caustic). This increases the steam consumption by 0.65-0.7 Tons/Ton
caustic.
The high purity product is sold at a premium over mercury cell product in high end industries
thus increasing the revenue by 10-12 crores annually from caustic alone.

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

87
Cost Benefit Analysis

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


88

89
Aluminium
Energy Intensity 35 – 40% of manufacturing Cost
Energy Costs Rs.5000 million ( US $ 100 million)
Energy saving potential Rs.500 million (US $ 10 million)

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

Energy Conservation in Aluminium Industry
90
1.0 Introduction
The aluminium industry emerged in India in early 1940s. The installed capacity has grown
from 2,500 tonnes in 1943 to 7,14,000 tonnes in 1997-98.
Aluminium production in the country has also progressively gone up from 4,045 tonnes in
1950-51 to 5,53,644 tonnes in 1997-98 both in private and public sector.
The electrical sector in India is the most important consumer of aluminium products with over
50% of the off - take of total production. Apart from this sector, aluminium has wide and varied
uses in transport, building and construction, consumer durables, utensils, packaging, coinage
and other miscellaneous uses. The per capita consumption in India is about 0.5 kg.
The total production of aluminium in India is accounted for by five major producers, namely
NALCO, HINDALCO, INDAL, BALCO and MALCO. These producers are integrated producers
from bauxite mining to metal production. The high capital cost of setting up an aluminium
smelter (at around US $ 3300/ton) and the need of a Captive Power Plant, have restricted
production only to these producers.
Company Installed capacity (tons) Production(tons)
NALCO 230,000 200,162

HINDALCO 242,000 200,607
INDAL 117,000 38,600
BALCO 100,000 88,198
MALCO 25,000 26,077
TOTAL 714,000 553,644
With the growing importance of the electric sector in India, the demand for the products of
this industry is bound to rise at a rapid rate in future.
In Aluminium industry, both aluminium refining and smelting process are energy intensive.
Considerable attention has to be paid to energy conservation in both refining and smelting
process. Data collected and analysis indicate that the energy saving potential in Aluminium
industry is about 8-10 % of the total energy bill.
2.0 Energy intensity in Indian Aluminium Industry

The industry is highly energy intensive. It accounted for 2.8% of total energy Indian industry
energy consumption. In terms of energy consumption the aluminium industry ranks first with
figures of 300 GJ /ton of metal compared with the figures of 20 and 15 GJ/ton for copper and
zinc respectively.
Electrical energy is the major energy consumption in Alumina refining and Smelter. In Aluminium
refinery next to electrical energy coal and fuel oil are the major energy consumers.
The share of energy cost is about 35-40% of the manufacturing cost. The total energy cost
involved in Indian Aluminium industry is about Rs 500 Crores/annum.

91
3.0 ENERGY CONSUMPTION PATTERN

Aluminium is a highly energy intensive process with the most efficient operation requiring about
300 GJ/ tonne of the metal. The major areas of energy consumption in the Aluminium refining
process (Bayer process) are the digestion and calcination stages.
3.1 Typical energy consumption in Alumina plant
Calcination
5.07 GJ/T
31.2%
Alumina
Evaporation
4.3 GJ/T
26.5%
Bauxite
Settling Precipitation
Preparation Digestion Washing 1.06 GJ/T
0.37 GJ/T 4.79 GJ/T 0.65 GJ/T 6.5%
2.3% 29.5% 4.0%
3.2 Energy consumption is Smelting process

Al2O3
Radiation,
16.2 KG/Ton Convection &
Other losses
Through
Electrolysis Process
Process heat
29.2 GJ/T
5.8 GJ/T
Electricity 14.9 GT/T
through
effluent gases
Molten metal
0.9 GJ/T
Total Energy input is 16.24 GJ/T. Distribution of energy consumption in a medium level Alumina
plant among the various process stages is shown in fig.

92
On average, around the world, it takes some 15.7 kWh of electricity to produce one kilogram
of aluminium from alumina.
4.0 ENERGY SAVING POTENTIAL IN INDIAN ALUMINIUM INDUSTRY

There are five major manufacturers with total installed capacity of 7 lakh tons per annum of
Aluminium in India. The total energy consumption in the Aluminium industry is about Rs 500
Crores.
Annual Saving Potential Investment

Energy Bill required
Rs Crores Rs Crores % of Energy bill Rs Crores
500 50 8-10% 100
5.0 ALUMINIUM MANUFACTURING PROCESS

The most important ore for aluminium is bauxite, which contains gibbsite (Al2O3. 3H2O),
boehmite (Al2O3), Diaspore (Al2O3.H2O) and oxides of silicon, iron and titanium in varying
amounts.
Aluminium is manufactured from bauxite using refining and smelting process. In Aluminium
refining process, Alumina is produced from Bauxite. Bayer process is used for producing
Alumina from Bauxite. From Alumina, Aluminium is manufactured using Hall Heroult smelting
process.
5.1 Alumina refining - Bayer process

The aluminium industry relies on the Bayer process to produce alumina from bauxite. It
remains the most economic means of obtaining alumina, which in turn is vital for the production
of aluminium metal. Typically about two tonnes of alumina are required to produce on tonne
of aluminium.
The bayer process can be considered in three stages:
Extraction
The hydrated alumina is selectively removed from the other (insoluble) oxides by transferring
it into a solution of sodium hydroxide (caustic soda):
Al2O3.xH2O + 2NaOH —> 2NaAlO2 + (x+1) H2O
The process is far more efficient when the ore is reduced to a very fine particle size prior to
reaction. This is achieved by crushing and milling the pre-washed ore. This is then sent to a
heated pressure digester.
Conditions within the digester (concentration, temperature and pressure) vary according to the
properties of the bauxite ore being used. Although higher temperatures are theoretically
favoured these produce several disadvantages including corrosion problems and the possibility
of other oxides (other than alumina) dissolving into the caustic liquor.
Modern plants typically operate at between 200 and 240 °C and can involve pressures of
around 30atm.

93
The resulting liquor contains a solution of sodium aluminate and undissolved bauxite residues
containing iron, silicon, and titanium. These residues sink gradually to the bottom of the tank
and are removed. They are known colloquially as “red mud”. The amount of redmud generated,
per tonne of alumina produced, varies greatly depending on the type of bauxite used, from
0.3 tonnes for high grade bauxite to 2.5 tonnes for very low grade.
Decomposition
Crystalline alumina trihydrate is extracted from the digestion liquor by hydrolysis:
2NaAlO2 + 4H2O —> Al2O3.3H2O + 2NaOH
This is basically the reverse of the extraction process, except that the product’s nature can
be carefully controlled by plant conditions (including seeding or selective nucleation, precipitation
temperature and cooling rate).
The clear sodium aluminate solution is pumped into a huge tank called a precipitator. Fine
particles of alumina are added to seed the precipitation of pure alumina crystals as the liquor
cools. The alumina trihydrate crystals are then classified into size fractions and fed into a
rotary or fluidised bed calcination kiln.
Calcination
Alumina trihydrate crystals are calcined to remove their water of crystallisation and prepare
the alumina.
The flow diagram of the Bayer process is shown in fig.

94
Material balance for the production of one tonne of Alumina is given below.
Bauxite
49%
A1203
2247 kg
CaO 39 kg
Na2Co3 74 kg
Water 921 l
ALUMINA REFININGS
90.9%
EFFICIENT
RED
MUD
1963 kg
GAS &
Alumina
1000 kg
ALUMINA
1000 kg
5.2 Aluminium smelting – Hall-Heroult process

The basis for all modern primary aluminium smelting plants is the Hall-Héroult Process, Alumina
is dissolved in an electrolytic bath of molten cryolite (sodium aluminium fluoride) within a large
carbon or graphite lined steel container known as a “pot”.
The production of aluminium involves the electrolysis of alumina dissolved in molten crystolite
(Na3Al F6) at 960oC – 970oC using carbon anodes. The carbon anode is of either Soderberg
(Self baking type) or prebaked type.
An electric current is passed through the electrolyte at low voltage, but very high current,
typically 150,000 amperes. The electric current flows between a carbon anode (positive),
made of petroleum coke and pitch, and a cathode (negative), formed by the thick carbon or
graphite lining of the pot.
Molten aluminium is deposited at the bottom of the pot and is siphoned off periodically, taken
to a holding furnace, often but not always blended to an alloy specification, cleaned and then
generally cast.
A typical aluminium smelter consists of around 300 pots. These will produce some 125,000
tonnes of aluminium annually. However, some of the latest generation of smelters are in the
350-400,000 tonne range.

95
On average, around the world, it takes some 15.7 kWh of electricity to produce one kilogram
of aluminium from alumina.
The Potline
Pots are organised into “potlines” within an aluminium smelter
A pot consists of two main parts:
1. A block of carbon, which has been formed by baking a mixture of coke and pitch. This
block serves as an anode (or positive electrode).
2. Under the anode is a large rectangular steel box lined with carbon made by baking a
mixture of metallurgical coke and pitch. This lining is the Cathode (or negative electrode).
Between the anode and the cathode is a space filled by electrolyte. This mixture must be
heated to about 980°C, at which point it melts and the refined alumina is added, this then
dissolves in the molten electrolyte.
This hot molten mixture is electrolyzed at a low voltage of 4-5 volts, but a high current of
50,000-280,000 amperes. This process reduces the aluminium ions to produce molten aluminium
metal at the cathode, oxygen is produced at the graphite anode and reacts with the carbon
to produce carbon dioxide.
2Al2O3 + 3C —> 4Al + 3CO2
However some of the metal, instead of being deposited at the bottom of the cell, is dissolved
in the electrolyte and reoxidised by the CO2 evolved at the anode:
2Al+ 3CO2 —> Al2O3 + 3CO
This reaction can reduce the efficiency of the cell and increases the cell’s carbon consumption
The electrolyte used is cryolite (Na3AlF6) which is the best solvent for alumina. To improve the
performance of the cells various other compounds are added including aluminium fluoride and
calcium fluoride (used to lower the electrolyte’s freezing point).
The electrolyte ensures that a physical separation is maintained between the liquid aluminium
(at the cathode) and the carbon dioxide/carbon monoxide (at the anode).
Anode
The carbon anodes used in the Hall-Heroult process are consumed during electrolysis.
Two designs exist for these anodes; “Söderberg” and “Pre-

Bake”.
Pre-Bake anodes are made separately, using coke particles

bonded with pitch and baked in an oven. Pre-bake anodes
are consumed and must then be changed. Soder berg
anodes on the other hand are baked by the heat from the
electrolytic cell, they do not need changing but are
“continuously consumed”.
Pre-Bake carbon anodes

96
Soderberg Cell
Soderberg technology uses a continuous anode which is delivered to the cell (pot) in the form
of a paste, and which bakes in the cell itself.
Prebake Cell
Pre-bake technology uses multiple anodes in each cell which are pre-baked in a separate
facility and attached to “rods” that suspend the anodes in the cell. New anodes are exchanged
for spent anodes - “anode butts” - being recycled into new anodes.
The newest primary aluminium production facilities use a variant on pre-bake technology
called Centre Worked Pre-bake Technology (CWPB). This technology provides uses multiple
“point feeders” and other computerised controls for precise alumina feeding.
A key feature of CWPB plants is the enclosed nature of the process. Fugitive emissions from
these cells are very low, less than 2% of the generated emissions. The balance of the
emissions is collected inside the cell itself and carried away to very efficient scrubbing systems,
which remove particulates and gases.

97
Computer technology controls the process down to the finest detail, which means that
occurrence of the anode effect - the condition, which causes small quantities of Perfluorocarbons
(PFCs) to be produced - can be minimised. All new plants and most plant expansions are
based on pre-bake technology.
Material balance for producing 1 tonne of Aluminium from Alumina is shown in fig.
99%
Alumina
Bath Carbon
Make – up Anode
43 kg
Electrolytic
Reduction
960 C
Gas
1340 kg
Molten & Dust
Aluminium
Flux
Blending C 12 etc
Slag
(A1=A1203)
A1
INGOTS
1000 kg
6.0 List of Energy saving proposals in Alumina Refining plant
6.1 Aluminium Refinery

Medium term projects
1. Install variable frequency drive for spent liquor pump feeding to evaporator
2. Install variable frequency drive (VFD) for red mud pond feed pump
3. Install variable frequency drive for filtered aluminate liquor pump
4. Install seal pots for condensate recovery at digesters, evaporators, HP and LP heaters
5. Install variable frequency drive (VFD) for spent liquor pump feeding to PHE
6. Optimise the operation of filter feed pumping system

98
7. Optimise the operation of the slurry pumps in precipitation area
8. Optimise excess O2% in kiln ii by continuous monitoring
9. Avoid air infiltration in kiln flue gas exhaust line
10. Replace Red mud filter vacuum pumps with new high efficiency vacuum pumps
11. Utilise the standby body in evaporator and increase the steam economy
Long term projects

1. Install thermo-compressor and recover flash steam from pure condensate tank in evaporator
section
2. Install mechanical conveying system to convey material from ESP bottom to kiln
3. Segregate Pick-Up And Drying Zone Vacuum In Red Mud Filters
4. Sweeten the digestion process by adding Gibbsitic bauxite having higher solubility in
downstream of higher temperature digestion circuit.
6.2 Aluminium Smelter

Medium term projects
1. Installation of Data acquisition system
2. Installation of Thyristor control in coke conveying vibrators in carbon plant
3. Install correct size cooling water supply pump for rectifier cooling
4. Install a screw conveyor and avoid the operation of a centrifugal fan in Carbon plant
5. Installation of variable frequency drive for fire hydrant pump
6. Installation of variable fluid coupling for scrubber fans
7. Reduce external bus bar voltage drop across bypass joints and across rod to stud joints
8. Improve insulation of sidewalls of the pots to minimise the heat loss due to convection
and radiation
Long term projects
1. Convert the Soderberg technology to the pre baked cathode technology in the pots
2. Install point feeding in the Aluminium Pots
3. Coating of cathode surface of electrolytic cells with Titanium Boride (TINOR)
4. Replacement of hot tamping mix with cold tamping mix
5. Install variable fluid coupling for scrubber ID fans and avoid damper control

99
Case study –1
INSTALL VARIABLE FREQUENCY DRIVE FOR SPENT LIQUOR

PUMP FEEDING TO EVAPORATOR
Back ground
The centrifugal pumps have to be selected to match with the process requirement. Selection
of higher capacity or head of the pump results in operating the pump with valve throttling to
match with the process requirement.
The valve throttling at the discharge side of the pump leads to pressure loss across the
control valve and hence energy loss. This could be avoided by optimising the operation of the
pump with variable frequency drive and keeping the control valve fully opened.
Present status
The spent weak liquor from the hydrate filtration and red mud filtration sections are concentrated
in the evaporators. Centrifugal pump is used for pumping the hydrate filtration from the spent
liquor tank to the evaporator.
The design specifications of the pump are as follows:
• Capacity = 100 m3/h

• Head = 75 m WC
• Motor = 75 kW
The pump is operating with severe discharge valve throttling (about 40-50% opening). This
indicates excess capacity/ head available in pump.
The detailed analysis reveals that the actual head required for the pump is not more than 75
m WC, comprising of static head of 10 m WC, pressure drop across preheaters of 50 m WC
and line losses (due to friction and bends) of 10 m WC.
The maximum feed rate maintained in the new evaporator stream is 75-80 m3/h.
The schematic diagram of the system is shown in fig.

From Hydrate
Filtration
Evaporator
80 m3/h
Spent liquor
tank
40%
1752 – ½
100 m3/h
75 m
75 kW
(58.5 kW)

100
The operation of a pump with valve throttling is an energy inefficient method of capacity
control, as a part of the energy supplied to the pump is lost across the valve.
The best energy efficient option to optimise the excess capacity/ head as well as achieve
operational flexibility is to install a variable frequency drive (VFD) for the pump and vary its
RPM.
The VFD can be operated in a closed loop with pressure sensor control. The pressure sensor
will continuously sense the header pressure and give a signal to the VFD, which in turn will
either increase or decrease the speed of the pump, exactly matching the varying requirements.

Variable frequency drive (VFD) with feed back control for the spent liquor feed pump to new
evaporator was installed.
Benefits
Reduction in power consumption of about 400 units/day was achieved.
Financial analysis
This amounted to an annual monetary saving (@ Rs 3.50/unit) of Rs 0.18 million. The
investment made was Rs 0.45 million. The simple payback period for this project was
31 Months.


101

102
Case study –2
INSTALL THERMO-COMPRESSOR AND RECOVER FLASH

STEAM FROM PURE CONDENSATE TANK IN EVAPORATOR
SECTION
Background
When high pressure condensate is exposed to lower pressure, due to enthalpy difference a
part of condensate flashes into steam. Generally in process plant the high pressure flash
steam is recovered using flash vessels.
If the condensate pressure is very low and exposed to atmosphere, the flash steam is also
sent to atmosphere. This leads to heat loss. The cost of flash steam is as high as the cost
of main steam.
Hence there is a good potential to save energy by recovering the flash steam using the
thermo compressors. The thermo compressor is operating based on the venturi principle.
Motive steam at comparatively higher pressure is used to compress the low pressure flash
steam and delivered at an intermediate pressure. The steam at intermediate pressure can be
utilised for the process.
Present status
The digestor section is the heart of the alumina processing plant. There are two streams of
digestors in the plant, with each stream having seven digester vessels. The steam consumption
in the digesters is about 58-60 TPH at a pressure of 70 kg/cm2.
The condensate from the digestor coils is collected in a flash vessel located in the digestor
section. The flash steam at a pressure of about 4 – 6 kg/cm2 is utilized in the red mud filtration
plant for causticizing slurry preparation, pond water heating and filtrate heating applications.
The condensate from the flash vessel at a pressure of 4 – 6 kg/cm2 is sent to the pure
condensate tank. The pure condensate tank is at atmospheric pressure and hence flashing
of condensate occurs.
The best method of avoiding flash steam is to recover it and utilize to replace/ substitute costly
live steam. One of the methods of recovering flash steam is to install thermo-compressors.
Flash steam recovery using thermo-compressor systems have been in successful operation
in several chemical & petrochemical, pulp & paper and sugar industries. This becomes
particularly attractive, when the plant has commercial cogeneration.
The recovered flash steam can be used for to either substitute MP/ LP steam or is connected
directly to the steam header. The schematic diagram of the system is shown below.

103
70 ksc
60 TPH
415°C
Digester
Flash
Steam
Vent
Flash 4 – 6 ksc Steam
60 TPH Vessel
70 ksc
260°C
140°C Pure
Condensate
Tank
100°C Condensate to
Steam Plant

Thermo compressor was installed to recover the flash steam from the pure condensate tank
and the recovered steam is sent to low pressure steam header.
The motive steam used is about 18-20 TPH at a pressure of 12 kg/cm2.
The schematic diagram of the modified system is shown below.
Thermo
Compressor
Motive Steam 14 Evaporator or
– 15 ksc LP header
3 TPH Flash
Steam
PCT
Steam Plant

104
Benefits
The quantity of flash steam recovered was about 3.0 TPH.
Financial analysis
This amounted to an annual monetary saving of Rs 5.48 million. The investment made was
Rs 3.00 million. The simple payback period for this project was 7 Months.


105

106
Case study – 3
INSTALL SEAL POT SYSTEM FOR CONDENSATE RECOVERY
Background
Conventional steam are prone for frequent failure and hence steam leakage. In large steam
users, specifically wherever the steam consumption is more than 1 ton/hr failure of steam
traps lead to heavy steam leakage and hence energy loss.
The latest trend is installing seal pots wherever the steam consumption is more than 1 ton/
hr. in a seal pot condensate level is maintained in an enclosed vessel. The draining of
condensate is done using an automatic control valve, which is operated based on seal pot
condensate level. A vent is also provided in the seal pot for removing the non condensable
gases.
Installing the seal pots for condensate recovery totally eliminates the steam leakage and
maximises the condensate recovery.
The advantage with a seal pot system, is that it is highly reliable and requires very little or
no maintenance. However, the system will require higher level of instrumentation and control.
Present status
The digestors and evaporators are the major consumers of live steam in alumina refinery
plant. The next major steam consumers are the HP heaters and LP heaters. Steam traps are
installed for condensate recovery in all the users.
Over a period of time, due to frequent failure of steam traps, these have got by-passed or
removed. This results in steam passing and considerable heat loss.
The trend amongst the industries, where steam consumption is more than 1 TPH, is to replace
the steam traps with seal pot systems.
The seal pot system, comprises of an empty vessel (called the seal pot), to which the
condensate line is connected. The seal pot is provided with a small vent at the top, for release
of non-condensable gases.
A control valve is provided at the bottom of the seal pot to regulate the condensate flow. This
valve operates in closed loop with a level indicator controller (LIC) provided at the seal pot.
The condensate is pumped to the steam plant, through the pure condensate/ alkaline
condensate tanks.

107
The schematic diagram of the steam trap system is shown in fig.
MP steam
Digester
Air
vent
Seal
pot

Seal pots were installed for condensate recovery in the following equipment.
• Digesters
• Evaporators
• HP heaters & LP heaters
Benefits
The steam savings achieved was about 250 kg/hr.
Financial analysis


108

109
Case study – 4
OPTIMISE EXCESS O2% IN KILN BY CONTINUOUS

MONITORING
Back ground
For the combustion process the quantity of air supplied is an important parameter. To ensure
the complete combustion of the fuel the quantity of air supplied should be more than the
stoichiometric air quantity of the fuel.
Oxygen level in the flue gas is an indication of the quantity of excess air sent for the combustion
process. Higher the O2 level, higher will the quantity of excess air sent and vice versa.
With increase in quantity of excess air sent for combustion, the flue gas loss increases and
hence the operating efficiency of the furnace decreases.
For oil-fired system the optimum recommended O2 level in the flue gas is 3-4%.
Present status
The calcination of alumina is carried out in the kiln. The production rate in the kiln is 530MT/
day of calcined product. The average fuel consumption in the kiln is about 2000 lit/hr.
Combustion analysis was carried out in Kiln. The percentage of Oxygen level in the exhaust
flue gas and its temperature were measured at the outlet of the kiln.
The measured value at the kiln exhaust is as below:

• O2 % - 8.0 %
• Temperature - 201 oC
The quantity of excess air supplied is very high compared to the requirement. Hence, there
is a good potential to save energy by optimising the quantity of excess air sent for the
combustion process

Online oxygen analyser was installed and the % of oxygen level in
the flue gas is continuously monitored.
The combustion air supply to the kiln is controlled and percentage

oxygen of 3% is maintained in the flue gas.
Benefits
On a conservative basis atleast 2% increase in combustion efficiency and hence reduction in
fuel consumption was achieved.

110
Financial analysis


111

112
Case study -5
SEGREGATE PICK-UP AND DRYING ZONE VACUUMS IN RED

MUD FILTERS
Background
The rotary drum filters are used for red mud filtration in the Alumina plant. The rotary drums
are subjected to vacuum where filtration is taking place. The vacuum is created using the
vacuum pumps.
The rotary vacuum filter is divided into two major zones – pick-up zone and drying zone. The
pick-up zone is where the drum dips into the slurry in the trough and built-up of cake starts.
This zone typically requires a vacuum of about 380-400 mm Hg.
On the other hand, the drying zone is one where, the built-up of cake on the drum is complete
and drying takes place. This zone typically requires a vacuum of about 250-280 mm Hg.
Typically in this system one set of vacuum pumps are used for maintaining the same vacuum
at both the zone. Maintaining higher vacuum has no direct benefit on the process.
In vacuum pumps the power consumption is proportional to the level of vacuum created.
Hence there is a good potential to save energy by segregating the two zones and installing
two set of vacuum pumps, operating at the required vacuum level.
Present status
There are 11 nos. of vacuum pumps (about 4 to 5 will be in operation) to cater to the vacuum
requirements of the rotary vacuum filters in the red mud filtration area. These vacuum pumps
are one of the major electrical energy consumers in the aluminium refining plant.
The design specifications of the vacuum pumps are:

Capacity = 1320 m3/h
Vacuum = 510 mm Hg
Speed = 720 RPM
Motor = 125 HP
Vacuum in both pick-up and drying zones are maintained at 380-400 mm Hg. This is because
all the vacuum pumps are connected to a common header and the pick-up & drying zones
are connected to this common header.
Maintaining a higher vacuum in the pick-up zone has no direct benefit on the process, but on
the other hand results in higher power consumption in vacuum pumps.

113
The typical vacuums required are 400-450 mm Hg in pick-up zone and 250-300 mm Hg in
drying zone.

The pick-up zone and drying zone vacuum headers are segregated and vacuum pumps are
dedicated to individual zones.
Pick up zone vacuum pumps are operated at a vacuum level of 380-400 mmHg and for the
drying zone the vacuum pumps are operated at a vacuum level of 250 mm Hg.
250 mm Hg
300 mm Hg 400 mm Hg
400 mm Hg
400 mm Hg
RMF 1320 m3/h

510 mm Hg
125 HP
11 Nos. (6↑)
Benefits
Segregation of vacuum pumps for the pick up and drying zone resulted in electrical energy
saving of 1800 units/day.
Financial analysis


114

115
Case study –6
SWEETEN THE DIGESTION PROCESS BY ADDING GIBBSITIC

BAUXITE HAVING HIGHER SOLUBILITY IN DOWNSTREAM
OF HIGHER TEMPERATURE DIGESTION CIRCUIT
Background
The hydrated alumina is selectively removed from the other (insoluble) oxides by transferring
it into a solution of sodium hydroxide (caustic soda). Bauxite is crushed and pre washed and
then sent to a heated pressure digester.
Conditions within the digester (concentration, temperature and pressure) vary according to the
properties of the bauxite ore being used. Typically the digesters operate at between 200 and
240 °C and can involve pressures of around 30atm.
The latest trend is addition of Gibbsittic Bauxite in suitable flash tank in the down stream of
digestion circuit. This increases productivity without any further addition of steam.
About 30 grams per litre more Alumina can be dissolved by addition of Gibbsitic bauxite in
digested Boehmitic slurry stream. It results in substantial increase in Alumina super saturation
level utilizing the heat energy of flashing circuit. This has been shown in the Alumina solubility
curve.

116
Gibbsitic slurry addition in the downstream of slurry addition
600 psig steam

Gibbsitic Bxt. Sweetening
Boehmitic
Bxt. Slurry
Slurry S.H.Tic
243 0 C 243 0 C 243 0 C 243 0 C

FREQUENY
DRIVE FOR
Spent Liquor FLOW
CONTROL
1 2 3 4 5 6 7

Gibbsitic slurry addition was taken up in the down stream
of the digestion circuit.
Benefits
Implementation of the above project resulted in annual
saving of 113.88 Lakh KWH of electrical power, 16,985
MT of coal and 1577 KL of fuel oil.
Financial analysis
This amounted to an annual monetary saving of
Rs 42.9 million. The investment made was Rs 0.95
Cost benefit analysis million. The simple payback period for this project was
• Annual Savings - Rs. 42.90 millions 1 Month.
• Simple payback - 1 month

117

118
Case study –7
REPLACE OLD HORIZONTAL STUD SODERBERG (HSS) CELLS

WITH MODERN POINT FEEDER PREBAKE CELLS
Back Ground
For Aluminium smelting horizontal stud soderberg (HSS) cells are used. The characteristics
of HSS system are as follows:
• Higher specific energy consumption
• Higher GHG & fluoride emissions
• Lower level of automation
• Higher raw material consumption
• Higher solid waste generation
The latest trend is installing multipoint feeder prebake cells. Pre-bake technology uses multiple
anodes in each cell which are pre-baked in a separate facility and attached to “rods” that
suspend the anodes in the cell. New anodes are exchanged for spent anodes - “anode butts”
- being recycled into new anodes.
The newest primary aluminium production facilities use a variant on pre-bake technology
called Centre Worked Pre-bake Technology. This technology provides uses multiple “point
feeders” and other computerised controls for precise alumina feeding.

119
Computer technology controls the process down to the finest detail, which means that
occurrence of the anode effect - the condition, which causes small quantities of Perfluorocarbons
(PFCs) to be produced - can be minimised.
The characteristics of prebake technology are as follows:

• Economical for capacities of 150000 tpa and above
• Highly automated and capital intensive technology
• Normal line amperage over 150 KA
• Lower specific energy and raw material consumption
• Dry scrubbing of exhaust gases with alumina for fluoride recovery
Present status
In one of the Aluminium smelters in India, relatively old Horizontal Stud Soderberg (HSS) cells
are used for production of aluminium from alumina.
The present specific energy consumption of Aluminium production is as below.
AC for electrolysis - 15.558 kWh/Kg of Aluminium

It is proposed to revamp the entire system by installing modern point feeder prebake (PFPB)
cells. The proposed system require energy consumption of about 990 million kWh/year to
produce 29500 tons/year of aluminium.
The specific energy consumption for producing one tonne of Aluminium would be as given
below.
• AC for electrolysis – 14.00 kwh/kg of Al. (Electrical energy)
Benefits
The benefits of the new proposed system are as follows:
• Retrofit prebake cells with point feeders, operate at around 10% higher energy efficiency
• About 50% GHG emissions reduced due to modern process controls
• 50% reduction in hazardous waste generated
• 30% reduction in water consumption
• Reduction in specific consumption of raw materials – Coal tar pitch, cryolite, aluminium
fluoride and Petroleum coke
Cost benefit analysis Financial Analysis

• Annual Savings - Rs.84.10 million The annual energy saving potential @ Rs 1.80/unit is
Rs 84.10 million.

120

Energy Conservation in Glass Industry
120
Glass
Growth percentage 7.2 %
Energy Intensity 30 % of manufacturing cost
Energy Costs Rs.5000 million (US $ 100 Million)
Energy saving potential Rs 500 million (US $ 10 million)

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

121
About the sector:

The Indian glass industry is an energy-intensive industry and has been recognized by its rapid
growth and modernization efforts after the economic reforms initiated by the government in
1990. It represents one of the largest markets and the manufacturing capacity for glass
products in the region after China.
Over 80 % of the industry output is sold to other industries, and the glass industry as a whole
is very dependent on the building industry, and the food and beverage industry.
The glass industry is diverse, both in the products made and the manufacturing techniques
employed. Products range from intricate hand-made lead crystal goblets to huge volumes of
float glass produced for the construction and automotive industries.
The float glass, container glass, glass fiber and glass tableware are manufactured by about
100 large scale companies which operate with modern and large scale melting furnace
technologies. They are mostly located in Gujarat, Bombay, Calcutta, Bangalore and
Hyderabad.
The industry, on the other hand, is also represented in the country by more than 300 medium
and small-scale enterprises and cottage industry units. The historical glass-making town of
Firozabad in UP State is a well-known location, which meets the 70 per cent of demand for
glass products in the country by using outdated pot and tank furnaces.
Manufacturing techniques vary from small electrically heated furnaces in the ceramic fibre
sector to cross-fired regenerative furnaces in the flat glass sector, producing up to 600 tonnes
per day.
An indicative breakdown of the different sectors of glass industry is given in the table below.
Sector % of Total Production
Container Glass 60
Flat Glass 20
Continuous Filament Glass Fibre 2.0
Domestic Glass 4.0
Special Glass 14
Container glass production is the largest sector of the glass industry, representing around 60
% of the total glass production. The sector covers the production of glass packaging i.e.
bottles and jars although some machine made tableware may also be produced in this sector.
The beverage sector accounts for approximately 75 % of the total tonnage of glass packaging
containers. The main competition is from alternative packaging materials such as steel,
aluminium, cardboard composites and plastics.
Production pattern and Growth rate of Glass Industry in India

An account of the different segment of this industry is given below:
The overall production growth in the glass industry was recorded at 7.2% during 2002 as
compared to 6.5% last year.

122
Barring glass tableware, other segments of the glass industry registered a moderate growth
with glass containers and wares at 9%, sheet and float glass at 5%.
Glass Containers and Hollow Ware

There are 44 units producing glass containers and hollow wares with an installed capacity of
15 lakh tonnes per annum.
Flat Glass
The combined capacity of sheet glass, float glass and figured and wired glass is around 135
million sq. m. per annum. The present per capita consumption of float/sheet glass in India is
0.5 kg, which is very low in comparison to 2.5 kg in Indonesia and 3.5 kg in China.
Vacuum Flask and Refills

There are, at present, 8 manufacturing units with a total installed capacity of around 36 million
numbers per annum. Production in 2000-01 was about 18 million numbers.
Laboratory/Scientific Glassware
This segment of the glass industry comprises items like neutral glass tubing, laboratory
glassware and chemical process equipment. There are six units in this segment. The installed
capacity of neutral glass tubing is 46600 tonnes per annum. The growth rate is expected to
be around 3% per annum during the period 2001-02.
Fibre Glass
Production of fibreglass is highly capital and technology intensive. The present installed
capacity is about 55,000 MT per annum. The expected growth rate of the industry is 12%.
Glass Manufacturing process:

The manufacture of any glass can be split up into four phases:
1. Preparation of raw material,
2. Melting in a furnace,
3. Forming and
4. Finishing

123
The below diagram gives typical glass manufacturing process:
The products of this type of process are predominantly flat glass, container glass, and pressed
and blown glass. The procedures for manufacturing glass are the same for all products except
forming and finishing.
As the sand, limestone, and soda ash raw materials are received, they are crushed and stored
in separate elevated bins. These materials are then transferred through a gravity feed system
to a weigher and mixer; here the material is mixed with cullet to ensure homogeneous melting.
The mixture is conveyed to a batch storage bin where it is held until dropped into the feeder
to the melting furnace.
All equipment used in handling and preparing the raw material is housed separately from the
furnace and is usually referred to as the batch plant.
As material enters the melting furnace through the feeder, it floats on the top of the molten
glass already in the furnace. As it melts, it passes to the front of the melter and eventually
flows through a throat leading to the refiner. In the refiner, the molten glass is heat conditioned
for delivery to the forming process.
After refining, the molten glass leaves the furnace through forehearths (except in the float
process, with molten glass moving directly to the tin bath) and goes to be shaped by pressing,
blowing, pressing and blowing, drawing, rolling, or floating to produce the desired product.
Pressing and blowing are performed mechanically, using blank molds and glass cut into
sections (gobs) by a set of shears.
The float process is different, having a molten tin bath over which the glass is drawn and
formed into a finely finished surface requiring no grinding or polishing. The end product
undergoes finishing (decorating or coating) and annealing (removing unwanted stress areas
in the glass) as required, and is then inspected and prepared for shipment to market.
Any damaged or undesirable glass is transferred back to the batch plant to be used as cullet.

124
Furnaces in a glass Industry

The furnace most commonly used is a continuous regenerative furnace capable of producing
between 50 and 300 tons of glass per day. For smaller capacities recuperative furnaces or
pot type furnaces without heat recovery are also being used.
A furnace may have either side or end ports that connect brick checkers to the inside of the
melter.
Side port regenerative furnace

125
End port regenerative furnace
Process Description
Container Glass
Glass containers are produced in a two stage moulding process by using pressing and blowing
techniques.
There are five essential stages in automatic bottle production.
1. Obtaining a piece of molten glass (gob) at the correct weight and temperature.
2. Forming the primary shape in a first mould (blank mould) by pressure from compressed air
or a metal plunger.
3. Transferring the primary shape into the final mould (finish mould).
4. Completing the shaping process by blowing the container with compressed air to the shape
of the final mould.
5. Removing the finished product for post forming processes.

126
Simplified diagrams of the two main forming processes are shown in figure
Glass containers are conveyed through various inspection, packaging, unpacking, filling and
re-packaging systems.
Flat Glass
The term flat glass strictly includes all glasses made in a flat form regardless of the form of
manufacture. However, for the purposes of this document it is used to describe float glass and
rolled glass production.
Most flat glass is produced with a basic soda lime formulation, a typical float glass composition.
Float glass and rolled glass are produced almost exclusively with cross-fired regenerative
furnaces.
The Float Glass Process

The basic principle of the float process is to pour the molten glass onto a bath of molten tin,
and to form a ribbon with the upper and lower surfaces becoming parallel under the influence
of gravity and surface tension.
The molten glass flows from the furnace along a refractory lined canal, which can be heated
to maintain the correct glass temperature. At the end of the canal the glass pours onto the
tin bath through a special refractory lip (“the spout”) which ensures correct glass spreading.

127
At the exit of the float bath the glass ribbon is taken out by lift-out rollers, and is passed through
a temperature controlled tunnel, the lehr, to be annealed.
Glass is thus gradually cooled from 600°C to 60°C in order to reduce residual stresses,
caused during the forming process, to an acceptable level.
The cooled glass ribbon is cut on-line by a traveling cutter.
On-line coatings can be applied to improve the performance of the product (e.g. low emissivity
glazing).
Continuous Filament Glass Fibre

The most widely used composition to produce continuous fibres is E Glass, which represents
more than 98 % of the sector output.
The glass melt for continuous filament glass fibre is generally produced in a cross-fired fossil
fuel recuperative furnace.
The molten glass flows from the front end of the furnace through a series of refractory lined,
gas heated canals to the forehearths.
The glass flowing through the bushing tips is drawn out and attenuated by the action of a
high-speed winding device to form continuous filaments.
The filaments are drawn together and pass over a roller or belt, which applies an aqueous
mixture, mainly of polymer emulsion or solution to each filament. The coated filaments are
gathered together into bundles called strands that go through further processing steps,
depending on the type of reinforcement being made.
The main products are chopped strands, rovings, chopped strand mats, yarns, tissues, and
milled fibres.
Chopped strands are produced by unwinding the cakes and feeding the filaments into a
machine with a rotating bladed cylinder.

128
Energy Consumption pattern

Glass making is energy intensive and the process energy accounts for a full 30 percent
of the cost of glass products. In general, the energy necessary for melting glass accounts
for over 75 % of the total energy requirements of glass manufacture. Other significant
areas of energy use are forehearths, the forming process, annealing, factory heating and
general services.
The choices of energy source, heating technique and heat recovery method are central to the
design of the furnace. The same choices are also some of the most important factors affecting
the environmental performance and energy efficiency of the melting operation.
In recent decades the predominant fuel for glass making has been fuel oil, although the use
of natural gas is increasing. There are various grades of fuel oil from heavy to light, with
varying purity and sulphur content. Many large furnaces are equipped to run on both natural
gas and fuel oil, and it is not uncommon for predominantly gas-fired furnaces to burn oil on
one or two ports.
The third common energy source for glass making is electricity, which can be used either as
the only energy source or in combination with fossil fuels.
The energy usage pattern in different types of industries is as below:
Container glass:
The typical energy use for the Container Glass Sector, which accounts for around 60 % of
total glass output is: furnace 79 %, forehearth 6 %, compressed air 4 %, lehr 2 %, and others
6 %.
Float glass:
The energy usage distribution for a typical float glass process is shown in.2 below, but energy
usage in particular processes may vary slightly. It can be seen that over three quarters of the
energy used in a glass plant is expended on melting glass. Forming and annealing takes a
further 5 % of the total. The remaining energy is used for services, control systems, lighting,
factory heating, and post forming processes such as inspection and packaging.

129
The energy usage distribution for a typical continuous filament process is shown below.
Energy usage in particular processes may vary depending on the size of the melter and the
type of downstream processes. It can be seen that generally over three quarters of the energy
is used for melting. Forming, including bushing heating, and product conversion account for
around 15 %, and the remaining energy is used for services, control systems, lighting, and
factory heating.
Continuous Filament glass:
As discussed earlier fuel oil and natural gas are the predominant energy sources for melting,
with a small percentage of electricity. Forehearths and annealing lehrs are heated by gas or
electricity, and electrical energy is used to drive air compressors and fans needed for the
process. General services include water pumping, steam generation for fuel storage and trace
heating, humidification/heating of batch, and heating buildings.
In order to provide a benchmark for process energy efficiency it is useful to consider the
theoretical energy requirements for melting glass.
The three important components, which forms the basis for the theoretical requirement is as
below:
• The heat of reaction to form the glass from the raw materials;
• The heat required, enthalpy, to raise the glass temperature from 20 °C to 1500 °C; and
• The heat content of the gases (principally CO2) released from the batch during melting.
The actual energy requirements experienced in the various sectors vary widely from about 3.5
to over 40 GJ/tonne. This figure depends very heavily on the furnace design, scale and
method of operation. However, the majority of glass is produced in large furnaces and the
energy requirement for melting is generally below 8 GJ/tonne.

130
Some of the more general factors affecting the energy consumption of fossil fuel fired furnaces
are outlined below. For any particular installation it is important to take account of the site-
specific issues, which will affect the applicability of the general comments given below.
a) The capacity of the furnace significantly affects the energy consumption per tonne of glass
melted, because larger furnaces are inherently more energy efficient due to the lower
surface area to volume ratio.
b) The furnace throughput is also important, with most furnaces achieving the most energy
efficient production at peak load. Variations in furnace load are largely market dependent
and can be quite wide, particularly for some container glass and domestic glass products.
c) As the age of a furnace increases its thermal efficiency usually declines. Towards the end
of a furnace campaign the energy consumption per tonne of glass melted may be up to
20 % higher than at the beginning of the campaign.
d) The use of cullet can significantly reduce energy consumption, because the chemical
energy required to melt the raw materials has already been provided. As a general rule
each 10 % increase in cullet usage results in an energy saving of 2 - 3 % in the melting
process.
Energy saving potential (data from CMIE)

The total cost of production of glass in India account to a total of Rs 1470 crores. The energy
cost alone forms about 30% the total manufacturing cost.
The energy saving potential in Indian glass industry is about 10-15% of the total energy
cost. The energy saving offers a good investment potential of about Rs 130 crores in
the glass sector.
Energy Conservation:
Process energy accounts for a full 30 percent of the cost of glass products. In the face
of growing challenges from foreign manufacturers and other materials, the glass industry
seeks to reduce energy use as part of its broader effort to lower glass production costs.
Present glass manufacturing facilities clearly offer a large opportunity for energy savings.
Whereas melting one ton of glass should theoretically require only about 2.2 million
Btu, in practice it requires a minimum of twice that much because of a variety of losses
and inefficiencies and the high quality of glass that is often required. One of the main
goals set forth in the glass vision statement is to cut the gap between theoretical and actual
energy requirements by half.
In a glass industry, the melting process is by far the most energy intensive of the primary
glassmaking processes and is responsible for the majority of energy consumption.
The figure records 75% on the tank furnace; and more energy, nearly 85%, is consumed in
the case of the pot furnace.

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Thus, when energy conservation efforts are made, top priority must be placed on the furnace,
then on the lehr.
The unit energy consumption means the energy required to make the product of unit amount
(1 kg or 1 ton). It is expressed either by unit energy consumption if energy is used as the unit
or by unit fuel consumption if the amount of fuel is used as the unit.
Basically, energy conservation in the glass factory is to reduce the unit energy consumption.
To reduce unit energy consumption, it is necessary to reduce the amount of fuels used, while
it is important as well to increase production without increasing the amount of fuels, and to
reduce the failure rate of production, thereby ensuring production increase in the final stage.
ENERGY SAVING SCHEMES IN GLASS INDUSTRY

List of all possible energy conservation projects in a typical glass industry
1. Install Variable Frequency Drive (VFD) For Combustion Air Blower
2. Install Variable Fluid Coupling for cooling blowers in furnace
3. Install correct head fans for furnace cooling
4. Reduce rpm of furnace chimney blower by 10%
5. Replace the existing inefficient cooling blowers with energy efficient blowers with efficiency
greater than 75%
6. Avoid recirculation through the stand-by blower of throat cooling
7. Replace old inefficient reciprocating compressors catering to instrumentation requirements
with high efficiency compressors
8. Install lower capacity air compressor to cater high pressure compressed air requirements
catering to furnace primary air requirements and minimize unloading power consumption
by compressor
9. Segregate low pressure and high pressure compressor air systems and operate LP air
system catering to instrumentation systems at lower pressure
10. Install Variable Frequency drives to screw compressor catering to process air requirements
(furnace combustion requirement) and reduce power consumption

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

requirements
12. Install correct head pumps for cooling tower catering to cooling requirements of
instrumentation compressors
13. Avoid water flow through idle compressors / condensers and install next low head pumps
for hp compressor cooling
14. Optimise the combustion air supply to the furnace and maintain 3% O2 in the flue gas
15. Preventing cold air from entering through the inlet opening of the lehr and reducing heat
loss in the furnace
16. Improve insulation of the walls of the lehr and reduce radiation losses
17. Reduce the conveying length of product from the furnace to the lehr and reduce
temperature drop
18. Install automatic voltage stabilizer in street lighting feeder and optimise operating voltage
19. Replace copper ballast with high frequency electronic ballast in all fluorescent lamps
20. Optimize pressure settings of air compressors
21. Arrest leakages in compressed air system
22. Install transvector nozzles for identified cleaning points
23. Replace existing V-belt drives with flat belt drives for identified equipment
24. Convert delta to star in the identified lightly loaded motors
25. Balance system voltage to avoid unbalance in motor load
26. Replace faulty capacitors
27. Install automatic voltage stabiliser and operate lighting circuit at 210 volts
28. Install soft start cum energy saver for motors
29. Replace old motors with energy efficient motors
30. Use transluscent sheets to make use of day lighting
31. Install timers for automatic switching ON-OFF of lights
32. Install timers for yard and outside lighting
33. Grouping of lighting circuits for better control
34. Operate at maximum power factor, say 0.96 and above
35. Switching OFF of transformers based on loading
36. Optimise DG set operating frequency
37. Optimise DG set operating voltage
38. Replacement of Aluminium blades with FRP blades in cooling tower fans
39. Install temperature indicator controller (TIC) for optimising cooling tower fan operation,
based on ambient conditions
40. Install dual speed motors/ VSD for cooling tower fans

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Case Study - 1
Preheat Feed Material Furnace Using

Waste Heat from Flue Gas
Background
Batch and cullet is normally introduced cold into the furnace, before being heated and melted
by the heat in the glass tank. And the flue from the furnaces after the regenerator typically
leaves at a temperature of about 500-600oC.
An important process improvement currently being contemplated by the glass industry is the
preheating of the batch feed by using exhaust gases from the furnace.
An analysis of the melt furnace and its regenerator indicates that there is enough energy
availability in the furnace exhaust gases to preheat the incoming combustion air to present
levels and to preheat the batch to 400 oC. Depending upon the specific operating conditions,
5-10% of the energy necessary to melt glass could be obtained from waste heat.
By this method, the total fuel consumption by the furnace can be reduced by atleast
5%. The economics of batch/cullet preheaters are strongly dependent on the capacity of the
furnace and the preheater.
This preheating method allows a better usage of energy in the furnace area. But such a
preheat operation is difficult to accomplish without modification in the batch handling methods.
Normally, a number of storage bins hold the raw material. The raw materials are weighed
individually, fed to a collecting belt, and conveyed to a mixer. A pan mixer is used to blend
the dry materials. From the mixer, the blended batch is transferred to a surge hopper and
feeder. The material is then fed to a pelletiser, where water is added to about 4% by weight
as a binder for the pellets. The pelletised material is then conveyed through a high temperature
continuous preheater, which is heated by the waste gases of the glass melting furnace.
The presently available systems for preheating the batch feed is as below:
Direct preheating
This type of preheating involves direct contact between the flue gas and the raw material
(cullet only) in a cross-counter flow. The waste gases are supplied to the preheater from the
waste into direct contact with the raw material. The outlet temperature of the cullet is up to
400 ºC.

134
The system can also incorporate a bypass that allows furnace operation to continue when
preheater use is either inappropriate or impossible.
Diagram of a direct preheater:
Indirect preheating
The indirect preheater is in principle a cross-counter flow, plate heat exchanger, in which the
material is heated indirectly. It is designed in a modular form and consists of individual heat
exchanger blocks situated above each other. These blocks are again divided into horizontal
waste gas and vertical material funnels. In the material funnels the material flows from the top
to the bottom by gravity. Depending on the throughput, the material reaches a speed of
1 - 3 m/h and will normally be heated up from ambient temperature to approximately 300°C.
The flue gases will be let in the bottom of the preheater and flow into the upper part by means
of special detour funnels. The waste gases flow horizontally through the individual modules.
Typically the flue gases will be cooled down by approximately 270°C – 300°C.
In general, the following benefits can be experienced.
• Energy savings of atleast 5 %.
• Reduction in NOx emission (due to lower fuel requirements and lower furnace temperatures).

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• In the case of direct preheating, reduction of acidic compounds, SO2, HF, and HCl, of
60%, 50% and 90% respectively have been found (difference before and after cullet bed).
Case study
A container glass plant with a furnace capacity of 370 tonnes/day had a specific energy
consumption of about 4000 kJ/kg of glass. The temperature of exit flue gas from the furnace,
after the regenerator is about 450-500oC.
The fuel consumption of the plant was about 35kl/day. The cullet in the feed amounted to
about 60% of the total batch onto the furnace.
The plant team installed an indirect type batch preheating system for their furnace. In order
to keep the loss of heat of the transport system, as low as possible the preheater was located
as close as possible to the doghouse. The ideal location was directly above the batch charger.
After this installation, the flue gas got cooled to a temperature of about 200-250oC. As a
result, the total reduction in oil consumption by the plant is about 10% of the fuel consumption.
The technique also gave an increase in furnace capacity by 10 % - 15 % without compromising

the furnace life. If the pull rate is not increased a small increase in furnace life may be
possible.
If a plant utilizes electric boosting technique, by getting more heat into the furnace the technique
can also reduce the requirement from electric boosting.
The cost economics of the project is as below:
Investment – Rs 4.00 million
Savings – Rs 1.50 million
Payback – 32 months
Other general factors to be considered

• To prevent material agglomeration the maximum entry temperature of the flue gases
should not exceed 600°C.
• In some cases, problems with odor generation from the preheater have arisen, due to
organic fumes released during pre-drying of the cullet. The problems are caused by
burning of food particles and other organics in the external cullet.
• Material preheating consumes electric energy, particularly for direct heating which requires
an Electrostatic Precipitator. These off sets a portion of the energy saving but it is not
substantial.
• For economic reasons the temperature of the waste gas available should at least be 400
- 450°C.
• Direct Cullet/batch preheating systems can theoretically be installed at any existing glass-
melting furnace with greater than 60 % cullet in the batch. The use of a direct preheater
causes increased emissions of particulate matter (up to 2000 mg/Nm3) and secondary

136

137
Case study - 2
The installation of preheater have successfully implemented

in many of the European industries and some of the expammle
installations are as below:
(All container Glass)
Direct preheating:
Four furnaces at Nienburger Glas, Nienburg, Germany.
Gerresheimer Glas, Dusseldorf, Germany.
Wiegand Glas, Stein am Wald, Germany.
Gerresheimer Glas, Budenheim, Germany.
Indirect preheating:
PLM Glasindustrie Dongen BV, Dongen, Netherlands.
PLM Glass Division, Bad Münder, Germany.
Vetropack, St. Prex, Switzerland – no longer operating.
Edmeston EGB Filter:

Irish Glass, Dublin, Ireland.
Leone Industries, New Jersey, USA (oxy-fuel fired furnace).
The installations as such in India are still in the initial stages of implementation and
offer a very good potential for energy savings.
The project has a good potential to be replicated in about 100 organized sectors and
200 to 250 small scale manufacturers in India.

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Case study - 3
WASTE GAS HEAT RECOVERY SYSTEMS IN FURNACES
Background
Glass is maintained at a temperature of about 1550oC, in the tank. The hot flue gas from the
furnace leaves at a temperature of about 1600oC.
The heat in the exit flue gas can be effectively utilised by preheating the incoming air to the
combustion furnace. There are two options available for this purpose. The installation of:
1. Regenerators
2. Recuperators
Regenerators:
The regenerator is designed in a way that high temperature exhaust gas is passed through
the checker bricks, and the heat is absorbed by these bricks. After the combustion, gas is fed
for some time (15 to 30 minutes), air is fed there by switching, and the brick heat is absorbed,
raising the air temperature. The air is used for combustion. This procedure is repeated at
intervals of 15 to 30 minutes. Thus, two regenerators are required for each furnace.
The exhaust gas temperature is 1350 to 1450°C at the regenerator inlet, and drops 400 to
500°C at the regenerator outlet. Air enters the regenerator at the room temperature, and is
heated to reach 1200 to1300°C at the outlet. Then, it is used as secondary air for combustion.
Most glass container plants have either end-fired or cross-fired regenerative furnaces. All float
glass furnaces are of cross-fired regenerative design.
Preheat temperatures up to 1400 °C can also be attained leading to very high thermal
efficiencies.
Cross-Fired Regenerative Systems

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A cross-fired regenerative furnace

In the cross-fired regenerative furnace, combustion ports and burners are positioned along the
sides of the furnace. The regenerator chambers are located either side of the furnace and are
connected to the furnace via the port necks. The flame passes above the molten material and
directly into the opposite ports. The number of ports (up to 8) used is a function of the size
and capacity of the furnace and its particular design. Some larger furnaces may have the
regenerator chambers divided for each burner port.
This type of design using effectively a multiplicity of burners is particularly suited to larger
installations, facilitating the differentiation of the temperature along the furnace length necessary
to stimulate the required convection currents in the glass melt.
End-Fired Regenerative Furnace

In the end-fired regenerative furnace the principles of operation are the same, however, the
two regenerative chambers are situated at one end of the furnace each with a single port. The
flame path forms a U shape returning to the adjacent regenerator chamber through the
second port.
This arrangement enables a somewhat more cost effective regenerator system than the
cross-fired design but has less flexibility for adjusting the furnace temperature profile and is
thus less favoured for larger furnaces.
End-fired regenerative furnace

140
Side view of end-fired regenerative furnaces
Plan view of end-fired regenerative furnace

Regenerative furnaces achieve a higher preheat temperature for the combustion gases, up to
1400°C compared with 800°C for recuperative furnaces, resulting in better melting efficiencies.
The generally larger size of the regenerative furnaces also makes them more energy efficient
than the smaller recuperative furnaces. This is because structural losses are inversely
proportional to the furnace size, the main reason being the change in surface area to volume
ratio.
A modern regenerative container furnace will generally have an overall thermal efficiency of
around 50 %, with waste gas losses around 20 %, and structural losses making up the vast
majority of the remainder.
Maximizing heat recovery in regenerators:

Furnace geometry is constantly undergoing refinements to optimise thermal currents and heat
transfer, both to improve glass quality and to save energy. The developments are often
combined with developments in combustion systems to reduce emissions and save energy.
Normally, furnace geometry changes are only possible for new furnaces or rebuilds.
The energy recovered by regenerators may be maximized by incorporating the right type and
quantity of refractory material into the regenerators.
The refractory material should possess high thermal conductivity, hence resulting in higher
heat recoveries.
One of the problems faced by companies in regenerators is that, they get corroded with the
exit flue gas and results in clogging of the flue gas path with particulate carry over in flue
gases inside the regenerators. This ultimately reduces the heat recovery in the system. Hence
one of the important factors to be considered is to select a right type of refractory material
that can withstand corrosion.
There are a variety of checker works available nowadays and the best one needs to be
choosed for better heat recovery. The most common is the bricks are available in standard
sizes of 65mm thickness with basic materials such as magnesite and chrome. These refractory
materials are used for their resistance to handle alkaline corrosion in flue gases.

141
Blocks shaped in the form of cruciform or chimney blocks on account of their lesser thickness
are more efficient in Magnesite high alumina and AZS compositions. However, heat transfer
can be improved by using specially shaped packing and fusion cast materials. For example,
fusion cast corrugated cruciform will enhance the heat exchange efficiency compared to
standard brick packing and typical fuel savings of 7 % are quoted.
With better quality basic and AZS electrocast refractories, regenerator checker life can be
increased and increase upto 8 years have been improved in various factories.
In addition, these materials are very resistant to chemical attack from volatiles in the waste
gas stream and show very much reduced deterioration in performance (compared to bricks)
throughout the campaign. So far, around 320 installations of corrugated cruciforms have been
reported world-wide.
Increased refractory area:

The energy recovered by regenerators may be maximized by increasing the surface area to
specific volume ratio. In practice, these may be organised in enlarged regenerator chambers
or in separate but connected structures, giving the term multi-pass regenerators in some
cases.
The law of diminishing returns applies, as the regenerator efficiency is approaching

asymptotically its maximum limit. The principle limitations are the cost of the extra refractory
bricks, and in the case of existing furnaces the limitation of available space and the additional
cost of modification of furnace infrastructures.
Modification of regenerator structures on existing furnaces (if this is technically and economically
feasible given the plant layout) can only be made during furnace reconstruction.
Exhasust Gas Losses

Approx 40%
Combustion Air
Recup
erato
Losses through the

Crown and walls 20 –
Energy Recovered 40%
through the
preheating of the Melting Furnace
combustion air
approx 30%
Melting and
Energy input Refining energy 20
from Gas / Fuel – 40%
oil 100%

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Case study – Install Regenerators for glass melting

furnaces
One glass bulb making unit in southern part of India had a unit melter
of capacity 16tonnes/day. The total furnace oil consumption by the
furnace is about 700lit/ton.
There was no flue gas recovery by the furnace and the temperature
of exit flue gas is about 1500oC. This can be effectively utilized to
preheat the incoming combustion air.
The plant installed a new regenerative furnace of 16 ton/day capacity

and achieved a saving of 1800 kl/annum of furnace oil.
Benefits (check the cost benefit as the below thing is taken from a
1987 report)
There was a tremendous reduction in the specific fuel consumption

by the furnace. The new specific fuel consumption is about 310 lit/ton of glass melted.
The cost economics of the project is as below:
Investment – Rs 30.0 million
Savings – Rs 20.0 million
Payback – 18 months
Majority of the organized sectors in India have adopted this technology of regeneration in the
melting furnaces. The major thrust, which needs to be applied, is towards the small-scale
sectors, which constitutes about 250 glass industries.
These industries can be installed with recuperative heaters for their furnaces and thus this
area would offer a huge energy saving potential in the energy consumption by the melting
furnaces.
Recuperative Furnaces:
The recuperator is another common form of heat recovery system usually used for smaller
furnaces. In this type of arrangement the incoming cold air is pre-heated indirectly by a
continuous flow of waste gas through a metal (or, exceptionally, ceramic) heat exchanger. Air
preheat temperatures are limited to around 800°C for metallic recuperators, and the heat
recovered by this system is thus lower than for the regenerative furnace. The lower direct
energy efficiency may be compensated by additional heat recovery systems on the waste
gases, either to preheat raw materials or for the production of steam.
However, one consequence is that the specific melting capacity of recuperative furnaces is
limited to 2 tonnes/m2/day compared to typically 3.2 tonnes/m2/day for a regenerative furnace
in the Container Glass Sector. This lack of melting capacity can be partially compensated by
the use of electric boosting.
Normally, recuperators would be ideally suited for low capacity industries (about 10TPD).
Recuperators can be of either metallic/refractory type. The temperature limitations of these
types of recuperators are 1000oC and 1500 oC respectively.

143

144
The maximum temperature upto which the combustion air can be preheated would be 850 -
900oC. This limits the thermal efficiency of the recuperative furnace. Typically, the thermal
efficiency of a recuperative furnace without heat recovery will be closer to 20 %.
Case study:
One of the tank type glass-melting furnaces with a fuel consumption of 1450 lit/day was
installed with a metallic recuperator. The flue gas temperature from the furnace is about
1100oC and the combustion air is heated to a temperature of 600oC.
The plant achieved a savings of 25% savings in fuel consumption. The cost benefit analysis
of the project is as below:
Annual savings - Rs 0.88 million
Investment - Rs 0.3 million
Payback - 5 months

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146
Case study - 4
Improve Insulation Practices in furnace:
Background
Furnace Walls:
The insulation of furnace walls requires great attention, as the wrong selection of refractory
material would result in decreased production quality as well as increased energy consumptions.
Presently, all modern glass-melting furnaces are lined with AZS electrocast blocks in glass
contact areas and superstructures. The refractory material has the resistance to prevent the
corrosion of glass.
But the disadvantage is that it possesses high thermal conductivity making it less energy
efficient.
Therefore, the electrocast material is backed up with a solid high alumina block and insulation
to minimize heat loss.
The table below shows the heat loss at different parts of the glass tank with and without
insulation:
HEAT LOSS (W/M2)
Without Insulation With Insulation
G.T Crown 6900-8000 1800
End wall -do- 3500
Super Structure -do- 1800
Tank Blocks 11600-15100 2800
Bottom 10500-12800 1400
high alumina
Case study: block
A 200 tpd container glass manufacturing industry had

a melting furnace with its sidewalls at a temperature
of 230 oC initially. The total surface area at this
temperature was about 6 m2. The amount of heat
= 120oC
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 950

147
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)
Payback - 8 months

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149
Case study - 5
Modifications in the design of crown to reduce radiation loss

and improved quality of glass
a. Reduce gap in the crown of melting furnace and reduce radiation of loss
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.
Payback - 48 months

150

151
Redesigning the crown to minimize contamination of glass
4820
Size of the crown bricks
375 x 150 x 75 / 65 2592

375 x 230 x 75 / 65 144
The raw material fed into the glass-melting furnace consists of small quantities of Na2CO3,
added as flux to reduce the melting temperature of glass.
At high temperatures Na2CO3 vaporizes and condenses on the super structures. This high pH
droplet on top of refractory, corrodes the super structure, and would drop back into the melt
along with some corroded particles. This would result in quality problems in the batch, and
hence would increase the reject percentage.
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.

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Case study - 6
Installation of Modern Instrumentation & control Systems for

furnaces:
Instrumentation and Control, forms one of the major energy saving component in a glass
industry.
The various parameters in a melting furnace viz., the level of molten glass in the furnace, the
temperature distribution in the furnace, the oxygen % in the flue gas needs to be monitored
on a continuous basis.
This would result not only in reduce energy consumptions but also in increased product
quality. The various types of controls available nowadays for the furnace are as below:
Level indicator control:

Inorder to measure the level of molten glass in the tank, platinum tipped probes are being
used. This probe moves up and down through the tank furnace and he accurately gives the
level of glass in the furnace. The feedback from the element in certain cases is interlinked
with the feed rate to the furnace. Thus maintaining the level of glass in the furnace. The probe
has an accuracy of + 1 mm.
The other methods of measuring the level of glass include the Laser based Level Indicator
control (LIC) and Pneumatic LICs using LP compressed air.
Temperature indicator Control:

The required temperature of glass in the furnace should be about 1550oC. This needs to be
precisely controlled inorder to reduce radiation loss from the furnace. Any slight increase in
the temperature would result in huge loss as radiation from the furnace. Normally, a tolerance
of about + 5oC is allowed in the glass furnace.
The latest controls for measuring the glass temperatures include the noble metal based
thermocouples. Typically, there would be two nos. of thermocouples, one at crown and one
at bottom. The values from the thermocouples need to be counterchecked with the reading
from an optical pyrometer.
Flue gas analyser:

The other most important parameter in a glass-melting furnace is the percentage of oxygen
in the flue gas. The % O2 should be monitored on a continuous basis and a value of less than
2% O2 should be maintained in the flue gas. Any increase in this value would result in huge
losses from the furnace as flue gas loss.
Online oxygen analyzers should be necessarily installed in the flue gas duct of the furnaces
to measure the O2 %. The signal from the analyser can also be given as a feedback to control
the oil pump as well as the blower supplying combustion air. The values from the online oxygen
analyser should be counter checked with the values from portable oxygen analyzers.

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The above measures should be followed on a continuous basis and an energy saving of
atleast 2% in the energy consumed by the furnace can be reduced, by these methods.
Case study - 7
Redesign the mesh belt in lehr and avoid heat loss
Background
The mesh belt is made of steel wire or stainless steel. When it enters the furnace and is
heated the energy consumed by the mesh belt will be twice the amount consumed by the
product. Good potential to reduce the energy consumed in the lehr exists by redesigning and
reducing the mass of the mesh belt, conveying the products.
Case study:
A container glass industry with a production through the lehr of 630 kg/h enters at a temperature
of 400°C into the lehr. The soaking temperature in the lehr is 550°C. The total quantity of heat
required to heat the product with a specific heat of 0.252 is 23814 kcal/h
A mesh belt of weight 20 kg/m and 1.5 m width carries the products at an rpm of 380 mm/
min. The total heat required to heat up the belt is (with Cp = 0.132) 48304 kcal/h, which is
twice the value of heat required to heat the glass product.
To save this heat, the belt wire length and diameter was minimized, and the weight was
reduced, by making the pitch loose.
However, care should be taken to check the reduced strength of belt after alterations.
Replace old reciprocating compressors with centrifugal compressors having lower specific
energy consumption.
Compressed air usage in a plant is one of the major electrical energy consumers. Typically,
the process air demands in the plant requires compressed air at a pressure of about 3.5 –
4.0 kg/cm2.
The compressed air demand of these process users are met by positive displacement (usually
reciprocating) compressors. The specific energy consumption of these types of compressors
is about 0.12 kW/cfm.
The compressed air requirements with pressure requirements of the order of 4.0 kg/cm2 can
be met using centrifugal compressors. These types of compressors would have lower specific
energy consumption for the same deliver pressure. The typical specific energy consumption
for pressures of about 3.5 kg/cm2 would from 0.09 to 0.10 kW/cfm. Therefore energy saving
upto 20% can be easily achieved by the installation of a centrifugal type of compressor.
Case study
A 550tpd container glass manufacturing unit has a process air demand of about 10000 cfm
of compressed air at a pressure of about 3.5 kg/cm2.

154
The plant had four nos. of reciprocating compressors of 2500 cfm capacity each to meet the
compressed air demands. The specific energy consumption by the compressors was
0.125 kW/cfm.
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.
Annual savings (compressor

savings alone) - Rs 0.52 million
Payback period - 35 months

155

156
Case study - 8
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 one-third of the energy consumption by the pneumatic conveying system.
Benefits
The cost-economics of the proposed energy saving project will be as follows:
Payback - 19 months
Other projects
Oxy fuel firing systems to reduce fuel consumption in the furnace:

This technique of oxy-fuel firing involves the replacement of the combustion air with oxygen.
The elimination of the majority of the nitrogen from the combustion atmosphere reduces the
volume of the waste gases. Therefore, energy savings are possible because it is not necessary
to heat the atmospheric nitrogen to the temperature of the flames.

157

158
Good potential to reduce oil consumption exists by reducing this remaining 3/4th portion of
combustion air. Fuel consumption would reduce to 1/5th of initial consumption.
Moreover, the formation of thermal NOx is greatly reduced, because the only nitrogen present
in the combustion atmosphere is the residual nitrogen in the oxygen, nitrogen in the fuel etc
The principal deterrents to the increased use of oxygen enrichment of fossil fuel firing are the
cost of oxygen and the possible effect of the higher flame temperatures on the furnace life,
particularly on the silica crown roof.
Typically, the cost of supplying O2 when compared with the cost of reduced fuel firing would
be 10% costlier.
The project becomes more attractive when the O2 plant is set up nearby to the glass plant.
The project can be contemplated by higher capacity plants or by cluster of smaller plants.
Then the project becomes more attractive.
The project has been successfully implemented in countries like United States of America and
the other European countries. The major reason being the stringent environmental regulations
followed in those regions. The plants have also achieved substantial benefits by the
implementation of the project.
In India, however, Oxy-fuel works out to be quite costly and as is mentioned above, the project
could be considered where totally new furnaces are being put up, wherein the cost of
regenerators can be eliminated.
The performance of refractories in oxy-fuel furnaces is still a gray area and considerable
developments have to be made for a foolproof solution.
Installation Of Sand Beneficiating Unit At Raw Material Site

Beneficiation is a process of washing the raw material with water inorder to eliminate unwanted
material. Typically in India, the iron oxide content in the raw material is about 0.1 to 0.2%. The
optimum allowable limit in the raw material varies depending upon the quality of glass.
Iron oxide content in the raw material also turns out to be advantageous when it the batch
requires a certain composition of iron oxide.

159
Many plants in India have set-up captive beneficiation unit in their factory site. This involves
transportation of unwanted material along with raw material to the factory and results in increased
transportation costs.
There is a good potential to eliminate this cost by setting up beneficiation unit at the raw
material site. Thereby a saving of about 10% on the transportation cost can be achieved.
This project would not involve a separate investment by the plant, but should be taken care
rom the inception of the plant.

160
Supplier Address Refractories:
Preheaters : Carborundum Universal Ltd – cross check

Zippe Industrieanlagen GmbH, address
Alfred-Zippe-Strasse, Tiam House Annexe,28 rajaji Road, Chennai
D – 97877 Wertheim, Germany, 600 001, India
P.O Box 1665, D – 97866 Werthim, Tel: +91 44 2511652
Germany Fax +91 44 2510378
Tel: + 49 9342 8040
Fax: + 49 9342 804138 Glass Fabrication equipment manufacturer
Email: zippe@zippe.de Oilvotto
www.zippe.de 10051 Avigliana (Torino) Italy
Tel: +39 011 9343511
SORG (Melting furnaces, preheaters) Fax: +39 011 9343593
Nikololaus Sorg GmbH & Co KG Email: info@olivotto.it
PO Box 1520 www.olivotto.it
97805 Lohr am Main Indian Representative for Olivotto
Germany CV Chalam & Consultants
Tel: 0 9352 / 5 07-0
Fax: 0 93 52/5 07-196 / 507-204-507-234 Fuller
email : nsorg@sorg.de Ingenieurburo
www.sorg.de Dipl-Ing(FH) Herman Fuller
Schulstrabe 39
Indian representative for Zippe & Sorg D – 94518 Spiegelau
Mascot Engg. Company Tel. +49 – 0 –8553518
World Trade Centre Fax +49 – 0 –8553514
Cuffe Parade Email: info@f-gt.de
Tel: + 91 22 2187165 www. f-gt.de
Fax: + 91 22 2187166 Instrumentation & Control
Email: mascot@vsnl.com
www.mascotindia.com Glass Service Inc
Crown, regerators, recuperators, refractory Rokytrive,60,75501,Vsetin
materials Czech replublic
Email: glass@gsl.cz
Vesavius VGT – DYKO www.gsl.cz
Wieesenstr, 61 Oxygen suppliers
40549 Dusseldorf – Germany BOC Gases/India Oxygen ltd
Tel: +49-211-502900 Oxygen House, P43 Taratala road,
Fax: +49-211-502659 Kolkatta700-088, India
Email: info@vgl-dyko.de Tel +33 91 2478 4709
Fax + 33 91 478 4974

161
Ceramics
Per Capita Consumption 0.09 ceramic sq.m per annum

Sanitary : 16 – 17 Million pieces /
annum
Growth percentage 11% per annum in last 3 years
Energy Intensity 20 – 25% of manufacturing cost
Energy Costs Rs.2350 million (US $ 47 million)
Energy saving potential 15% of the energy cost

Rs.350 million (US $ 7 million)
Investment potential on
energy saving projects Rs.725 million (US $ 14.5 million)

Energy Conservation in Ceramic Industry
162
1.0 Introduction
The Ceramic industry is one of the age-old industries and has evolved over the centuries, from
the potter’s wheel to a modern 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%.
2.0 Growth of Ceramic Industry

2.1 Ceramic Tile Industry
There are at present 14 units in the organised sector with an installed capacity of 12 lakh MT.
Some of the units have either closed or merged with the existing units. It accounts for 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.
2.2 Sanitary ware Industry
Sanitary ware are also manufactured both in large and small-scale sectors with variance in
type, range, quality and standard. This industry has been growing by about 5% per
annum during the last two years. There is significant export potential for sanitary ware.
These are presently being exported to East and West Asia, Africa, Europe and Canada.
Sanitary ware demand amounted to nearly 80m. pieces worth US$1.1bn in 2000. India
represented 21% of the volume and only 10% of value.
The whole market is expected to grow by about 7-8% in the next five years, reaching
nearly 110 m. pieces in 2005. The fastest growing countries will include Bangladesh, India,
Vietnam, China and Sri Lanka.
2.3 Pottery ware Industry
Pottery ware signifying crockery and tableware are produced both in large scale and the small
scale sectors. There are 16 units in the organised sector with a total installed capacity of
43,000 tonnes per annum.
3.0 Per Capita Consumption

Per-capita ceramic tile consumption - 0.09 sq.m/annum
Per-capita sanitary ware consumption - 16-17 M pieces/annum
4.0 Energy Intensity

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%.

163
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.
5.0 Energy Saving potential

The various energy conservation studies conducted by CII, indicate an energy savings potential
of 15%, equivalent to an annual savings of about US $ 7 million. The estimated investment
required to achieve the savings potential is US $ 14.5 million.
The ceramic industry is highly energy intensive and is one of the major energy consumer
in the country. Energy costs account for nearly 20 to 25% of the manufacturing cost and
hence, energy conservation is strongly pursued as one of the attractive options for improving
the profitability in the Indian Ceramic Industry.
5.1 Target specific energy consumption figures
Kilns and dryers are the major energy consumers of ceramic industry. As this constitutes
to 80-90% of the total thermal energy bill, the specific energy consumption of the kilns has
been highlighted.
A typical comparison of specific energy consumption of different types of kilns is as follows:
Type of Ceramic In Periodic Kilns (Kj/Kg) In Tunnel Kilns (Kj/Kg)
Fire bricks
(fired at 1200-1400oC) 6000-8000 2500-3500
High alumina refractories

(fired at 1400-1600oC) 12000 3500
Basic refractories
(fired at 1600-1750oC) 12000-16000 6000-7000
Major factors that affect the energy consumption in all types of ceramic industry
The major factors that affect the energy consumption in the ceramic industry are as follows:
• Types of kilns and dryers
• Capacity utilisation of kilns and driers
• Combustion control systems
• Type of heat recovery system
• Type of insulation used at kilns and driers
• Types of presses
• Types of spray driers

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6.0 Manufacturing process of ceramics

Naturally occurring inorganic substances are heat-treated after adjustment of the grain size
and moisture, and some of them are completely molten to be formed into ceramics; while
others are formed, heat-treated and made into the ceramic products in the sintered state
immediately before being molten.
The former product formed in the molten state is known as glass, and the latter product
finished in the sintered state includes pottery, refractory, sanitary ware, tiles and cement.
These ceramics are called traditional ceramics. By contrast, extremely fine particles of high-
purity inorganic substances such as alumina (Al2O3), Silica (SiO2), Zirconia (ZrO2) and silicon
Nitride (Si3N4) are sintered at a high temperature and made into ceramics; they are called
advanced ceramics. These advanced ceramics are used in electronic parts and mechanical
parts. The following describes the traditional ceramics production process:
6.1 Broad Classification of Ceramics
The Ceramic units can be classified based on the product, into three broad categories as:
• Electro Porcelain
• Tiles & Sanitary ware
• Refractory
Process Description
The process description in manufacturing of the above three categories of ceramic products
is as follows :
6.2 Electro Porcelain
The main raw materials used in this process are quartz, feldspar, china clay and ball clay. In
addition, small quantities of fusible salts, such as calcium carbonate, barium carbonate, zinc
oxide, etc. are used to prepare the glaze melt.

165
Jaw crushers and hardening mills are used, to pulverise the quartz and feldspar to 45 micron
fineness. The clay, if hard, is ground in ball mills. The crushed raw material is then mixed with
clay in blungers and a homogeneous slip is passed through screens and ferro filters to
remove the impurities.
Filter presses are used to remove the water. The cakes are then sent through de-airing pug
mills and the extruded mass is used to make solid core or moulded insulators, as per the
requirements.
Hollow and solid core electro-porcelains are dried by electro-osmosis initially, and then in
humidity driers, after turning on lathes to the required shape. The formed wares are dried in
batch driers, using conventional heat sources.
The dried wares are glazed and then fired in the kilns to about 1250-1300oC. The insulators
are fitted with metal caps and are tested for porosity and desired electro-mechanical qualities.
The accepted ones are then sent for packing and despatch.
The process flow diagram of electro-porcelain is shown in the below:
6.3 Sanitary-ware and tiles
The main raw materials used in the process are quartz, feldspar, silica sand (as substitute for
quartz) and clay. In addition, small quantities of homogenising materials are used to prepare
glaze.
Quartz and feldspar are crushed in jaw crusher and then fed to a ball mill. The fineness of
the material is reduced to, around 50 microns.
The crushed raw materials is then mixed with powdered clay in blungers. A magnetic drum
and filter chamber are installed to remove impurities. The slip, that is formed, is kept agitated
in agitators to homogenise and then stored in silos.

166
For glazed preparation, the ball clays are ground in smaller ball mills along with water and
other ingredients.
The slip is poured into the moulds by hand held hose. The cast wares are then dried in driers,
from an initial moisture content of 15% to 0.5%.
The dried wares are glazed in several spray glazing booths, where compressed air is used.
The glazed wares are then fired in the kilns upto a temperature of 1200oC. The output from
the kiln is inspected before packing and despatch.
The process flow of tiles industry is almost similar to sanitary ware except for the following
changes :
After homogenisation, the material is dried in a spray drier. The dried material is pressed with
presses. The pressed product is passed through drier and fired in a kiln at 1150oC to 1300oC
to get the final product.
The process flow diagram of sanitary-ware and tiles are shown below :
6.4 Refractories
Refractory manufacturing can be broadly divided into three sections namely:
• Raw material preparation section
• Brick making or press section
• Firing/drying

167
In raw material preparation, crushing of raw material (from stores) to a desired size and mixing
of raw material to the required composition is carried out. In brick making or press section,
brick is made to the desired shape/weight in presses. The formed bricks are fired in kilns.
The process flow diagram of refractories is shown below :
7.0 Energy Saving schemes

An exhaustive list of all possible energy saving projects in the Ceramic industry is given below.
The projects have been categorised under short-term, medium term and capital-intensive
projects.
The projects which have very low or marginal investments and have an energy saving
potential of upto 5% has been categorised as short-term. The projects which require
some capital -investment having a simple payback period of less than 24 months and having
an energy saving potential of upto 10% has been categorised as medium-term.
The short-term and medium-term projects are technically and commercially proven projects
and can be taken up for implemented very easily.
There are several projects, which have very high energy saving potential (typically 15% or
more), besides other incidental benefits. These projects have very high replication potential
and contribute significantly to improving the competitiveness of the Ceramic industry. However,
some of these projects require very high capital-investment and hence has been categorised
separately under case studies.

168
8.0 Energy Saving schemes

8.1 House-Keeping Measures – Energy Savings Potential of 5%
A. Electrical
1. Install delta to star convertors for lightly loaded motors
8. Optimise TG/DG sets operating frequency
9. Optimise TG/ DG sets operating voltage
10. Improve operating power factor of diesel generator
11. Balance system voltage to avoid unbalance in motor load
B. Kiln
12. Install auto interlock between the brushing dust collection blowers and the glazing lines
13. Avoid air infiltration and operate the Vertical Shaft Kiln (VSK) exhaust fan with damper
control
14. Improve combustion efficiency of VSK by optimising excess air levels
C. Spray Drier
15. Arrest air infiltration in spray drier system
16. Replace LPG with Diesel firing in the spry drier
D. Vertical Drier
17. Switch off chiller circuit when hydraulic press is not in operation
18. Reduce idle operation of hydraulic press pump by installing suitable interlocks
E. Utilities
19. Optimise pressure setting of air compressors
23. Avoid/ minimise compressed air leakages by vigorous maintenance
24. Install level indictor controllers to maintain chest level
25. Install hour meters on all material handling equipment, such, pulpers, beaters etc.

169
8.2 Medium Term Measures - Savings Potential upto 10%
A. Electrical
1. Install Automatic voltage stabilizer for lighting feeder
2. Replace copper ballast with high frequency electronic ballast in all fluorescent lamps.
3. Replace old motors with energy efficient motors
B. Kiln
4. Convert electrical heating to thermal heating system for LPG vaporizer
5. Install variable frequency drive for rapid air cooling fan
6. Segregate combustion and atomizing air fans in Kiln
7. Install variable frequency drive for hot air fan in kiln
8. Install variable frequency drive for smoke air fans
9. Improve insulation of vertical shaft kiln (VSK) to reduce radiation losses
10. Replacement with correct size combustion air blower in Kiln
11. Loading of acid bricks on top of refractory bricks on a continuous basis to maximize box
formation
C. Spray Drier
12. Install variable frequency drive for spray drier exhaust fan
13. Replacement with correct size combustion air blower in kiln
D. Vertical Drier
14. Install VFD for press b/f fan & optimize the pressure drop across bag filter
15. Install soft starter cum Energy saver for friction screw press
8.3 Case Studies- Savings Potential upto 15%
This chapter includes 9 actual case studies, which have been implemented successfully in the
Ceramic industry
Each of the individual case studies presented in this chapter includes.
• A brief description of the equipment / section, where the project is implemented.
• Description of the Energy Saving Project
• Benefits of the energy Saving Project
• Financial analysis of the project
A diagram of the system or photograph of the project is also included, wherever applicable.
The data collected from the plant is presented in its entirety. However the name of the plant
is not revealed to protect the identity of the plant. Similar projects can be implemented by
other units also to achieve the benefits.

170
A word of caution here. Each plant is unique in its own way and what is applicable in one plant
may not be entirely applicable in another identical unit. Hence these case studies could be
used as a basis and fine-tuned according to the individual plant requirement before taking up
for implementation.

171
Case Study 1
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.

The top Portion of the ring chamber kiln was thoroughly
cleaned and was filled with 75 to 100 mm thick layer of
insulating powder. The application of the insulating powder
did not significantly add to the weight of structure.
Implementation Status and time frame

Filling the top portion of the ring chamber kiln with insulating powder in stages of 25 mm thick
layers carried out during the implementation. The total implementation activity was completed
in 4 months time. The plant team did not face any problem during and after implementation.
Benefits of the Project

The insulation of the top portion of the kiln drastically reduced the surface temperature from
110oC to 50oC, resulting in a lower fuel consumption.

172
Financial Analysis
The annual energy saving achieved was Rs. 0.40 million. The Investment made was
Rs. 0.20 million, which has got paidback in 6 months.
Benefits of insulation of top portion of ring chamber kiln

• Reduction in surface temperature from 110°C to 50°C
• Fuel savings


173

174
Case Study 2
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.
Heat Balance of Arc Furnance

The arc furnace consists of a steel shell. The temperature of fusion
varies from 1200 to 1250oC. To avoid damage of the steel shell,
water cooling panels are provided to keep the shell temperature
below the softening point. The usage of water panels is an important
safety requirement, but unfortunately carries away enormous amount
of heat energy from the arc furnace. This results in higher energy
consumption of the arc furnace in a typical ceramic fibre industry.
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.,

175

The furnace was insulated by providing one layer of special insulated bricks (high Alumina
bricks) on the inner side of the shell. This reduced the heat loss to shell cooling water
considerably, thereby reflecting in the overall reduction of energy consumption.
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 minimised heat loss.
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.
Benefits of insulation on the inner side of steel shell
• Minimised heat loss
• Reduced specific energy consumption
• Reduced shell cooling water consumption


176

177
Case Study 3
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.

The practise of constructing single layered insulating brick for the
temporary door was changed to a multi-layer (3 Layers) insulating
brick construction. An air gap was also maintained between the layers. The concept is
schematically shown here.
Concept of the proposal

The provision of multi-layer insulating brick with air gaps, acts as an additional insulation for
the temporary door, resulting in minimisation of heat losses.

The provision of additional layers of insulating bricks at the doorway reduced the heat loss from
the door sides drastically. The outside surface temperature of the doors was around 50oC after
the new construction.

178
Financial Analysis
The annual energy saving achieved was Rs. 0.30 million. The investment made was
Rs. 0.10 million which has got paidback in 4 months.
Benefits of multilayer of insulating brick for door way

• Door surface temperature reduction from 100°C to 50°C
• Fuel savings


179

180
Case Study 4
Optimisation of Kiln Loading
Background
Ceramic products like tiles, sanitary ware, crockery,
insulators, etc., are glazed in Kilns, which is a
major consumer of thermal energy. The
optimisation of product loading in the kilns can
result in substantial energy savings.
The raw wares, after pressing / moulding is coated

with ceramic material and then fed into the kiln for
glazing. The raw wares are stacked in the kiln
cars and then pushed into the kiln. The stacking
pattern plays a vital role in energy consumption of
Optimised load on kiln car
the kilns.
Conventionally, for ease of handling, the raw wares are stacked with huge spaces between
them. The space provided is also determined by the contour of the raw wares. The minimisation
of space between the raw wares by proper planning can facilitate improved loading of the kiln,
leading to energy savings.
Previous Status
The energy consumption figures of a sanitary ware unit, having 50-60 standard products with
fixed shapes/contour is as shown below:
Oil consumption Production Specific Energy

Kiln
Litres / month Tons / Month Consumption Litres / ton
Kiln 1 119360 378.48 315.36

Kiln 2 34519 86.52 398.97

The plant team developed a new supporting structure so as to load the kiln to the maximum.
The gaps between the wares were minimised to increase the loading. In some cases two tier
/ three tier system was adopted to maximise the loading.
Concept of the Project

In any kiln, there are fixed losses viz., radiation losses, kiln car heating etc., irrespective of the
loading. When the load factor is very high, the fixed energy losses get distributed to a larger
volume of production resulting in lower specific energy consumption.

181
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.
The operating parameters before and after modification are shown below :
Description Kiln 1 Kiln 2
Before After Before After
Oil consumption Litres / month 119360 121844 34519 32827
Production Tons / Month 378.48 401.27 86.52 100.07
Specific Oil Consumption Litres / ton 315.36 303.64 398.97 328.05
Reduction in Specific Oil

Consumption Litres/ton - 11.72 - 70.92
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


182

183
Case Study 5
Installation of Low Thermal Mass (LTM) Cars in Tunnel Kiln
Background
A typical LTM kiln car
In a ceramic industry, kiln is one of the major

consumer of energy. Conventionally, the ceramic
tile and sanitary ware industry use the open flame
tunnel kiln, to fire the products. The open flame
tunnel kiln is a continuous type kiln, wherein, the
raw product is fed on one side and on the other
side the finished product is taken out.
The raw product undergoes firing, drying & cooling

cycles, as it moves over from the front end to the
back end of the kiln. The material movement
through the tunnel is by kiln cars, run on rails.
The kiln cars are like train bogies designed to hold the products. The Kiln cars are constructed
with refractory and insulating bricks. Due to their high thermal mass, Kiln cars consume
considerable amount of heat energy supplied to the kiln. Normally, the heat absorbed by kiln
cars is as high as 40 - 50% of the total heat energy supplied to the Kiln.
The thermal mass reduction of the kiln cars can give tremendous energy savings. Low thermal
mass materials (LTM) are now being used for kiln car construction, which reduces the thermal
mass considerably.
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 Consumption
MT / day MT / Ton
13 102 24480 3.36 0.137

The following modifications were made to reduce the weight of the kiln cars :
• Previously refractory bricks were used as supporting pillars for holding the racks. This was
replaced with Hollow Ceramic Coated Pipes
• Introduction of ceramic fibre blankets at the base of the car instead of refractory brick base

184
• Use of cordierite (Hollow) blocks to hold the raw

wares instead of solid refractory mass
The car furniture weight was reduced from 287 Kg/

car to 220 Kg/car (23% weight reduction)

Hollow
The use of low thermal mass materials (cordierite ceramic pipe
Hollow
etc.) in kiln cars resulted in thermal mass reduction, corderite Ceramic fiber
thereby resulting in fuel savings.
Hollow Corderite holding structure with ceramic
The other advantages of LTM materials are Fuel coated pipe supports
conservation, Increased capacity and longer service
life. The incidental advantages due to LTM materials are less Thermal shock resistance, Ease
of assembly and a good mechanical strength.
Implementation, problem faced and time frame

The implementation of this project was done in phases; so as to minimise the production loss.
This was mainly due to limited availability of kiln cars. The plant team did not face any major
problems during the implementation of this project.
The time taken for the implementation was one month.
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

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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.
Benefits of LTM cars

• Increase in production
• Reduction cycle time
• Fuel savings


186

187
Case Study 6
Installation of Recuperators at the Cooling End of Kiln and

Utilising 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
moulded 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 moulded 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.

A recuperator was installed at the exhaust of the kiln. The hot air generated by indirect heat
exchange was fed to the driers. This resulted in elimination of leco fired hot air generator.
The schematic of the modification is highlighted in the figure.
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.

188
Benefits of recuperators
• Waste heat from kiln cooler utilised
• Elimination of fuel for drying raw wares


189

190
Case study 7
Utilisation Of Exhaust For Kilns Vertical Driers
Background
The Raw material is poured into the mould through the hopper and then pressed in the
hydraulic press. The Green tiles from the press are then fed through the vertical drier to further
reduce the moisture content. The temperature required in the vertical drier is about 150oC.
The low moisture content tiles are then fed through the roller kiln for firing at a temperature of
about 1200oC. Generally the exhaust gases from the kiln are at a temperature of 200-250oC.
Previous Status
In one of the ceramic tiles industry, on a continuous basis about 3000 – 3500 kg/hr at a
temperature of 240°C was getting vented from the kiln exhaust.
The vertical driers located close to the kiln needed hot air at a temperature of 150°C for
drying.
Proposed Line
E
HAG
240°C
3000 – 3500 kg/hr
Kiln

191
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


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193
Case study 8
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.

Variable Frequency Drive was installed in the circulating air fan in Vertical Driers. The speed
of the fan was varied depending on the temperature inside the drier.
Financial Analysis
Installation of Variable Frequency Drive for circulating air fans in Vertical Dreirs # 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. Reduction in power consumption of the circulating air fan by at least 25%
b. Reduction in thermal energy consumption


194

195
VD – 1
HAG
VD – 2
HAG HAG

196
Case study 9
Replace conventional tunnel kiln with energy saving roller kiln

for sanitary ware firing
Background
In a ceramic industry, kiln is one of the major
consumer of energy. Conventionally, the ceramic
tile and sanitary ware industry use the open flame
tunnel kiln, to fire the products. The open flame tunnel
kiln is a continuous type kiln, wherein, the raw
product is fed on one side and on the other side the
finished product is taken out.
Previous Status
In one of the ceramic sanitary ware industry, an open flame tunnel kiln was used for firing
applications.

The conventional tunnel kiln was replaced by roller kiln for the production of sanitary stoneware
products, made in a large variety of shapes and sizes. The products, which are placed on heat
resistant ceramic plates, are transported on ceramic rollers through the roller kiln. Products
spend about 10 hours in this kiln compared with 25 hours in a tunnel kiln where products are
transported using wagons. The products are fired at a maximum temperature of 1250 °C.
Energy consumption details Tunnel Kiln Roller Kiln
Per Kg dry product 0.342 m3 0.131 m3
Per piece 4026 m3 1.64 m3
Per year 2,380,000 m3 914,000 m3
The Principle
The unfired sanitary stoneware products are placed
on heat resistant ceramic plates (see Figure).
These are then transported on rollers, first through
the drying section and subsequently fired in the
firing section. The products pass through the kiln
over ceramic rollers in about 10 hours. The speed
of the drive for the rollers can be adjusted to the
Schematic slice of the roller kiln
appropriate residence time. The roller kiln consists
of a firing section and a cooling section.

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The products are fired at a maximum temperature of 1250°C. The burners and all the cooling
air inlets and outlets can be adjusted individually. The advantage of the application of this type
of roller kiln for sanitary stoneware products is the quick firing process with the overall process
time reduced from 25 to 10 hours compared to a tunnel kiln. The new kiln also offers the
possibility of firing products which vary in shape, colour and size.
Financial Analysis
Installation of roller kiln resulted in an annual energy saving of Rs 6.74 Million. This required
an investment of Rs 14.37 Million and had a simple payback period of 26 months.
Benefits
a. Reduction in energy consumption by at least 62%
b. Reduction in process time of 15 hours


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199
Copper
Per Capita Consumption 400 gms
Energy Costs Rs.5000 million (US $ 100 Million)
Energy saving potential Rs 750 million (US $ 15 million)
energy saving projects Rs.1500 million (US $ 30 Million)

Energy Conservation in Copper Smelters
200
1.0 Introduction
Copper is the eighth most abundant metal in the Earth’s crust. It is mined in at least 63
countries including India. Major producers of copper are Chile, the USA, Canada, Indonesia,
Australia, Russian Federation, Peru, China, Poland, Mexico and Zambia.
Copper has the highest conductivity of all commercial metals. It is easily recyclable.
Copper is used for conducting heat and electricity, roofing, plumbing and piping, timber
preservation, coins and scientific instruments. Almost every electrical device has a copper
component.
The demand for copper is increasing and is used extensively in many areas such as
automobiles, construction industries, architectural applications, new generation super-conductors
and co-axial fibre optic cables.
1.1 Copper Production in India

The present copper production in India is about 3.6 to 4.0 Lakh TPA. The percapita consumption
of copper is about 400 gms as against world average of 3 kgs and North America’s 15 kgs.
Due to the increase in use of copper in different fields, the consumption of copper in India is
increasing. The copper production has increased considerably after 1996. Many smelts units
are planning to increase their capacity.
1.2 Major Players

In India copper ore is available in the states of Jharkand, Madhya Pradesh and Rajasthan.
Hindustan Copper Limited (HCL) is the integrated producer of primary copper in India and was
established in 1967.
Hindustan Copper Limited (HCL) has copper mines at Khetri,Kolihan in Rajasthan, Rakha
Copper Project in Jharkhand and Malanjkhand Copper Project in Madhya Pradesh. HCL has
been involved in exploration, mining, beneficiation, smelting and refining of copper.
Sterlite Copper, A unit of Sterlite Industries India Limited has set up a smelter plant in 1996 at
Tuticorin, Tamil Nadu. The smelter is having a capacity of 1,75,000 TPA. It also produces
sulphuric acid and phosphoric acid. The plant receives copper ore from Australia. It also has
a refinery unit at Silvassa.
Indo Gulf, through Birla Copper, has set up a copper Smelting and Refining complex at Dahej
in Bharuch district of Gujarat in 1999. The plant produces Copper Cathodes, Continuous Cast
Copper Rods & Precious Metals. Apart from copper products, Sulphuric Acid, Phosphoric
Acid, Di-Ammonium Phosphate, other Phosphatic Fertilizers and Phospho - Gypsum are also
produced at this plant. The plant has increased its smelter capacity from 1,00,000 TPA to
1,80,000 TPA in the year 2000.

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Table 1.1: Production capacity and locations

S.No Plant Location Product Capacity
1 Hindustan Khetri Copper Copper cathode, 31000 TPA Copper

Copper Limited Complex, Rajasthan Sulphuric Acid, cathode
Phosphoric acid
2 Indian Copper Copper Cathode, 16500 TPA

Complex, Sulphuric Acid, Copper Cathode
Jharkhand Gold, Silver,
Palladium, Selenium,
Tellurium, Nickel
Sulphate, Copper
Sulphate
3 Malanjkhand Mine – Copper 20000 MT

copper Project concentrate concentrate /
Annum
4 Taloja Copper Continuous cast 60000 TPA

Project, copper rods
Maharashtra
Hindustan Zinc Chanderiya Lead- Copper cathode 2100 TPA

Limited Zinc Smelter,
Rajasthan
5 Sterlite Copper Tuticorin, Copper Cathodes, 1,75,000 TPA

Tamil Nadu sulphuric Acid
and Phosporic acid
6 Silvassa Refined Copper 1,00,000 TPA
7 Birla Copper Dahej, Copper Cathodes, 1,80,0000 TPA

Dist Bharuch, Continuous Cast
Gujarat Copper Rods,
Precious Metals,
Sulphuric Acid,
Phosphoric Acid,
Di-Ammonium
Phosphate, other
Phosphatic
Fertilizers and
Phospho – Gypsum
1.3 Energy Intensity of Copper smelters

Copper smelting is highly an energy intensive process. It requires both electrical and thermal
energy. The energy component of manufacturing is about 45% to 55%.

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The major electrical energy consumers in a copper smelter are compressors, Fans & blowers,
pumps and heater loads. The average electrical load requirement for a 2.0 million tons per
annum plant is about 24 MW.
The copper smelters also utilize thermal energy through the fuels such as Furnace Oil, Diesel,
LPG and coal.
The specific electrical energy consumption varies from 1190 to 1250 units/ton of copper. The
specific thermal energy consumption is 1.1 to 2.0 Gcal/ton of copper depending on the type
of plant. The overall specific energy consumption varies from 2.1 to 2.8 Gcal/ton of copper.
As copper is produced from sulphite and concentrate ores, a large amount of Sulphur di-oxide
is generated as a by-product. Due to this, copper smelter complexes have other plants like
sulphuric acid, phosphoric acid and fertilizer plants. The total energy consumption of copper
complexes in India is about Rs.5000 million (US$ 100 million)
1.4 Energy Saving Potential and Investment

The various energy conservation studies conducted by CII – Energy Management Cell and
feedback received from various industries through questionnaire survey indicate an energy
saving potential of 15%. (Excluding waste heat recovery potential)
This is equivalent to an energy saving potential of about Rs.750 million. The estimated
investment required to realize this savings potential is Rs.1500 million.
The copper smelters in India have power generation potential of about 30 MW through waste
heat recovery. The investment opportunity in this alone is Rs.750 million.
2.0 Process Description - Smelting and Converting

Copper is manufactured through the process of smelting and converting the sulphide ores of
copper. All the Indian manufacturers except Hindustan copper import copper concentrate from
other countries. Hindustan Copper Limited has captive copper mines in the states of Madhya
Pradesh, Rajasthan and Jharkhand.
The Pyrometallurgical processing of the copper concentrate includes the processes of smelting,
converting, and fire refining.
The block diagram of the copper manufacturing is as below:

Flux
Copper
Copper Copper Smelter Anodes
Concentrate Refinery
Oxygen
Rock Phosphate
SO2
Energy
Sulphuric
Sulphuric Acid Phosphoric
Acid Plant Acid Plant
Sulphuric Phosphoric Pure

Acid Acid Copper

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Smelting
Smelting consists of melting the sulfide concentrate in an oxidizing atmosphere, which produces
a copper rich (35-70% Cu) molten sulfide phase called matte. The other products in the
smelting process are a low copper silicate slag, and flue gas with sulphur di oxide (SO2).
The capture of SO2 is environmentally important and economically significant due to the
production of Sulphuric acid (H2SO4.). Smelting is carried out either in a reverberatory or flash
furnace. Flash furnaces are replacing older reverberatories and account for approximately 75%
of the world’s current smelting capacity.
The slag and matte products are separated in a rotary holding furnace and the slag granulated
into a pit with removal of the slag to a storage bin being carried out by a mechanical grab.
Matte is transferred to the converters by ladle.
Converting
Converting is a two step process in which matte is made into “blister” copper. The first stage
of converting is the removal of iron in a slag and the generation of flue gas containing SO2.
The second stage involves the further oxidation of the remaining copper sulfide to liquid or
“blister” copper. Converting has traditionally been performed batch style. Recent developments
have led to continuous converting, but these technologies are not widely used.
The final pyrometallurgical step is fire refining. Fire refining consists of an oxidation step
followed by reduction. The “blister” copper is oxidized to lower the sulfur content of the copper
to approximately 0.001%. Following oxidation, oxygen is removed by the introduction of a
reducing agent such as natural gas or ammonia. The final oxygen content is typically between
1500 and 3500 ppm.
Anode Furnace
The removal of sulfur and oxygen is imperative to ensure a flat, thin casting needed for the last
process in the production of pure copper, electrorefining. Most industrial casting involves the
use of an anode casting wheel. The molten copper from fire refining is poured into a tiltable
tundish where the amount of copper is weighed to ensure proper anode weights.
After achieving the desired weight, the copper is poured into an anode shaped mold on the
casting wheel. There are twenty to thirty such molds on the wheel. The wheel is then rotated
and copper is poured into the next mold. As the process continues, the copper anode is cooled
within the mold due to water cooling of the wheel and water spray on top. After about a one-
half rotation, the anodes are removed from the mold.
Some smelters use a continuous caster instead of a casting wheel. The continuous caster
uses two water cooled steel belts (one on top, the other on the bottom) and stationary edge
dams to contain the molten copper. As the belts rotate, the copper is moved through the caster
and cooling occurs. When the copper leaves the caster, it is a solid continuous strip with the
correct anode thickness. Anodes are made from the strip by shearing. The copper anodes are
then sent to copper refinery for refining to cathode copper (99.999% copper).
Sulphur dioxide
Sulphur dioxide (SO2) is emitted from the copper smelters as a by-product of the smelting
process. This is converted to sulphuric acid, which is either sold or sent to fertilizer plant for
the production of fertilizer.

204
Phosphoric Acid
The sulphur dioxide emitted as by-product from the smelting process and sulphuric acid from
sulphuric acid plant is reacted with rock phosphate and phosphoric acid is produced.
3.0 Energy Saving Schemes
3.1 List of Energy Saving Projects
3.1.1 Concentrate Handling & Smelters
Short Term
1. Reduction of Idle Running Hrs.of Feed Conveyors by Automation
2. Replacing exisiting pump with correct size pump for Rotary Holding Furnace - Hygine
Venturi Scrubber fan
3. Installation of correct size pump for Slag Granulation pump / cooling tower pump
4. Reduce false air entry into the gas duct and reduce fan power consumption
5. Utilise the heat of smelter furnace exhaust gases to preheat the blower air
6. Install waste heat recovery system for Anode Furnace exhaust and utilise to preheat
combustion air
Medium Term
1. Installation of Variable Speed Drive for smelting furnace Induced Draught Fan
2. Installation of Variable Fluid Coupling For Converter plant ID Fan
3. Installation of Auto Inlet Guide Vane (IGV) operation for Converter Blower.
4. Installation of Variable Frequency Drive for lime recirculation at scrubber exhaust system
of Anode furnace
5. Replacing old fan with an energy efficient fan for direct exhaust fan at Anode furnace
6. Replace existing main firing burner with high efficiency burners in the Anode Furnaces
7. Avoid radiation losses through feed door by covering the openings in the Anode Furnaces
Long Term
1. Installation of Variable Fluid Coupling for Rotary Holding Furnace - Hygiene Venturi Scrubber
fan
2. Installation of Double charge casting system to decrease preheating time
3. Install a waste heat recovery system and generate steam and power from Smelter exhaust
gas
4. Install vapour absorption machine (VAM) refrigeration system in Sulphuric Acid Plant by
utilising the heat of smelter furnace exhaust gases

205
3.1.2 Sulphuric Acid Plant

Short Term
1. Effective Utilisation of Acid Coolers in Sulphuric Acid Plant to Reduce Cooling tower
Pumps Load
2. Replacing existing pump with correct size pump in Sulphuric Acid Plant Cooling water
pump and matching with the requirement
Long term
1. Installation of variable fluid coupling for SO2 blower at Sulphuric Acid Plant
3.1.3 Phosphoric Acid Plant

Short Term
1. Optimising the size of Cold Well Pumps in Phosphoric Acid Plant
2. Improvement Of Boiler Efficiency in Phosphoric Acid Plant
Medium Term
1. Installation of Variable Speed Drive for Gypsum Slurry Pump in Phosphoric Acid Plant
2. Installation of Variable Speed Drive for return Acid Pumps, HH Cloth Wash Pump and
dilute cake wash pump in Phosphoric Acid Plant
3.1.4 Utility Areas

Short Term
1. Reduction in Oxygen plant venting and saving energy
2. Installation of Temperature Indicator Controllers for Cooling Tower Fans in ISA,SAP,PAP
3. Reduction of compressed air usage in the plant
4. Replacing existing lime plant and spray pond make up pump with smaller size pump and
avoid the final effluent transfer pump
5. Installation of guide vane control system to control the blower capacity
6. Installation of correct head pump for raw water pumping, soft water pumping system
7. Segregating cooling water requirements of compressors & smelter plant
8. Utilisation Of Vent Compressed Air In Oxygen Plant
Medium Term
1. Replace old inefficient compressors with energy efficient compressors
2. Installation of variable frequency drives for screw compressor
3. Installation of Variable speed drives for cooling tower fans
4. Conversion of V-belt drives to flat belt drives in compressors and blowers

206
Long term
1. Replacing electrical heating with steam heating for FO heaters and LPG vaporizer –
Reduction of energy cost
2. Utilisation of waste heat from captive power plant and avoiding operation of phosphoric
acid plant boiler
3.1.5 Electrical Systems

Short Term
1. Replacing copper chokes with Energy Efficient Electronic chokes in fluorescent lamps
2. Installation of energy efficient lamps in place of low efficacy lamps
3. Convert delta to star connection in lightly loaded motors
4. Installation of automatic voltage stabilizer for the main lighting feeder and operating at 210
volts
Medium Term
1. Installation of automatic power factor controllers and maintaing high PF
2. Installation of separate lighting transformers and optimising the lighting voltage
3. Replace old rewound motors with energy efficient motors
4. Installation of Soft Starter cum Energy saver for lightly loaded motors
Long Term
1. Installation of on-load tap changer (OLTC) for the main transformer and optimising the
voltage
2. Installation of harmonic filtes and reducing Total Hormonics Distortion

207
Case study – 1
Install waste heat recovery system for ISA furnace exhaust

gases to generate steam & Power
Background
Pyrometallurgical processing of the concentrate consists of smelting, converting, and fire
refining.
a copper rich (35-70% Cu) molten sulfide phase called matte. The other products in the
smelting process are a low copper silicate slag, and flue gas with sulphur di oxide (SO2).
The flue gases generated in the smelting process is at a very high temperature of about
1200°C. The major portion in the flue gas is sulphur di oxide.
There is a tremendous potential to tap this waste heat. In view of the dust concentration,
cohesive nature of dust and presence of SO2 in the exhaust gas, suitable dust collection
system to be installed.
Present Status
At a concentrate feed of 50 TPH, about 2,40,000 m³/hr of flue gas is leaving the ISA furnace
at around 1200°C.

There are different options available to utilize the waste heat from the copper smelters. Different
energy saving opportunities are tried in other countries and are working well. Similar potential
is available in Indian copper smelters also.
Alternative-1
Installation of a Mechanical Dust Collector (MDC) followed by a Waste Heat Recovery Boiler
(WHRB) to generate 15 TPH of steam at 11 Ata. This steam can also be used to meet the
steam requirements of the Phosphoric Acid Plant (PAP).
Alternative – II
Installation of a Mechanical Dust Collector (MDC) followed by a Waste Heat Recovery Boiler
(WHRB) to generate 15 TPH of steam at 42 Ata. This steam can be use in an extraction-cum-
back pressure turbine. About 2 TPH shall be extracted at 11 ksc and balance 13 TPH will go
to the back-pressure mode at 2 ksc. This back-pressure steam can be utilised for process
steam requirements.
Alternative - III
Install a Mechanical Dust Collector (MDC) followed by a Waste Heat Recovery Boiler (WHRB)
to generate 15 TPH of steam at 42 Ata. This steam can be made to pass through a condensing
turbine to generate 6.5 MW of power. This is about 20% of total power requirement of the plant.

208
Implementation Methodology
The proposed ISA furnace exhaust gas heat recovery shall be a separate stream, parallel to
the existing stream.
Whenever, the proposed stream gets choked with dust and requires shutdown for cleaning,
this stream can be by-passed. The existing stream can then be brought on-line and the
production can be continued, without a shutdown.
Benefits
Alternative - I
The estimated annual savings that can be achieved by implementing this alternative is
Rs.47.80 million. The investment required (estimated) will be around Rs.24.00 million, which
will get paid back in 6 months.
Alternative - II
The estimated annual savings that can be achieved by implementing this alternative is
Rs.90.00 million. The investment required (estimated) will be around Rs.60.00 million, which
will get paid back in 8 months.
Alternative - III
The estimated annual savings that can be achieved by implementing this alternative is Rs.122.00
million. The investment required (estimated) will be around Rs.130.00 million, which will get
paid back in 13 months.

Note:
This project though straightforward and simple has not been implemented in any of the plants
in India. It is a proven project in other industrial sectors and in other countries.
Overall waste heat recovery potential for generating power from copper smelters in India is
about 30 MW. The investment potential is around Rs. 750 million.

209

210
Case study – 2
Install Vapour Absorption Machine (VAM) for refrigeration
system in Sulphuric Acid Plant (SAP) by utilising the heat
of ISA furnace exhaust gases
Background
Chilled water system, having a heat load of about 400 TR is used in Sulphuric Acid Plant in
a copper smelter complex. Vapour compression system is used for generating the chilled
water. The specific energy consumption is about 0.70 kW/TR. The temperature requirement
of chilled water is 12°C.
In copper smelters waste heat available is very high. The generation of chilled water through
vapour absorption machine (VAM) is more economical, more so, when steam is generated
through waste heat. In copper smelters, the furnaces let out very high amount of heat through
flue gas. By utilizing this waste heat, the chilled water requirement of the plant can be met by
using vapour absorption machines.
Previous Status
Vapour compression system of about 400 TR was used in sulphuric acid plant. Waste heat
at 1100°C was let out from the furnace.

Installation of Vapour Absorption Machine (VAM) for refrigeration system in Sulphuric Acid Plant
(SAP) by utilising the waste heat of smelter furnace exhaust gases
This project is not implemented in any of the copper smelters. But it is very easy to implement
and implemented in many chemical plants. Recommended to install a vapour absorption
machine of 400 TR using the aste heat from the smelter furnace exhaust gases.
The smelter furnace exhaust gases can be used to generate steam in a waste heat recovery
boiler (WHRB), which will supply steam of about 2.5 TPH to VAM. Before the flue gases enter
the air preheater, the temperature of the flue gases has to be reduced, by passing through a
dedicated small gas cooler. The gases are then passed through a mechanical dust collector
(MDC), so as to reduce the dust concentration.
The proposed system, is a separate exhaust gas dust, parallel to the existing duct. The gases
passing through this new duct will be used for the preheating of blower air. Whenever there
is a choking of the new duct, this is used as by-pass and
the gases are passed through the existing duct.
Benefits
The annual savings potential is about Rs.6.00 million. The
total investment required is Rs.11.10 million, which will • Investment - Rs. 11.1 millions
pay back in 23 months. • Simple payback - 23 months

211

212
Case study – 3
Installation of Variable Fluid Coupling for SO2 blower at

Sulphuric Acid Plant
Background
a copper rich (35-70% Cu) molten sulfide phase called matte, a low copper silicate slag and
flue gas with sulphur di oxide (SO2).
The sulphur di oxide in the flue gas is sent to sulphuric acid plant for the production of sulphuric
acid. A high capacity fan handles the sulphur di oxide from smelter plant.
The capacity utilisation of the SO2 blower varies depending on convertor operation in the
smelter. The load on the blower is higher when ISA furnace and the convertor are in operation.
When ISA furnace alone is running, the capacity utilisation is less.
-10 to –20 MM
Mixer Quencher Vent.. Humidif.
-156MM
-969MM
-151MM -770MM
2728 MM
ESP
Mixer
2300 kW
The capacity of the blower was controlled by motorized valve. Operation of a blower with valve
control is energy inefficient practise. An energy efficient way of controlling the capacity of a
blower is by varying the RPM of the blower.
Previous Status
The capacity of the blower was adjusted by inlet guide vane control of the blower. The pressure
drop across the suction damper was:
• When ISA & convertor in operation = 21%
• When ISA furnace alone in operation = 44%
The power consumption of the blower during high flow was 2300 kW.

213

The plant team installed a variable fluid coupling for the SO2 blower and avoided the operation
of inlet guide vane
After installation of the variable fluid coupling, the speed of the fan was controlled manually
based on the ISA plant and converter plant operation. The implementation was done in a
phased manner and the closed loop operation of the VFC was put into effect in a months time.
Benefits
The annual saving achieved was Rs. 7.30 million. The Cost benefit analysis
plant team invested Rs. 5.00 million for the variable fluid
coupling and controls, which paid back in 9 months.
This project has a replication potential in four more plants.

214

215
Case study – 4
Installation of Variable Frequency Drive for ISA furnace ID fan
Background
In a copper smelter, a 132 kW ID fan handles ISA furnace exhaust gases. The capacity
requirement of the fan varies depending on the draft level and gas quantities. Damper control
was practiced in ID fan of the furnace to meet the capacity variation.
Operation of a fan with valve control is an energy inefficient practice. An energy efficient way
of controlling the capacity of a blower is by varying the RPM of the blower.
Previous Status
The ID fan of the smelter furnace was
consuming 63 kW of power. The pressure
drop across damper of the fan was 46%.
The higher pressure drop was due to the
excess capacity available in the fan.
Also, the fan flow and the drought was
varying with the process conditions.

A 132 kW variable frequency drive was
installed for the smelter furnace ID fan. The speed of the fan was reduced based on the actual
requirement. The loss across the damper was eliminated.
After the installation of VFD, the damper of the fan was kept open at 100%. The VFD reduces
the speed of the fan based on the drought. The control signal for the VFD is from the pressure
transducer and operates in closed loop.
Benefits
The annual savings achieved was Rs.1.42 million. The investment for the VFD and controls
was Rs. 0.87 million, which paid back in 8 months.


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217
Case study – 5
Install Variable Fluid Coupling for Rotary Holding Furnace (RHF)

- HVS FAN
Background
In a copper smelter, RHF – HVS fan is used for handling the exhaust gases. The capacity
requirement of the fan varies depending on the draft level and gas quantities. Damper control
was practiced in ID fan of the furnace to meet the capacity variation.
Operation of a fan with valve control is energy inefficient practise. An energy efficient way of
controlling the capacity of a blower is by varying the RPM of the blower.
Previous Status
The RHF – HVS fan was consuming 250 kW of power. The pressure drop across damper of
the fan was 35%. The higher pressure drop was due to the excess capacity available in the
fan. Also, the fan flow and the drought was varying with the process conditions.
An energy efficient way of capacity variation of a fan is to install a variable speed arrangement
such as variable fluid coupling and adjust the RPM of the fan depending on the requirement.

A variable fluid coupling was installed for the RHF – HVS fan. The speed of the fan was
reduced based on the actual requirement. The loss across the damper was eliminated.
Implementation Methodology & Difficulties

After the installation of VFC, the damper of the fan was kept open at 100%. The VFC reduces
the speed of the fan based on the drought. The control signal for the VFC is from the pressure
transducer and operates in closed loop.
For implementation of this project, the motor and fan base has to be modified and VFC is
installed in between fan and motor. This project was implemented during the stoppage of the
plant. The time required for implementation is about 15 days.
Benefits
The annual saving achieved was Rs. 1.32 million. The investment for the variable fluid
coupling was Rs. 1.00 million, which paid back in 10 months.
Cost benefit analysis Replication Potential

• Annual Savings - Rs. 1.32 millions This project has a replication potential in four more
• Investment - Rs. 1.0 millions plants.

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219
Case Study-6
Replacing Electrical Heating with Steam Heating for F.O Heaters
and LPG Vaporiser
Background
In copper smelters, Furnace Oil (FO) and LPG are used as fuel in ISA furnace, rotary holding
furnace and converters. Electrical heaters are used at various locations of the plant for heating
the furnace oil at different sections of the plant and also vaporising the LPG. The plant also
has a furnace oil fired boiler at phosphoric acid plant.
The variable cost of electrical power is Rs.3.50/unit and the landed cost of furnace oil is
Rs.10.50/litre. The cost comparison of electrical heating and steam heating was analysed.
The cost of electrical heating is Rs.4000/MM kCal and the cost of thermal heating is only
Rs.1500/MM kCal.
This indicates that electrical heating is atleast 2.5 times costlier than oil fired heating for the
same quantity of heat output. The cost of heating operation can be reduced, by replacing
electric heating with the cheaper steam heating.
Previous Status
In one of the copper smelters, electrical heating was used for heating furnace oil and vaporising
LPG.
The capacity of heaters at various locations and the average consumption is as below:
Sl no. Location of heater Capacity of Average Average

heaters operating Load
(in Nos. x kW) time(in %) (in kW)
1 FO Main storage tank 3 x 24 40 29
2 LPG Vaporiser 3 x 36 50 54
3 Anode furnace day tank 2 x 54 20 11
4 Line heaters 2 x 54 35 28
Total capacity 396 122

The average load of electrical heaters was around 122 kW on a continuous basis.
Replacing electrical heating with steam coil heating for F.O heaters and LPG vaporizer.
Implementation status
The plant team replaced all the electrical heaters with steam coil heaters for all the Furnace
Oil heating and LPG vapouriser in a phased manner.
Benefits
The implementation of this project resulted an annual savings of Rs. 2.00 million. The investment
made was around Rs.1.00 million. The simple payback period was 13 months.

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221
Case Study –7
Installation of Variable Fluid Coupling for converter blower
Background
Converting in a smelter is a two step process in which matte is made into “blister” copper. The
first stage of converting is the removal of iron in a slag and the generation of flue gas containing
SO2. The second stage involves the further oxidation of the remaining copper sulfide to liquid
or “blister” copper.
The converter blower supplies air to the converter. In one of the copper smelters, converter
blower was operated for 11 to 12 hrs/day. Out of which for 5 to 6 hrs/day air was vented out.
Generating the air and venting out is energy inefficient practice.
The venting of air from the converter blower was mainly due to the excess capacity of the
blower.
Previous Status
In a 1.0 million tons per annum copper smelter, converter blower was operated with venting
of air. Generating the air and venting out is energy inefficient practice.

The plant has installed a Variable fluid coupling for the converter blower, which was consuming
an average power of 1200 kW. The energy loss due to venting of air was completely avoided.
Implementation Status & Difficulties

After the installation of the VFC, the converter blower speed is reduced based on the actual
requirement. Closed loop system is used for varying the speed of the blower.
For implementation of this project, the motor and fan base has to be modified and VFC is
installed in between fan and motor. This project was implemented during the stoppage of the
plant. The time required for implementation is about 15 days.
Benefits
The annual savings achieved was Rs. 1.20 million. The investment made was
Rs. 0.8 million which will paid back in 10 months.


222

223
Case study 8
Utilise heat of smelter furnace exhaust gases to preheat the

combustion blower air and reduce oil consumption
Background
In a 1.75 MTPA capacity copper smelter, smelter furnace is used for smelting the concentrate.
Furnace oil is used in the furnace. Combustion air is supplied by FD fan, which sucks air from
the atmosphere. The exhaust gas from the furnace was let out at a very high temperature of
about 1100°C. By preheating the combustion air, using the exhaust gas, the furnace oil
consumption was reduced. Air preheaters are used for recovering the heat from flue gas.
Previous Status
there is a choking of the new duct, this can be by-passed and the gases can be passed
through the existing duct.
Energy saving Project

Utilise heat of smelter furnace exhaust gas to preheat the combustion blower air and reduce
oil consumption.
Implementation methodology
The plant team installed a air preheater and the combustion air was pre heated upto 200 °C.
Before the flue gases enter the air preheater, the temperature of the flue gases was reduced,
by passing through a dedicated small gas cooler. The gases were then passed through a
mechanical dust collector (MDC), so as to reduce the dust concentration. The implemented
system has a separate exhaust gas dust, parallel to the existing duct. The gases passing
through this new duct will be used for the preheating of blower air. Whenever there is a choking
of the new duct, this can be by-passed and the gases can be passed through the existing duct.
Benefits
The annual savings in furnace oil was Rs. 3.60 million. This required an investment (for the
ir pre-heater) of Rs. 1.00 million, which paid back in 3 months.


224

225
Case Study – 9
Install waste heat recovery system for anode furnace exhaust
and utilise to preheat combustion air
Background
In the anode furnace, refining of Blister Copper (98.5% Cu) to Anode Copper (99.9% Cu)
takes place. This conversion has two phases – an oxidation phase (about 45 – 60 min)
followed by a reduction phase (about 180 – 200 min). The heat required for the refining
process is provided by the firing of FO and LPG.
The flue gases coming out of the furnace combustion chamber at an average temperature of
about 450°C. The air required for combustion was sent through a blower at 40°C.
There was a good potential to utilise the waste heat of flue gases to preheat the combustion
air and save energy.
Previous Status
Combustion air at 40°C was used at Anode furnace. The exhaust gas temperature from the
anode furnace was about 450°C.

Preheating combustion air from the exhaust gas and reduce oil consumption.
The plant has installed a waste heat recovery systems (air-to-air H.E) for the anode furnace
and the combustion air was preheated to 200°C. This has resulted in fuel savings.
Benefits
The annual savings achieved was Rs. 1.08 million. The investment made by the plant was
Rs.0.50 million and got paid back in 6 months.


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227
4.0 List of Suppliers/ Contractors

Name of Company and Address Area of expertise
MIM Holdings Limited ISA Technology, Copper smelter

(A . B . N . 009814019) Level 1.3, technology supplier
MIM Plaza410, ANN StreetBrisbane,
Australia
Outokumpu Harjavalta Metals Outokumpu Engg Contractor Oy

OyHarjavalta (Flash smelting process)
Teollisuuskatu, 1Harjavalta, FIN-29200
Finland
http://www.outokumpu.com
Jukka Järvinen Pentti Ahola
+358 2 535 8111
+358 2 535 8207
Chematics International Co. Limited Sulphuric Acid Plant

Fromson Equipment Division
77, Railside Road
Don mills street, Ontario, Canada
Postal Code M3A 1B2
Ph:001 416 447 5541
Fax.:001 416 447 5541
M/s Hydro Agri, Rotterdam Phosphoric Acid Plant

Massluisedijk,103,
3133, Ka VLQQRDINGHEN
Netherland
Postal code:3133 KA
Tel:31-10-248-2279
Fax:31-10-248-2221
Hindustan Dorr-Oliver Limited Consultant for phosphoric acid plant

Dorr-Oliver House
Chakala, Andheri East
Mumbai – 400 099
Tel.: 022 – 2832 5541, 2832 6416/ 17/18
Fax: 022 – 2836 5659
Email: hdoho@hind-dorroliver.com
Web : www.hind-dorroliver.com
Kvaerner Powergas Limited (Mumbai) Basic and detailed engineering, project

Powergas House 177 Vidyanagari Marg management, procurement, inspection/
Kalina, Mumbai 400 098 expediting, construction supervision for
Telephone: +91 (0) 22 691 5901 petrochemicals, chemicals, synthetic fibres,
Telefax: +91 (0) 22 691 5934 ferrous and non ferrous metals,
E-Mail: http://www.kvaerner.com industries.

228
ME Engineering Limited Waste Heat Recovery systems

Sai Chambers for copper smelters
15 Mumbai Pune Road,
Wakadewadi,Pune 411 003,India
Tel: 00-91-20-5511010
Fax: 00-91-20-5511234
www.me-engineering.co.uk
Thermax House, Waste Heat Boilers, Vapour

4, Mumbai Pune Road,Shivajinagar, Absorption Machines
Pune 411 005
Tel : (020) 5512122
Fax : (020) 5511226
Email : abunglow@thermaxindia.com
Thermal Systems (Hyd) Pvt. Ltd. Waste Heat Recovery Steam Generating
Plot No.1, Apuroopa TownshipI Systems for S.A. Plants, Nitric Acid,
DA, Jeedimetla Ammonia, Hydrogen plants and
Hyderabad - 500 055 metallurgical plants
Tel: 040 - 309 8272/ 8273
Fax: 040 - 309 7433
L & T, Baroda Power plant and waste heat recovery
Bharat Heavy Electricals Limited Supplier power plant equipments

BHEL Building, Siri Fort Road
New Delhi – 110 049
Tel: 011 – 26493031
Fax: 011 – 26493021
Voith Supplier of Variable Fluid Coupling
Greaves Supplier of Variable Fluid Coupling
Air Products, USAINOX Air Products ltd. Supplier of industrial gases

56, Jolly Maker Chambers
No.2, Nariman Point, Mumbai - 400 021
Telephone: +91 (0)22 2020345 / 6314 / 7374
Fax: +91 (0)22 2025588
Praxair India Limited Supplier of industrial gases

Praxair House No. 8, Ulsoor Road
Bangalore 560042India
Tel.: +91.80.555.9841
Fax: +91.80.559.5925
Air Liquide Engineering India (PVT) Ltd. Oxygen Plant

3-5-874, plot no.15, hyder guda
Hyderabad

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Paper
Per Capita Consumption 5 kg
Energy Intensity Rs 1500 million (US $ 300 million)
Energy Costs 25% of manufacturing cost
Energy saving potential Rs.300 Million (US $ 6 Million)

saving projects Rs.500 Million (US $ 10 Million)

Energy Conservation in Pulp and Paper Industry
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1.0 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.
It’s almost impossible to imagine a life without paper. In fact, paper is such a versatile
medium, its uses are only limited to the imagination.
2.0 Growth of Paper Industry

The pulp and paper industry plays an important role in a country’s economic growth.
2.1 World Scenario

The world’s paper and board production, which was about 15 Million tons in 1950, has grown
steadily to reach about 326 million tons in 2001. This accounts for nearly 3.5% of world’s
production and 2% of the world trade.
The compound annual growth rate (CAGR) of the world paper industry is 2.8%.
USA is the leading producer of paper with over 100 million tons, which accounts for nearly
1/3rd of the world’s paper production.
The capacity additions in the paper sector have been taking place of late in the Asian region.
The growth of the paper industry, region-wise is depicted in the graph below:
7.00% 6.50%
6.00%
5.00% 4.40%
4.00%
3.10% 3.10%
3.00% 2.50%
2.10%
2.00%
1.00%
0.00%
A frica A sia A ustralia Europe L atin North
A merica A merica

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2.2 Indian Scenario

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 breakup of the mills, capacity-wise is as follows:
• Small (upto 10000 TPA) : 285 numbers and 1.90 million tons
• Medium (< 20000 TPA) : 65 numbers and 1.00 million tons
• Integrated (> 20000 TPA): 30 numbers and 2.50 million tons
These mills produce various types of paper products, such as, writing & printing paper, kraft,
paperboard, newsprint etc.
The mills are located all over India. The region-wise break-up of number of mills and capacity
is highlighted below:
Region Mills in terms of Mills in terms

numbers of production
Numbers % %
East 44 11.6 23.6
West 128 33.7 29.7
South 65 17.1 25.0
North 143 37.6 21.7
The installed capacity of the paper plants in India (2000-2001) is 5.41 million tons of paper
and 1.1 million tons of newsprint.
The total annual production figures are 4.65 million tons of paper and 0.46 million tons of
newsprint, accounting for about 86% & 42% actual capacity utilisation respectively.
2.3 Major players in India

The major integrated pulp and paper industries in India, in terms of installed capacity, are
given below:
1. A P Rayon Limited, Kamalapuram, Andhra Pradesh
2. Balakrsihna Industries Limited, Kalyan, Maharashtra
3. Ballarpur Industries Ltd., Illure, Maharashtra

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4. Ballarpur Industries Ltd., Ballarpur, Maharashtra

5. Ballarpur Industries Ltd., Daulatabad, Orissa
6. Ballarpur Industries Ltd., Yamunanagar, Haryana
7. Ballarpur Industries Ltd., Gaganapur, Orrisa
8. Bilt Graphic Paper Ltd., Pune, Maharashtra
9. Century Pulp & Paper, Lalkua, Uttar Pradesh
10. Emami Paper Mills Limited, Balgopalpur, Orissa
11. Global Boards Limited, Mahad, Maharashtra
12. Grasim Industries Limited, Mavoor, Kerala
13. Harihar Polyfibers, Kumaraptanam, Karnataka
14. Hindustan Newsprint Ltd., Newsprintnagar, Kerala
15. Hindustan Paper Corporation, Cachar, Assam
16. Hindustan Paper Corporation, Nagaon, Assam
17. ITC Limited, Bhadrachalam Paper Boards, Sarapaka, Andhra Pradesh
18. ITC Limited, Unit – Tribeni, Chandrahati, West Bengal
19. J K Corp Limited, Jaykaypur, Orissa
20. Mukerian Papers Limited, Mukerian, Punjab
21. Nath Pulp and Paper Mills Ltd., Aurangabad, Maharashtra
22. Orient Paper Mills, Amlai, Madhya Pradesh
23. Orient Paper Mills, Brajrajnagar, Orissa
24. Pudumjee Pulp & Paper Mills Ltd., Pune, Maharashtra
25. Rama Newsprint and Papers Limited, Surat, Gujarat
26. Rama Paper Mills Limited, Kiratpur, Uttar Pradesh
27. Rohit Pulp & Paper Mills Ltd., Udvada, Gujarat
28. Ruchira Papers Limited, Kala Amd, Himachal Pradesh
29. Satia Paper Mills Ltd., Rupana, Punjab
30. Seshasayee Paper & Boards Ltd., Erode, Tamil Nadu
31. Shreyans Industries Limited, Ahmedgarh, Punjab
32. Star Paper Mills Limited, Saharanpur, Uttar Pradesh
33. Tamilnadu Newsprint and Papers Limited, Karur, Tamil Nadu
34. The Andhra Pradesh Paper Mills Ltd., Rajahmundry, Andhra Pradesh
35. The Central Pulp Mills Ltd., Songadh, Gujarat
36. The Mysore Paper Mills Ltd., Bhadravati, Karnataka
37. The Sirpur Paper Mills Ltd., Sirpur Khagaznagar, Andhra Pradesh
38. The West Coast Paper Mills Ltd., Dandeli, Karnataka
39. Varinder Agro Chemicals Ltd., Barnala, Punjab

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3.0 Per Capita Consumption

The Indian per capita consumption of paper is 5 kg, in comparison to the Asian average
of 21 kg, World average of 55 kg and US average of 330 kg.
The per capita consumption of paper in the different parts of the world are depicted graphically
below:
The planning commission forecasts a per capita consumption of 5.4 kg by 2010 AD. So the
Indian pulp and paper industry has got a tremendous growth potential estimated at about 8%.
350 331.7
300 249.9
250 215.8
200
150
100
28.4 34 39.6
50 19
5
0
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In

The paper industry is highly energy intensive and is the sixth largest consumer of commercial
energy in the country.
The main fuel used in the pulp and paper industry is coal.
The other fuels used are furnace oil, LSHS, rice husk and coffee husk. LDO and HSD are
also used in diesel generators.
Large paper plants generate part of their own power through cogeneration, while smaller
plants depend exclusively on purchased power.
The energy cost, as a percentage of manufacturing cost, which was about 15% is presently
about 25%. This is mainly due to the increase in energy prices. Energy costs account for
nearly 23-25% of the overall manufacturing cost.
The total annual purchased energy consumption of the Indian Paper Industry is about 52
Million Giga Cal, which is equivalent to about Rs.15000 million.
The expenditure on energy ranks only next to the raw material in the manufacture of paper.
With the ever-increasing fuel prices and power tariffs, energy conservation is strongly pursued
as one of the attractive options for improving the profitability in the Indian pulp and paper
industry.

234
The specific energy consumption comparison of Indian paper industry vis-a-vis the international
trends is as follows:
Parameter Units Norm Indian Mills International Mills
Steam MT/ MT of FNP Avg. 11-14 6.5-8.5

Best 7.5 6.0
Power KWh/MT of FNP Avg. 1500-1700 1150-1250
Best 1200 -1300 900-1000
Water m / MT of FNP
3
Avg. 150 50
Best 75 25
Total energy GCal/ MT of FNP Avg. 52 -
Best - -
The typical break-up of steam and power of the various Indian mills vis-à-vis the international
mills is as below:
Steam consumption (MT/MT of FNP)

Section Indian Mills International Mills
Digestor 2.50-3.90 1.9-2.3(now 0.5)

Bleach Plant 0.35-0.40 0.20-0.25
Evaporator 2.50-4.00 1.50-2.30
Paper Machine 3.00-4.00 0.70-2.00
Soda Recovery Plant 0.50-1.10 0.30-0.50
Generator 0.02-1.20 0.45-0.70
Total 11.0 - 14.0 6.5 - 8.5
Power consumption (kWh/MT of FNP)

Section Indian Mills International Mills
Digester 58-62 43-46

Bleach Plant 88-92 66-69
Paper Machine 465-475 410-415
Soda Recovery Plant. 170-190 127-135
Stock Preparation 275-286 164-172
Utilities & Others 246-252 160-165
Chippers 112-128 92-98
Washing & Screening 145-155 116-123
Total 1500-1700 1150-1250

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5.0 Energy Saving Potential

The various energy conservation studies conducted by the CII – Energy Management Cell and
feedback received from the various industries through questionnaire survey and plant visits,
indicate an energy savings potential of 20%.
This is equivalent to an annual savings potential of about Rs.3000 million. The estimated
investment required to realize this savings potential is Rs.5000 million.
The pulp and paper industry has an attractive cogeneration potential of over 100 MW,
in addition to the existing cogeneration plants.
5.1 Major factors that affect energy consumption in paper mills

The major factors that affect energy consumption in the Indian pulp and paper industry are
as follows:
• Level of capacity utilisation
• Quality and type of paper produced
• Number and multiplicity of machinery
• Paper machine runnability and number of paper breaks
• Finishing losses
• Boiler type & pressure levels
• Level of cogeneration power generation
• Type of raw material preparatory section

- Type of chippers/ cutters
- Type of conveying system
• Digester system
- Type of pulping technology (extended delignification preferred)
- Installation of blow heat recovery
- Optimal bath liquor ratio
• Washing section
- Utilisation of advanced washers, such as, flat belt wire washers, double wire press, DD
washer and Twindle press
- Screening section
- Installation of advanced screening equipment
- Type of refiners
- Type of centri-cleaners (use of low pressure drop centri- cleaners reduces the pumping
power consumption)
• Paper machine press section

- Type of press
- % moisture after press section

236
- On-line moisture control

- Type of hood system
• Evaporation section
- Type of evaporator and number of stages
- Steam economy achieved (minimum should be 6)
• Extent of condensate recovery
• Type of river water pumping system and overall water consumption
• Levels of instrumentation
• Extent of utilisation of variable speed drives, such as, variable frequency drives (VFD),
variable fluid couplings (VFC), DC drives, dyno-drives etc.
These are the various major factors, which affect the specific energy consumption in paper
plants.
5.2 Target specific energy consumption figures

The overall specific energy consumption norms, for large integrated paper plants, producing
writing and printing paper, using 100% wood pulp and operating on sulphate process, should
be as highlighted below:
• Steam = 8.00 MT/MT of finished paper

• Power = 1300 kWh/MT of finished paper
• Water = 100 m3/MT of finished paper
The break-up of the target specific steam, specific power and specific water consumption
figures in the different sections of the plant are as follows:
Specific steam consumption break-up (MT/MT of FNP)

Section Steam
Pulping & washing 0.9
Bleaching 0.3
Black Liquor Evaporation 2.0
Chemical recovery boiler 0.8
Recausticising & Lime kiln 0.5
Paper machine 1.9
Deaerator 1.4
Miscellaneous 0.2
Total 8.0

237
Specific power consumption break-up (kWh/ MT of FNP)

Section Power
Chippers 10
Digester house 55
Washing and Screening 105
Bleaching plant 105
Stock prep., Paper m/c and Finishing 575
Power boilers 170
Intake well + Water treatment plant 60
Recovery (Evaporator, recovery boiler,

causticisers and lime kiln) 100
Effluent treatment plant 70
Lighting and workshop etc. 50
Total 1300
Specific water consumption break-up (100 m3/MT of FNP)

Section Water
Pulp Mill 30
Paper machine 20
Boilers incl. WTP and Cooling tower 30
Chemical recovery area 10
Miscellaneous 10
Total 100
6.0 Raw material profile

The paper units can be classified based on the raw material into three broad categories as:
• Wood based (Bamboo, hardwood etc.)
• Agro- based (Bagasse, rice & wheat straw, jute etc.)
• Waste paper based
The break-up of the paper mills based on raw material usage in India mills and International
mills are highlighted below:

238
Raw Material Usage Indian Mills International Mills

% of total mills % of total mills
Agro-based residues 31 4
Wood based 37 57
Waste paper based 32 39
7.0 Process description

Nearly 80% of the Indian paper mills use the sulphate process for pulping. Hence, the
sulphate process description is given below.
For waste paper based plants, the main sections are the stock preparation and paper machine
section. This has been covered in the process description.
Kraft sulphate process

The raw materials used for pulp making are hard woods like eucalyptus, bamboo and bagasse.
These fibrous materials are mainly composed of cellulose and lignin.
By cooking these raw materials with chemicals like NaOH and Na2S, the lignin is removed in
the form of black liquor, while the cellulose is separated in the form of pulp.

239
Chipper house
Hard wood logs are cut into smaller size by band saw. After wetting these logs with water
spray (to remove sand particles), they are fed into chippers to get chips of small size (1/2"
to 1").
Digesters
The chips are fed into digesters, where white liquor (a mixture of NaOH : Na2S with ratio of
80 : 20) is added. The contents are circulated. Then it is steamed for two hours and cooked
at 170°C. The total batch time is about 5 hours in a batch type digestor. After cooking the
contents are blown to a blow tank.
Washing
Washing is done next to free soluble impurities and at the same time to remove black liquor,
thereby recovering maximum amount of spent chemicals.
Usually, washing is practised in counter current fashion, involving 3 or 4 stages of washing

using rotary drum filters. The washed pulp is then sent for bleaching and the recovered weak
black liquor is sent to the evaporators.
Bleaching
Bleaching is done to increase the brightness of pulp. Lignin, which is the colouring matter in
the pulp, is converted to chlorolignin and is dissolved in water.
Bleaching is done in four stages:
• Chlorination
• Alkali extraction
• Hypochlorite bleaching
• Final washing
Washing is also done after each stage of bleaching. After the final washing, the bright pulp
is sent for stock preparation.
Stock preparation
Here, refining is done to give paper the desired properties. This can be done in double disc
refiners or conical refiners. After refining, the stock is subjected to sizing, loading and colouring.
Paper machine
After the stock preparation, the pulp suspension is sent to the paper machine, where the pulp
is converted into sheets of paper. The paper is drawn out from the other end and rolled into
bundles or cut into the required sizes.

240
Soda recovery
The black liquor from the washers is concentrated in the evaporators and fired in the soda
recovery boilers. After firing, the residue (green liquor) is treated with chemicals to get white
liquor, which is reused in the digesters.
8.0 Energy saving schemes

An exhaustive list of all possible energy saving projects in the pulp & paper industry is given
below. The projects have been categorised under short-term, medium term and capital-intensive
projects.
The projects which have very low or marginal investments and have an energy saving potential
of upto 5% has been categorised as short-term. The projects which require some capital -
investment having a simple payback period of less than 24 months and having an energy
saving potential of upto 10% has been categorised as medium-term.
and contribute significantly to improving the competitiveness of the paper industry. However,
these projects require very high capital-investment and hence has been categorised separately.
8.1 List of all possible energy conservation projects in a typical pulp and
paper industry
8.1.1 House-Keeping Measures – Energy Savings Potential of 5%

A. Chipper, Pulp Mill & Soda Recovery
1. Avoid idle running of chippers, conveyors, etc. by installing simple interlocks.
2. Ensure optimum loading of chippers
3. Avoid fresh water for pulpers and beaters and use back water
4. Interlock agitators with pumps at storage chests
5. Providing timer control for agitators for sequential operation
6. Optimise fresh water consumption in pulp mill washers e.g., alkali washer back water in
chlorine washer and chlorine washer back water in brown stock washed pulp.
7. In multiple effect evaporators, use stand-by effect also so as to improve the steam
economy.
B. Stock Preparation & Paper Machine

1. Optimise loading of refiners and beaters
2. Interlock agitators with pumps at storage chests
3. Minimise recirculation in receiving chest and machine chest
4. Optimising excess capacity/ head in pump by change of impeller or trimming of impeller
size

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5. Avoiding pump operation by utilisation of gravity head

6. Optimise capacity of vacuum pumps by RPM reduction
7. Install level indicating controllers for couch pit pumps
8. Optimising pressure of high pressure pump used for wire cleaning and deck showers
C. Co-Generation, Steam & Condensate Systems

1. Monitor excess air levels in boilers and soda recovery boilers
2. Arrest air infiltration in boiler flue gas path, particularly economiser and air preheater
section
3. Plug steam leakages, however small they may be
4. Always avoid steam pressure reduction through PRVs. Instead, pass the steam through
turbine so as to improve cogeneration
5. Insulate all steam and condensate lines
6. Monitor and replace defective steam traps on a regular basis
7. In case coal has higher percentage of fines, ensure wetting is done.
8. Monitor boiler blow down; use Eloguard for optimising boiler blow down
9. Installation of flash vessels for heat recovery from hot condensate vapours
10. Monitor the blow-down quantity of water in cooling towers and the quality of water
11. Install chlorine dosing and HCl dosing for circulating water.
D. Electrical Areas
E. Miscellaneous
5. Install level indictor controllers to maintain chest level
6. Install hour meters on all material handling equipment, such, pulpers, beaters etc.

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8.1.2 Medium Term Measures - Savings Potential upto 10%

1. Mechanical unloading system in chipper house
2. Install belt conveyor for conveying wood chips instead of pneumatic conveyors. In case
of space constraint, install cleated belt conveyors
3. Install auto slip power recovery systems for chipper motor
4. Install VSD for cutters and chippers
5. Install two stage preheating in digesters (combination of MP steam and LP steam)
6. Replace steam doctor by high pressure shower in brown stock washers
7. Retrofit additional effect in multiple effect evaporators
8. Install water ring vacuum pumps instead of steam ejectors in evaporators, depending on
the cost of steam.

1. Stopping broke deflaker when broke refiner is in operation
2. Install new correct size high efficiency pumps
3. Install new high efficiency fans & blowers in boiler
4. VSD for displacement pump, discharge pump, hot fill pump and warm fill pump of washing
and screening plant
5. Replace eddy current drive with VFD for washing and bleaching
6. Install suspension type agitators to keep the pulp in suspension during pumping
7. Optimising the capacity of vacuum pumps by RPM reduction or bleed-in control
8. Optimise the suction line size of water ring vacuum pumps
9. Install pre-separators for water ring vacuum pumps
10. Install mixing type agitators to mix different types of pulp
11. Introduce double dilution system
12. Install double disc refiners instead of conical refiners
13. Install VSD for paper machine fan pumps
14. Install VSD for tanks dilution pumps
15. Install VSD for mould fan pumps
16. Install VSD for flat box vacuum pump to avoid bleeding or throttling
17. Avoid interconnection of high and low vacuum sections
18. Optimise suction pipe line size for water ring vacuum pumps
19. Install pre-separators and extraction pumps for water ring vacuum pumps
20. Install dual speed motors for couch pit agitator and press pit agitator
21. Install VSD for MG machine/MF machine hood fans
22. Replace steam ejector with water ring vacuum pump in evaporator section
23. Install cascade condensate system in paper machine area

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24. Install flash steam recovery system for paper machines

25. Reel pulper operation optimized by effective utilization of winder pulper
26. Optimizing operation of hydraulic system of calender
27. Automatic operation of hood and ventilation system

1. Install automatic combustion control system/ oxygen trim control system in steam boilers
and soda recovery boilers
2. Install economiser/air preheater for boilers
3. Use of cheaper fuels, like bamboo dust, wood barks, pith etc.
4. Install boiler air preheater based on steam to enhance cogeneration
5. Install high temperature deaerator (120°C to 140°C) with suitable boiler feed water pump
to enhance cogeneration
6. Install heat recovery from boiler blow down
7. Convert medium pressure steam users to LP steam users to increase co-generation
8. Reducing moisture content of wet pith using screw presses for burning in boilers
9. Install condensate recovery systems in digesters, paper machines, evaporators and air
heaters
10. Install automatic blow down system for boilers
11. Install sonic soot blowers in place of steam operated soot blowing system
12. Install VSD for SA fan, FD fan and ID fan
13. Install VSD for boiler feed water pump
14. Install VSD for clarified water pumps
15. Install VSD for raw water/recycle water pumps
16. Install VSD for roots blower (agitation purposes)
17. Install VSD for final effluent discharge pumps
18. Replace dyno-drives with VSD in coal feeder
19. Install VSD for vibrating screen, lime feeder and mud filters in recovery boiler
D. Electrical Areas
1. Install maximum demand controller to optimise maximum demand
2. Install capacitor banks to improve power factor
3. Installation of thyristorised rectifiers
4. Replace rewound motors with energy efficient motors
5. Install energy efficient motors as a replacement policy
6. Thyristor room AC units provided wit timer control
7. Replace HRC fuses with HN type fuses
8. Replace 40 Watts fluorescent lamps with 36 Watts fluorescent lamps

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9. Replace conventional ballast with high efficiency electronic ballasts in all discharge lamps
10. Install SV lamps at wood and coal yard areas instead of MV lamps
11. Install LED lamps for panel indication instead of filament lamps
12. Install CFL’s for lighting in non-critical areas, such as, toilets, corridors, canteens etc.
13. Installation of neutral compensator in lighting circuit
14. Optimise voltage in lighting circuit by installing servo stabilisers
15. Minimising overall distribution losses, by proper cable sizing and addition of capacitor
banks
16. Replace V-belts with synthetic flat belts
E. Air Compressors
1. Ensure air compressors are loaded to a level of 90%
2. Set compressor delivery pressure as low as possible
3. Monitor pressure drop across suction filter and after filter
4. Segregate high pressure and low pressure users
5. Replace heater - purge type air dryer with heat of compression (HOC) dryer for capacities
above 500 cfm
6. Replace old and inefficient compressors with screw or centrifugal compressors
F. DG System
1. Use cheaper fuel for high capacity DG sets
2. Increase loading on DG sets (maximum 90%)
3. Increase engine jacket temperature (max. 85 o C) or as per engine specification
4. Take turbocharger air inlet from outside engine room
5. Installation of steam coil preheaters for DG set fuel in place of electrical heaters
6. Replace multiple small size DG sets with bigger DG sets
G. Miscellaneous
1. Floating type aerator in place of fixed aerators
2. High efficiency diffuser aerators instead of conventional aerators
3. Treatment of effluent through activated sludge lagoon resulting in stopping of aerators
4. Use of ETP filter cakes in boilers
5. Solar water heating for canteen and guest house
6. Reuse of water from hydratreater
8.1.3 Long Term Measures - Savings Potential of 10-15%

1. Install high capacity chippers with mechanized feeding
2. Install extented delignification cooking process

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3. Install oxygen delignification

4. Installation of TDR’s in place of beaters
5. Install medium consistency pumping
6. Replace brown stock washing with double wire press system
7. Install high efficiency washing system such as, Flat belt/wire washer, Double wire press,
Twin roll press
8. Install VSD for primary, secondary and tertiary centri-cleaners, pumps of unbleached and
bleached pulp.
9. Introduce ClO 2 and H 2 O 2 bleaching stages
10. Install pressure screens in pulp mill and avoid centri-cleaners
11. Install 7-effect evaporator instead of conventional triple-effect evaporator
12. Installation of falling film evaporator
13. Install 2-stage steam heating in black liquor pre-heater
14. Install soda recovery plant in medium sized paper plants
15. Install causticiser and rotary lime kiln
16. Increase in TAA to get higher solids concentration in black liquor
17. Installation of plate heat exchanger in evaporator section

1. Replace conical refiners with double disc refiners
2. Install conical port high efficiency vacuum pumps in place of flat port vacuum pumps
3. Replace centrifugal screens with pressure screen
4. Segregate high-vacuum & low-vacuum sections of the paper machine and connect to
dedicated systems
5. Segregation of high-head and low head users in cooling towers and process areas
6. Install tri-nip press section in paper machine to reduce drying load
7. Install computerised automatic moisture control system for paper machines
8. Install paper machine hood heat recovery system
9. Convert small steam turbines in paper machine area to DC or AC drive so as to enhance
cogeneration.

1. Convert chain grate/spreader stoker boilers to FBC
2. Install co-generation system for medium sized paper plants
3. Install vapour absorption system to utilise LP steam and enhance cogeneration
4. Install cascade condensate recovery system in paper machine
5. Install cascade evaporators in soda recovery plant
6. Maximising solids concentration in Recovery boiler
7. Rotary feeder for lime kiln feeding system

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8. Install steam-generating system from DG exhaust, if DG is run on a continuous basis

9. Install scoop type syphons in the dryer cylinders of paper machine instead of conventional
steam & condensate system with rotary joints
10. Install hood recovery systems in paper machine to minimise steam consumption
D. Miscellaneous
1. Replacement of Aluminium bus bars with Copper bus bars in caustic chlor unit
2. Replacement of Mercury cell bottom
3. Installation of DCS monitoring and targetting system for better load management
4. Installation of harmonic filters

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Case Study No.1
Replacement of Dyno-drives with Variable Frequency Drives

(VFD’s) in Washer Drum Drives
Background
The contents of the digester, after cooking, are blown down to a blow tank. The blown pulp
is then washed, to remove the dissolved lignin and chemicals.
Usually, washing is practised in counter current fashion, involving 3 or 4 stages of washing,

using rotary drum washers. The washed pulp is then sent for bleaching and further processing.
The rotary drum washers are operated under vacuum, utilising a barometric column. These
drum washers are driven by a variable speed system, to achieve the desired speed variation,
according to the throughput of the plant.
Previous status
In one of the old integrated paper plants, the washer drum drives were originally supplied with
AC commutator motors. As these commutator motors had frequent maintenance problems,
these were replaced with dyno-drives.
The dyno-drives, though have lesser maintenance problems, are inefficient at lower speeds.
As the washers were operating at 50 - 60% of the rated speed for majority of the time, the
replacement of these drives with more efficient drives, such as, variable frequency drives
(VFD) can result in substantial energy savings.

The dyno-drives of the washers were replaced with variable frequency drives (VFD’s).
Concept of the project

The dyno-drives are very inefficient at lower speeds. The dyno-drives also require special
attention and maintenance, because of its semi-open construction.
The variable frequency drives (VFD) are more efficient at lower/all speeds and require lesser
maintenance, in comparison to dyno-drive.
Implementation status, problems faced and time frame

The dyno-drives in both the washer drums were replaced with 22.5 kW variable frequency
drives (VFD’s). A VFD can achieve the exact speed variation requirement energy efficiently
depending on the process requirement.
The problem faced during the implementation stage was the frequent tripping of the VFD’s.
The supplier studied this and suitable remedial action was taken, to solve the problem. The
entire project was executed in 3 months time.

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Benefits achieved
The replacement of dyno-drives with VFD’s, resulted in a net reduction in power consumption.
The net power saving achieved was 36,024 units/year (equivalent of 5.23 kW). The other
major advantage is, the precise speed variation, which can be achieved.
Financial analysis
The annual energy saving achieved was Rs.0.11million. This required an investment of
Rs.0.25 million and had a simple payback period of 28 months
This project has very high replication potential in majority of the medium size paper mills in the
country and integrated paper mills also.

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Case Study No.2
Installation of Variable Frequency Drive (VFD) for Fan Pump
Background
The pumps in a paper plant, are major consumers of electrical power. The pumps are used
for pumping water & pulp through out the plant - in the pulp mill, stock preparation section,
paper machine and water pumping sections.
One such important pump, is the fan pump, which pumps the dilute stock to the paper
machine, through the centri-cleaners.
The quantity of the stock being pumped by the fan pump varies, according to the quality and
grade of the paper produced in the paper machine. The production of high GSM paper
requires lower fan pump capacity, while the production of lower GSM paper needs higher fan
pump capacity. Hence, normally the fan pump is designed for the maximum capacity
requirement. Thus, the fan pump will be operating at lower capacity, whenever high GSM
paper is produced.
Conventionally, the fan pump is controlled by throttling the discharge valve or by re-circulating
a part of the discharge, during such low capacity requirements.
The operation of a centrifugal pump with valve throttling or re-circulation is energy in-efficient,
as a part of the energy supplied to the pump, is either lost across the valve or wasted for re-
circulation.
The latest trend is to install variable frequency drive (VFD) and control the varying capacity
requirements, by varying the speed of the pump.
Previous status
In a large integrated paper plant having one of the paper machines of 50 TPD capacity, the
consistency of the pulp varied from 0.6% to as high as 1.0%. The quantity of the dilute stock
to be pumped also varied accordingly, between 180 m3/h and 125 m3/h.
A fan pump of the following specifications, is used to pump the stock:
• Capacity : 240 m3/h

• Head : 35 m
• Motor rating : 50 HP
This capacity and head were designed with a safety margin on the maximum requirement in
mind. Hence, the valves in the delivery line of the fan pump had to be throttled and more so,
when the high GSM paper was produced.
The operation of a pump with valve throttling is energy inefficient, as a part of the energy
supplied is lost across the valves.

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The fan pump was installed with a variable frequency drive (VFD) and the speed was varied
to meet the varying capacity requirements. The valves were kept fully open, during the
continuous operation of the pump.

The operation of a pump with valve throttling is an energy inefficient method of capacity
control, as a part of the energy is lost across the valves.
The best energy efficient way of capacity control, for such varying process conditions, can be
effectively achieved with a variable frequency drive (VFD).

There were no problems faced during the implementation of this energy saving scheme. The
time taken for the implementation was 6 months.
Benefits achieved
The installation of VFD for the fan pump, resulted in the following:
• Avoiding discharge valve throttling
• Exact matching of the process requirements
• Energy savings
The net power reduction achieved on installation of VFD for the fan pump was 54 kW.
Financial analysis
The annual energy saving achieved was Rs.0.25 million. This required an investment of
Rs.0.50 million and had a simple payback period of 24 months.

This project has very high replication potential in majority of the medium size paper mills in
the country and a few of the integrated paper mills also.
On a conservative estimate, this project can be taken up for replication in about 100 paper
mills in the country.

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Case Study No.3
Replacement of Suction Couch Roll by Solid Couch Roll in the

Paper Machine
Background
The paper machine performs the important function of converting the low consistency pulp to
dry paper. The water removal is initially done by high-speed drainage, suction through flat
vacuum boxes, suction couch & mechanical presses and drying in steam cylinders.
The latest paper machines have been installing the modern presses and reducing the load
on the steam drying section.
Another project, which has been taken up by some of the plants, is the replacement of the
suction couch with the solid couch.
The concept of this project, is based on utilising the method, which removes the maximum
quantity of water, with the least quantity of energy. This is particularly applicable, to plants
based on long fibre agro-pulp, which have a low drainage.
Previous status
In a medium size agro-based paper plant, the major portion of water from the wet end, is
removed by suction couch roll. The moisture removal is effected by a vacuum pump of 200
kW rating. This is a highly energy intensive process.

The suction couch roll was replaced by a solid couch roll, for the efficient removal of moisture
in the wet end of the paper machine.

Agricultural residue fibres have very low diameter and low water drainage rate. The quantity
of water removed by the suction couch is very low and the energy consumption was
disproportionately high.
The inlet consistency to the suction couch roll was around 18% and outlet consistency after
the suction couch roll was between 18.5 - 19.0%. To remove this moisture of 0.5 - 1.0% at
the suction couch roll, a vacuum pump of 200 kW rating was being used.
The operation of a vacuum pump can be avoided, by the installation of a solid couch roll. The
additional water load, i.e., 0.5 - 1.0%, can be well taken care by the press part, without posing
any adverse effect on the working of the press part.

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The suction couch roll was replaced with a solid couch roll, for the removal of moisture in the
wet end of the paper machine. There was an initial apprehension that, whenever a break
occurred at the wet end, it was due to the solid couch roll.
However, once the plant team got familiar with the running of the paper machine with a solid
couch roll, there were no further problems faced. The entire project was implemented in 2
months.
Benefits achieved
The operation of the 200 kW vacuum pump was completely avoided with the implementation
of this proposal.
Financial analysis
The annual energy saving achieved was Rs.2.67 million. This will require an investment of
Rs.1.00 million and had a simple payback period of 5 months.

This project has good replication potential in the agro-waste based small and medium size
paper mills. These mills typically have the suction couch roll for water drainage instead of the
modern presses.

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Case Study No.4
Installation of Seven Effect Free Flow Falling Film (FFFF)

Evaporator
Background
Multiple effect evaporators are installed in the liquor line between the brown stock washers
and the soda recovery boiler to efficiently remove large amounts of water from the liquor, so
that, the recovery boiler produces steam from this liquor economically.
The multiple effect evaporator is fed black liquor at 12-14% solids and concentrated to
between 40-55% solids. Most of the paper plants use the short tube or long tube vertical
evaporators, having five to seven effects, the first two effects being contained in one evaporator
body.
These conventional evaporators have the following disadvantages:
• A large heating area is required, since the units are broad.
• Requires hydrostatic head
• Has a high pressure drop
• Tendency to scale
The latest trend among the large integrated paper plants, is the installation of free flow falling
film evaporators. They are characterised by higher steam economy and better operational
performance.
Previous status
A large integrated paper plant had a conventional quintuple effect short tube vertical evaporator
system for the concentration of black liquor. The black liquor flow rate was about
2500 m3/h.
The steam economy achieved was 2.8 tons of water evaporation per ton of steam. These
evaporators had frequent operational problems, leading to increased mechanical down time.
Also the chemical losses were more due to the frequent water boiling.
The installation of FFFF evaporators can result in higher steam economy, reduced down time
and improved operational performance.

The quintuple effect short tube vertical evaporators were replaced with 7 - effect free flow
falling film (FFFF) evaporators.

The FFFF evaporators are characterised by the following advantages over the conventional
types:

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• In this type, the feed liquor is introduced at the top tube sheet and flows down the tube wall
as a thin film.
• Since the film moves by gravity, a thinner and faster moving film forms. This results in
higher heat transfer coefficients and reduced contact times.
• As a large heat transfer area can be packed into a given body, they occupy less floor
space.
• Heat transfer coefficients are high.
• There is no elevation in boiling point, due to

absence of hydrostatic pressure
• Very high steam economy, of the order of 6
• There is no static head to affect the

temperature driving force. This allows use of
a lower temperature difference for units to
operate. Hence, a superior evaporator
performance is achieved.

The latest 7 - effect free flow falling film evaporator, was installed in place of the conventional
short tube vertical evaporator. There were no problems faced during the implementation of
this project and the implementation was completed in 12 months.
Benefits achieved
The installation of 7-effect FFFF evaporator resulted in achieving a steam economy of 6. A
net saving of about 97000 MT of low-pressure steam was achieved as a result of this
modification. The modification also resulted in reduced down time and improved operational
performance.
Financial analysis
The annual steam savings achieved amounted to Rs.28.50 million. This required an investment
of Rs.36.90 million, which had an attractive simple payback period of 16 months.
There are only few installations of seven stage evaporators, particularly, the falling film
evaporators in the paper industry.
Hence, this project has very high replication potential in majority of the integrated paper mills
in the country.
On a conservative estimate, this project can be taken up for replication in about 10 integrated
paper mills in the country.

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Case Study No.5
Recovery of Chemicals from Spent Liquor Obtained from

Counter Current Washing of Unbleached Pulp in a Medium
Size Paper Mill
Background
The chemical recovery systems (evaporators, recovery, boilers etc.,) are an integral part of
any large integrated paper plant. The black liquor can be fired in the soda recovery boilers
to generate steam. The sodium salts recovered in the process is reused in the digesters.
Chemical recovery systems have been well proven and operating for many years in the large
integrated plants.
The installation of such chemical recovery systems in the medium size paper plants is generally
considered financially unattractive. But one leading medium size paper plant has taken lead
in this direction.
They have installed a fluidised bed reactor to recover the chemicals from spent liquor and
convert them into sodium carbonate pellets. These pellets are commercially sold, resulting in
additional revenue generation.
Previous status
In an agro-based medium size paper plant, the spent liquor obtained from the counter current
washing of unbleached agro-pulp, was getting mixed with wastewater and let out to effluent
treatment plant.
This increases the load on the effluent treatment plant, as it is not possible to bring down the
Sodium ratio in the effluent. The recovery of this spent liquor will not only reduce the effluent
load, but also recovers the valuable chemicals, which can be sold.

A fluidised bed reactor was installed, to recover chemicals from spent liquor, obtained from
counter current washing of unbleached pulp.

Spent liquor obtained after counter current washing of unbleached pulp has sodium lignate.
Spent black liquor is concentrated to 45% solids content to have autocombustion in the
reactor.
The heat from flue gases makes the concentrated black liquor to convert into dry solids.
When these dry solids are burnt, organic portion of solids are converted mostly into carbon
dioxide and water vapour and generate heat. While sodium compounds present is converted
into very useful chemical- sodium carbonate pellets.

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As mentioned above it is an exothermic reaction, therefore no auxiliary fuel is required once

combustion of solids present in spent liquors gets started. Sodium carbonate is used in the
manufacture of glass, sodium silicate etc.

A chemical recovery plant, to recover the chemicals from spent black liquor, obtained from the
counter current washing of the unbleached agro-pulp, was installed.
The entire quantity of weak black liquor, which was earlier sent to the effluent treatment plant,
is now processed in the soda recovery plant. This reduced the effluent load and related power
consumption.
The major problem faced during the implementation of this project was the de-fluidisation of
the bed in the fluidised bed reactor. The problem was diagnosed and found to be due to the
high chloride content in the wheat straw. The pre-treatment of the wheat straw, with water of
low chloride contents, reduced the chloride contents in the wheat straw. This eliminated the
problem of de-fluidisation.
The entire project was implemented in 12 months time.
Benefits achieved
The following benefits were achieved on the installation of chemical recovery system:
• Chemical recovery (Sodium Carbonate)
• Savings in power at the effluent treatment plant
• Savings in Urea and DAP at the effluent treatment plant
The summary of the financial benefits is as follows:
Income (per month) Expenses (per month)
Additional revenue generated by Fixed expenses (personnel, repairs &

sale of Na2CO3 = Rs. 3.78 million maintenance, financial etc.,) = Rs. 0.88 million
Saving in power, urea and DAP Variable expenses (diesel, power, steam etc.,)
at ETP = Rs. 0.36 million = Rs. 2.74 million
Total benefits = Rs. 4.14 million Total expenses = Rs. 3.62 million
Net monthly benefits = Rs. (4.14 - 3.62) million = Rs. 0.52 million

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Financial analysis
The net annual energy saving achieved was Rs.6.20 million. This required an investment of
Rs. 12.60 million, which had a simple payback period of 24 months.

The installation of such chemical recovery systems in the medium size paper plants is generally
considered financially unattractive.
But considering the other spin-off benefits, like additional revenue from pellets and huge
intangible benefits, such as, reduced load on ETP & related environmental benefits, this
project can have good replication potential in all the medium size paper mills.
On a conservative estimate, this project can be taken up for replication in about 50 medium
size paper mills in the country.

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Case Study No.6
Installation of Variable Frequency Drive (VFD) for

Boiler ID Fan
Background
The capacity requirements of the boiler ID fans, vary with the boiler operating conditions. In
such highly fluctuation conditions, the right sizing (capacity and head) of the fans is very
difficult. Some excess margins are added, to take of such uncertainties and safety
considerations. The excess capacity/head of a fan, is conventionally, controlled by a damper.
In a typical paper plant, the coal fired boiler, was operating with damper control. The varying
capacity requirements, can be exactly matched in an energy efficient manner, by the installation
of variable frequency drives.
Previous status
In a large integrated paper plant, the varying capacity requirements of the coal fired boiler -
ID fan was achieved with damper control.
The operation of a fan with damper control is an energy inefficient practise, as substantial
energy is lost across the damper.
The installation of a variable frequency drive (VFD) can, not only result in exact matching of
the varying capacity requirements, but also result in achieving energy savings.

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Variable frequency drives were installed for the coal-fired boiler ID fan and the soda recovery
boiler ID fan.

The operation of a fan with damper control is an energy inefficient practise, as substantial
energy is lost across the damper. The energy efficient method of capacity control is to vary
the RPM of the fan, to exactly match the varying capacity requirements.
The installation of a variable frequency drive can achieve this objective resulting in maximum
energy savings, in all speed ranges.

A variable frequency drive was installed for the coal-fired boiler ID fan.
There were some minor problems of tuning the variable frequency drive during the initial
stages.
The supplier’s service engineer rectified these problems. The implementation of the entire
project was completed in 3 months time.
Benefits achieved
The benefit of installing a variable frequency drive, for the coal-fired boiler ID fan is as follows:
Parameter Units ID fan Power Cons.
Power consumption without VFD kW 185
Power consumption with VFD kW 150
Power savings achieved kW 35
Financial analysis
Rs. 0.70 million and had an attractive simple payback period of 15 months.


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The project has very high replication potential in almost all the medium size paper mills and
some of the integrated paper mills.
Several integrated paper mills have installed variable fluid coupling (VFC) for the boiler (both
coal-fired and soda recovery) ID fans.
The comparative performance and cost-benefit analysis of the various variable speed devices,
decides the best selection of the type of variable speed drive (VSD) to be installed for the ID
fans.
Amongst the various VSD’s available, a variable frequency drive (VFD) will offer the maximum
energy savings and as well as maximum operational flexibility. Hence, it is advisable to
replace VFC with VFD.
For example:
• One of the integrated paper plants, by installing VFD for their soda recovery boiler ID fan,
the plant was able to achieve a power reduction of 72 kW at 80% motor speed and 27 kW
at 95% motor speed, as compared to VFC.
• The plant achieved an annual energy saving of Rs.1.08 million. This required an investment
of Rs.1.50 million, which had an attractive simple payback period of 17 months.
Similar to the boiler ID fans, VFD’s have also been installed successfully for the boiler FD fans
and SA fans.

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Case Study No.8
Conversion of Spreader Stoker Boilers to Fluidised Bed Boilers
Background
The paper plant is a major consumer of thermal energy in the form of steam. This steam
requirement is met by a battery of boilers fired by a solid fuel (coal) and also partly by the
Soda Recovery Boiler (SRB) in the case of the integrated plants.
In the older paper plants, the boilers were the conventional stoker boilers. These boilers were
characterised by:
• Higher unburnts in ash
• Lower thermal efficiency
The latest trend has been to install the fluidised bed boilers or conversion of the existing chain
/ spreader stocker boilers, which have the following advantages:
• Coal having high ash content/ low calorific value can be used
• Biomass fuels can also be used
• Lesser unburnts in ash
• Higher thermal efficiency
Hence, the older plants are also in a phased manner, converting their old stoker-fired boilers
to fluidised bed boilers. This case study describes one such project implemented in a paper
plant.
Previous status
A large integrated paper plant, had four numbers of spreader stoker boilers, operating to meet
steam requirements of the plant. These spreader stoker boilers, were designed for high
calorific value coal (4780 kCal/kg) with low ash content.
Due to non-availability of this type of coal, these boilers had to be fired with coal of low
calorific value and high ash content. This resulted in the capacity down-gradation and loss in
efficiency. The steam generation was only 14 TPH, as against the design rating of 30 TPH.
The boiler efficiency achieved was only 65%.

The plant team modified two of the spreader stoker boilers into fluidised bed combustion
boilers.

In addition to the benefits of fluidised bed combustion mentioned earlier, they also enable the
use of biomass fuels, such as saw dust, generated in the chipper house.

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Two of the four spreader stoker boilers were converted to fluidised bed combustion boilers.
This conversion to fluidised bed combustion boilers, enabled the use of saw dust, which is
generated in the chipper house.
There were no major problems faced during the implementation of this project. The
implementation was taken up in two stages and was completed in 18 months time.
Benefits
The steam generation capacity increased to 27 TPH and the thermal efficiency improved to
78%, with this modification. The improved thermal efficiency has resulted in an annual coal
saving of 5639 MT.
Additionally, the use of saw dust (calorific value of about 3000 kCal/kg) has resulted in an
annual coal savings of 3600 MT.
Financial analysis
The annual benefits achieved were Rs.10.50 million. This required an investment of Rs.27.00
million (for the conversion of two spreader stoker boilers to fluidised bed combustion boilers),
which had a simple payback period of 31 months.

This project can be replicated in majority of the older paper mills, both medium size and
integrated paper mills, particularly, those plants which is looking at augmenting its boiler
capacities and adopting high pressure cogeneration systems.

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Case Study No.9
Conversion of MP Steam Users to LP Steam Users to Maximise

Cogeneration
Background
The paper industry is a major consumer of power and steam. In all the integrated plants and
in a few medium sized plants, the co-generation system is installed to meet the power and
steam needs of the plant simultaneously.
This system facilitates the generation of cheaper power, fully meets the steam requirement
and partly the power requirements of the plant. The balance power requirement is met, either
from the grid or through condensing turbine, in the plant itself at a higher cost.
Hence, the paper plant should make every effort to increase the co-generation power to the
extent possible.
The generation of power from the turbine depends on the pressure level of the extraction. The
lower the pressure, the higher will be the generation of power per unit of steam extracted.
Hence, efforts should be made to replace the HP (High Pressure) / MP (Medium Pressure)
steam with LP (Low Pressure) steam to the extent possible.
One such case study involving replacement of MP steam with LP steam and implemented in
an integrated paper plant is described below.
Previous status
One of the large integrated paper plants in the country, had an extraction-cum-back pressure
turbine for the generation of power. The turbine specifications were as follows:
• HP steam pressure = 42 ata
• MP steam pressure = 12 ata
• LP steam pressure = 5.5 ata
The MP steam consumers, such as, malony filter, furnace oil preheaters in boilers and the
steam air preheaters consume MP steam. The heating requirements in these areas, can be
effectively met by LP steam.
The conversion of these MP steam users to LP steam users, can help in maximising the
cogeneration.

The detailed analysis of the temperature requirement of the various above listed MP steam
users, indicated that the LP steam can be used for providing the required heat, without any
problem.

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The comparison of power generation with MP steam and LP steam are as follows:
• 1 MT of HP steam extracted as MP steam generates 67 kWh
• 1 MT of HP steam extracted as LP steam generates100 kWh
Hence, replacement of 1 MT of MP steam with 1 MT of LP steam can aid in generating about

23 kWh of extra power.

The MP steam users, such as, the malony filter, furnace oil preheater and the steam air
preheater were converted to LP steam users.
There were no particular problems faced during the implementation of this project. The
implementation of the project was completed in 1 month time.
Benefits achieved
By the conversion of the identified MP steam users to LP steam users, there was an additional
annual power generation of 16.73 lakh kWh.
Financial analysis
The additional annual benefit achieved (on account of increased power generation) was
Rs.1.67 million. This did not require any major investment, as LP steam header was available
close to all these users.

• Investment - negligeble
This project has very good replication potential in almost all the paper plants have a commercial
cogeneration system.

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Case Study No.10
Utilisation of Bamboo Dust along with Coal Firing in the Coal

Fired Boilers
Background
Coal is used conventionally, as the basic fuel for
combustion in the boilers for steam generation.
The steam requirements of the entire plant are
met, by steam generated in these coal-fired
boilers. This is supplemented by steam
generation from the soda recovery boilers.
Previous status
In an integrated paper plant, two coal-fired boilers
met the majority of the steam requirements of
the entire plant. There was lot of bamboo dust
generated in the chipper house, which was being sold-off to outside parties.

The bamboo dust was fired along with coal in the boilers.

This is an excellent cost reduction and waste disposal method.
Even though, there are several proven cases of utilisation of alternate forms of fuel, including
waste fuels and low cost fuels, coal continues to be the most preferred fuel in most of the
paper plants, particularly the large integrated paper plants.
As the cost and ash content of the coal available to the paper sector is on the raising trend,
the use of supplementary fuels, such as, bamboo dust, rice husk, bagasse etc., have gained
increasing prominence.
This has assumed greater relevance, as the available coal resources are also fast dwindling.

Chipper dust was used along with coal as fuel, in the coal-fired boilers, on a trial basis. Once
the operational stability was achieved, the chipper dust was used to supplement the coal firing
on a continuous basis, except during the rainy season.
During the rainy seasons, the plant team faced serious firing problems, due to the higher
moisture content in the chipper dust. It was hence decided to stop the use of chipper dust
as supplementary fuel during the rainy season.
The time taken for the complete implementation of the project was 2 months, which also
included the initial trials conducted.

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Benefits achieved
With the use of bamboo dust as supplementary fuel to the coal firing in the coal-fired boilers,
there was a net annual reduction in coal consumption by 3312 MT.
Financial analysis
The annual energy saving achieved was Rs.4.14 million. This required only a minimal
investment to transport the bamboo dust available in the chipper house to the boiler house.
The project has excellent cost reduction and waste disposal potential. This coupled with the
increased use of agro-wastes, such as, wet & dry pith from bagasse, groundnut shells,
coconut shells, paddy husk etc., has tremendous long-term benefits.

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Case Study No.11
Installation of High-Efficiency Turbine Pumps for Raw Water

Intake
Background
Water is an essential commodity for the pulp & paper industry, from both energy and
environmental point of view.
The overall water consumption of the Indian pulp and paper industry varies from 175 - 250
m3/ton of finished paper (depending on the product) in large integrated paper plants.
Previous status
In one integrated paper plant, six pumps installed at the raw water intake well met the raw
water requirements of the entire plant. The pumps were of the following specification:
Three pumps Three pumps

• Capacity = 772 m3/h • Capacity = 522 m3/h
• Head = 35 m WC • Head = 35 m WC
• Motor rating =125 HP • Motor rating = 75 HP
• Design efficiency = 86.5% • Design efficiency = 80%
To meet the normal plant requirements, the operating pattern of the pumps were as follows:
• 3 pumps of 125 HP, run for 24 hrs/day
• 1 pump of 75 HP, kept as stand-by pump, to take care of any exigencies.
On detailed analysis of the pumps, it was observed that the three 125 HP pumps were
operating very close to the design efficiency. On the other hand, the two 75 HP pumps were
operating much below their best efficiency points.
The design efficiencies were not being achieved, on account of ageing and wear out of
impellers.

Three new high-efficiency river water turbine pumps were installed, in place of the existing 75
HP pumps.

impellers. The latest turbine pumps for river water intake have operating efficiencies as high
as 87%.

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Substantial energy savings can be achieved by the installation of high efficiency turbine pumps.

Three new high-efficiency, 125 HP turbine pumps were installed, in place of the old 75 HP
turbine pumps. To meet the raw water requirements of the entire plant, the operating pattern
of the pumps changed to:
• Three 125 HP pumps, run for 24 hrs/day
• One 125 HP pump, run for 12 hrs/day
• Two 125 HP pumps, kept as stand-by
No problems were faced during the installation of the new pumps, since there was a stand-
by pump available. The new pumps were installed one-by-one. The total time taken for
implementation of this project was 8 months.
Benefits achieved
The total power consumption (measured by a common energy meter) of the 5 pumps in
operation, before modification, was on an average 8000 units per day.
After the installation of new high efficiency turbine pumps for raw water intake, the total power
consumption (measured by a common energy meter) of the four pumps in operation was on
an average about 7000 units/day. Thus, there was a net reduction in power consumption by
an average of 1000 units/day (equivalent to 41.7 kW).
Financial analysis
The annual energy saving achieved was Rs.1.05 million. This required an one-time investment
of Rs.0.52 million and had a very attractive simple payback period of 6 months.


Water is an essential and power intensive utility for effective functioning of a paper mill.
Hence, efficient operation of pumps is very important, not only from the process point of view,
but also from cost point of view.
The project has excellent replication potential, in majority of the integrated and medium size
paper mills, which are dependent on rivers for raw water intake.

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Case Study No.12
Installation of Variable Frequency Drive (VFD) for Process Water

Pump
Background
In a typical paper plant, the centrifugal pumps are major consumers of electrical energy. The
capacity requirements of a centrifugal pump vary with the operating conditions and process
requirements.
Normally, the pumps are designed to operate at their maximum capacity and meet the peak
load demand of the plant. However, these conditions do not arise all the time. Due to the
variation in demand, the system pressure also varies.
For example, when the header pressure varies between 3 kg/cm2 and 4 kg/cm2 (assuming the
required pressure is 3 kg/cm2) the header pressure will approach 4 kg/cm2, during the period
of low demand.
This indicates generation of higher pressure, when it is not required, and a potential for saving
energy to the extent of 25% [(4-3)/4 x 100] during low demand condition exists.
Previous status
In a large integrated paper and paperboard plant, the process water pump was catering to
the water requirements in the plant.
The process water requirement was continuously varying, leading to fluctuations in the system
header pressure between 3.0 and 4.0 kg/cm2.
The installation of a variable frequency drive can exactly match the process requirements and
maintain a constant pressure of 3 kg/cm2, resulting in energy savings.

A variable frequency drive was installed for the process water pump, with a pressure indicator
controller (PIC) in a closed loop.

A variable frequency drive (VFD) can exactly match the process requirements by varying the
RPM. The PIC will continuously monitor the header pressure and give a signal to the VFD
panel to increase / decrease the RPM.
Whenever the process demand decreases, the header pressure increases above 3 ksc. The
PIC will sense this increase in pressure and will give signal to the VFD panel to reduce the
RPM, to match the set point and vice-versa.

280

A variable frequency drive was installed for the process water pump, with a PIC in a closed
loop. There were some minor problems of tuning the variable frequency drive during the initial
stages.
The supplier’s service engineer rectified these problems. The implementation of the project
was completed in 3 months time.
Benefits achieved
The benefit of installing the variable frequency drives, for the boiler ID fans and process water
pump are as follows:
Parameter Units Power cons. of

process water pump
Financial analysis
The annual energy saving achieved was Rs.1.15 million. This required an investment of Rs.
0.7 million and had an attractive simple payback period of 8 months

Variable speed drives are finding increasing application, not only from energy point of view,
but also from process point of view. The application purely depends on the variation in
demand and also the flexibility of operation desired.
In fact, some of the latest plants have almost 250-300 variable speed drives, a drive for
almost any application you can think of!!
Hence, variable speed drives have excellent application potential.

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The bamboo dust was fired along with coal in the boilers.

This is an excellent cost reduction and waste disposal method.
Even though, there are several proven cases of utilisation of alternate forms of fuel, including
waste fuels and low cost fuels, coal continues to be the most preferred fuel in most of the
paper plants, particularly the large integrated paper plants.
As the cost and ash content of the coal available to the paper sector is on the raising trend,
the use of supplementary fuels, such as, bamboo dust, rice husk, bagasse etc., have gained
increasing prominence.
This has assumed greater relevance, as the available coal resources are also fast dwindling.

Chipper dust was used along with coal as fuel, in the coal-fired boilers, on a trial basis. Once
the operational stability was achieved, the chipper dust was used to supplement the coal firing
on a continuous basis, except during the rainy season.
During the rainy seasons, the plant team faced serious firing problems, due to the higher
moisture content in the chipper dust. It was hence decided to stop the use of chipper dust as
supplementary fuel during the rainy season.
The time taken for the complete implementation of the project was 2 months, which also
included the initial trials conducted.
Benefits achieved
With the use of bamboo dust as supplementary fuel to the coal firing in the coal-fired boilers,
there was a net annual reduction in coal consumption by 3312 MT.
Financial analysis
The annual energy saving achieved was Rs.4.14 million. This required only a minimal
investment to transport the bamboo dust available in
the chipper house to the boiler house.
• Investment - negligible
The project has excellent cost reduction and waste disposal potential. This coupled with the
increased use of agro-wastes, such as, wet & dry pith from bagasse, groundnut shells,
coconut shells, paddy husk etc., has tremendous long-term benefits.

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Case Study No.11
Installation of High-Efficiency Turbine Pumps for Raw Water

Intake
Background
Water is an essential commodity for the pulp & paper industry, from both energy and
environmental point of view.
The overall water consumption of the Indian pulp and paper industry varies from 175 - 250
m3/ton of finished paper (depending on the product) in large integrated paper plants.
Previous status
In one integrated paper plant, six pumps installed at the raw water intake well met the raw
water requirements of the entire plant. The pumps were of the following specification:
Three pumps Three pumps
• Capacity = 772 m3/h • Capacity = 522 m3/h
• Head = 35 m WC • Head = 35 m WC
• Motor rating =125 HP • Motor rating = 75 HP
• Design efficiency = 86.5% • Design efficiency = 80%
To meet the normal plant requirements, the operating pattern of the pumps were as follows:
• 1 pump of 75 HP, kept as stand-by pump, to take care of any exigencies.
On detailed analysis of the pumps, it was observed that the three 125 HP pumps were
operating very close to the design efficiency. On the other hand, the two 75 HP pumps were
operating much below their best efficiency points.
impellers.

Three new high-efficiency river water turbine pumps were installed, in place of the existing 75
HP pumps.

impellers. The latest turbine pumps for river water intake have operating efficiencies as high
as 87%.

284
Substantial energy savings can be achieved by the installation of high efficiency turbine pumps.

Three new high-efficiency, 125 HP turbine pumps were installed, in place of the old 75 HP
turbine pumps. To meet the raw water requirements of the entire plant, the operating pattern
of the pumps changed to:
• Three 125 HP pumps, run for 24 hrs/day
• One 125 HP pump, run for 12 hrs/day
• Two 125 HP pumps, kept as stand-by
No problems were faced during the installation of the new pumps, since there was a stand-
by pump available. The new pumps were installed one-by-one. The total time taken for
implementation of this project was 8 months.
Benefits achieved
The total power consumption (measured by a common energy meter) of the 5 pumps in
operation, before modification, was on an average 8000 units per day.
After the installation of new high efficiency turbine pumps for raw water intake, the total power
consumption (measured by a common energy meter) of the four pumps in operation was on
an average about 7000 units/day. Thus, there was a net reduction in power consumption by
an average of 1000 units/day (equivalent to 41.7 kW).
Financial analysis
The annual energy saving achieved was Rs.1.05 million. This required an one-time investment
of Rs.0.52 million and had a very attractive simple payback period of 6 months.

Water is an essential and power intensive utility for effective functioning of a paper mill.
Hence, efficient operation of pumps is very important, not only from the process point of view,
but also from cost point of view.
The project has excellent replication potential, in majority of the integrated and medium size
paper mills, which are dependent on rivers for raw water intake.

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Case Study No.12
Installation of Variable Frequency Drive (VFD) for Process Water

Pump
Background
In a typical paper plant, the centrifugal pumps are major consumers of electrical energy. The
capacity requirements of a centrifugal pump vary with the operating conditions and process
requirements.
Normally, the pumps are designed to operate at their maximum capacity and meet the peak
load demand of the plant. However, these conditions do not arise all the time. Due to the
variation in demand, the system pressure also varies.
For example, when the header pressure varies between 3 kg/cm2 and 4 kg/cm2 (assuming the
required pressure is 3 kg/cm2) the header pressure will approach 4 kg/cm2, during the period
of low demand.
This indicates generation of higher pressure, when it is not required, and a potential for saving
energy to the extent of 25% [(4-3)/4 x 100] during low demand condition exists.
Previous status
In a large integrated paper and paperboard plant, the process water pump was catering to
the water requirements in the plant.
The process water requirement was continuously varying, leading to fluctuations in the system
header pressure between 3.0 and 4.0 kg/cm2.
The installation of a variable frequency drive can exactly match the process requirements and
maintain a constant pressure of 3 kg/cm2, resulting in energy savings.

A variable frequency drive was installed for the process water pump, with a pressure indicator
controller (PIC) in a closed loop.

A variable frequency drive (VFD) can exactly match the process requirements by varying the
RPM. The PIC will continuously monitor the header pressure and give a signal to the VFD
panel to increase / decrease the RPM.
Whenever the process demand decreases, the header pressure increases above 3 ksc. The
PIC will sense this increase in pressure and will give signal to the VFD panel to reduce the
RPM, to match the set point and vice-versa.

286

A variable frequency drive was installed for the process water pump, with a PIC in a closed
loop. There were some minor problems of tuning the variable frequency drive during the initial
stages.
The supplier’s service engineer rectified these problems. The implementation of the project
was completed in 3 months time.
Benefits achieved
The benefit of installing the variable frequency drives, for the boiler ID fans and process water
pump are as follows:
Parameter Units Power cons. of process

water pump
Financial analysis
Rs. 0.7 million and had an attractive simple payback period of 8 months

Variable speed drives are finding increasing application, not only from energy point of view,
but also from process point of view. The application purely depends on the variation in
demand and also the flexibility of operation desired.
In fact, some of the latest plants have almost 250-300 variable speed drives, a drive for
almost any application you can think of!!
Hence, variable speed drives have excellent application potential.

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Case Study No.13
Installation of Centralised Compressed Air System
Background
A centralised compressed air system has a single large / multiple number of compressors at
one location. On the other hand, a decentralised compressed air system has multiple numbers
of compressors, distributed over various locations.
Centralised compressor system is preferred in cases, where large capacity requirements at

identical pressure levels. In addition, they also have the following advantages
• The unloading operation of multiple compressors at different locations is avoided, thereby

saving substantial energy.
• This eliminates the requirement of stand-by compressors resulting in avoiding the investment
on stand-by equipment at the design stage
• Leads to usage of high capacity compressor, which are generally more efficient, compared
to smaller ones.
Previous status
A large integrated paper plant, had two compressed air units, catering to the compressed air
requirements of the entire plant. These units were located at two different locations
(decentralised).
The decentralised system necessitates the operation of multiple compressor units. This leads
to increase in both power consumption and mechanical maintenance problems.

The feasibility of installing a centralised compressed air system, in place of the decentralised
system was considered.

From the energy efficiency point, a good compressed air system layout is the one which,
offers the process the maximum plant efficiency and economy of operation.
Process variables, maintenance, location, capacity of the utilities and the energy consumption
must all be considered for this purpose.
A centralised compressed air system has the following advantages over the decentralised
compressed air system:
• Reduced power consumption
• Reduced manpower
• Better maintenance control

288

The old compressed air pipelines were replaced with new pipelines, to reduce the leakage
losses and line friction losses. Further, the compressors were located at one central location
for ease of operation and maintenance.
As compressed air is very vital for the efficient operation of instruments, the major problem
the plant team faced for the implementation of this project was the non-availability of a shut-
down.
The major modifications could be carried out, only during the entire plant shut-down. The
implementation of the project was completed in 18 months time.
Benefits achieved
There was a substantial reduction in the leakage losses and significant savings of power.
There was a net reduction in power consumption by 53 kW, with the above modification. The
maintenance costs also have reduced considerably.
Financial analysis
Rs. 0.7 million (for pipeline modification, civil works for relocation) and had an attractive
simple payback period of 20 months.

The project has good replication potential in several integrated paper plants, considering the
extent of compressed air distribution. The project also can be taken up in majority of the
medium size paper mills.

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Case Study No.14
Installation of Heat of Compression (HOC) Air Dryers
Background
Compressed air is an important utility in process and engineering industries. Instrumentation
applications require dry air. Any moisture present in the compressed air will condense at the
point of utilisation, causing damage to the instrumentation valves.
Drying of compressed air is achieved through various methods. However, the latest trend is
to install heat of compression (HOC) dryers.
Heat of compression dryer is a major technological improvement, having the following distinct
advantages:
• Utilises the heat in compressed air for regenerating the dessicant
• Electrical heaters are eliminated
• No purge air losses
Low atmospheric dew point is achieved, depending on the dessicant used
Previous status
A large integrated paper and board plant had compressed air requirements of about 112 m3/
min. About 50 m3/min of the compressed air was being dried using heater reactivated (lambda)
type air dryer.
The heater was rated for 32 kW heating capacity. The purge air loss in the dryer was about
10% of the total quantity of air being dried.
This type of air dryer in addition to being highly energy intensive, also leads to substantial
quantity of compressed air losses.

The heater reactivated compressed air drier was considered for replacement with heat of
compression (HOC) dryer, to reduce the operating cost of the drying unit.

An HOC dryer was installed alongside the existing dryer and utilised for drying of compressed
air. The dessicant used was activated alumina, which can give an atmospheric dew point of
- 40°C.
Some minor problems were encountered during the implementation of this project and necessary
rectification measures were carried out. These are as follows:
• Due to the attrition of the dessicant, carry-over of the dessicant powder was observed.
Entire quantity of the dessicant was removed, filtered and topped-up.

291
• Solenoid valves, which operate the four-way valves, were not connected properly. The
routing of air was traced at different cycles and the valves were rectified.
• Heating and cooling cycle times were not properly set, leading to improper regeneration.
This was studied and successfully corrected.
The project was commissioned during the shut down of the plant and was completed in 3
months time.
Benefits achieved
Substantial power savings were achieved, on account of the elimination of heater operation.
Also, compressed air losses were totally avoided, as there are no purge losses in HOC dryers.
Financial analysis
The annual energy saving achieved was Rs.0.7 million (Rs.0.34 million - on account of power
savings and Rs.0.36 million - due to elimination of purge losses). This required an investment
of Rs.1.48 millon, which had a simple payback period of 25 months.

Precautions to be taken for HOC dryer

• Select the dessicant, depending on the required dew point, life of dessicant and cost of
dessicant
• If the temperature (at the discharge of the compressor) of air is less than 135°C, as in the
case of screw/ centrifugal compressors, additional heaters are required for regeneration of
the dessicant
• Since air carries some dust, two after-filters need to be installed, one being a stand-by
Almost all the paper plants, small, medium and integrated (barring a few), have reciprocating
type air compressors and dessicant heated type or refrigerated type of drier.
This offers an excellent potential for increased adoption of HOC dryers by the Indian paper
industry.

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Case Study No.15
Installation of Blind Drilled Rolls (Dri-Press Rolls) instead of

Conventional Press Rolls in Press Section of Paper Machine
Background
The press section, has a very important role in the drying process and hence, steam
consumption of paper machine.
the overall Chipper is the first major equipment in a paper plant. These chippers are used to
produce wood chips, from the raw materials like hard wood, bamboo etc., for further processing
in the digester house.
Many of the old paper plants, in general, have conventional press rolls for de-watering. This
led to non-uniform moisture removal, which in turn affected the throughput through the system.
This resulted in very high specific steam consumption in the paper machine.
The recent technological advancements in water removal and increased runnability of paper
machines have led to the development of the blind drilled rolls (or Dri-Press rolls).
The blind drilled rolls enable more efficient water removal than any other de-watering technique.
The installation of blind drilled rolls is gaining increasing popularity, especially among the large
integrated paper plants.
Previous status
In a large integrated paper plant, the press section had the conventional press roll. The
dryness achieved with the press roll was about 40-42%.
This system had the following disadvantages:
• Lower throughput
• Increased de-watering requirement
• Higher downtime due to higher breakages at wet end
• Higher purging requirements
• High specific steam consumption
The installation of Dri-press rolls, can result in higher throughput and lower specific energy
consumption.

The conventional press rolls were replaced with blind drilled rolls.
Advantages of the project

These rolls have the following advantages:

294
• Higher dryness – The holes are precision drilled to optimize available land area and providing
uniform sheet de-watering
• Dynamic nip conditions
• Higher throughput
• Improved sheet quality
• Reduced steam consumption
• Reduced downtime and labour costs
• Eliminates the need for purge showers
• Extended felt-life
• Elimination of crushing
• Elimination of marking
Hence, blind drilled rolls can be installed in the press section to achieve maximum energy
efficiency.

The plant team replaced the conventional press rolls with blind drilled rolls in the two paper
machines in phases.
Initially, one paper machine was taken up for replacement and its performance was closely
monitored. On achieving satisfactory operating results, the second machine was replaced.
implementation of this project was completed during the planned shutdown.
Benefits achieved
The dryness with blind drilled rolls (for writing & printing paper) improved to 44-46%, as
compared to 40-42% with conventional press rolls, thereby, achieving 2-6% improvement in
dryness.
This results in equivalent savings in steam or fuel consumption. Besides, there was tremendous
improvement in machine runnability.
Financial analysis
Rs. 2.4 million, which had a simple payback period of 32 months.


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Case Study No.16
Installation of Extended De-lignification Pulping Process instead

of Conventional Pulping
Background
The pulping in pulp & paper industry is conventionally carried out in vertical stationary digestors.
These digesters are operated at a temperature of 170°C and 8 ata pressure. The steam is
drawn from 12 ata header or the medium pressure steam extraction from turbine.
The total batch time (Lid-to-lid) varies between 5 – 7 hrs, depending on furnish, black liquor
ratio and steam pressure & temperature.
The vertical digesters are highly energy intensive, consuming typically about 1.4 -1.5 tons of
steam/ ton of FNP. Also, during blowing operation, substantial amount of heat loss takes
place, besides, loss of chemicals and increase of effluent load.
The latest technological advancements pulping have led to the adoption of extended
delignification pulping process.
The extended delignification pulping process is not only energy efficient, but also environment
friendly. The system has the following features:
• Majority of heat is recycled in the system. The recycled heat is stored in the form of hot
black liquor and white liquor
• Pulp is blown at lower temperature, resulting in lower heat loss from the system
• Alkali rich white liquor addition takes place only at 115°C. This makes it more reactive with
alkali and aids in making the cook more selective leading to extended delignification.
• After cooking is over, the final displacement is performed with washer filtrate, eliminating
the need for one stage of washing
The installation of extended delignification pulping process can result in substantial benefits,
especially among large integrated paper plants.
Previous status
In a large integrated paper plant, the digestor house had conventional vertical stationary
digestors, having a combined capacity of 250 Tons of BD pulp/day.
The operating parameters were as follows:

• Steam consumption = 1.42 tons / ton of FNP
• Batch time = 6 hours (avg. time)
• Kappa number = 21-22
• Yield = 45.3%
• Washing loss = 16 kg/ ton of pulp (as sodium sulphate)
• Black liquor conc. = 14.2%
• Ash retention = 7%
• Paper breakage = 3.3%

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The conventional vertical digesters were replaced with extended delignification pulping process.
The major advantages of the project are:
• Upto 75% reduction in steam demand
• Higher brightness levels can be achieved due to low Kappa numbers
• Considerable savings in bleaching chemicals
• Uniform and better pulp quality (15-20% increase in tear/ tensile strength), resulting in better
machine runnability and efficiency
• Increased yield - atleast 46% possible
• Reduction in washing loss leading to reduction of make-up chemicals
• Reduced load on effluent treatment plant
• Due to in-digestor washing, one stage of washing gets eliminated
• Low screen rejects due to uniform cooking
• Lower black liquor viscosity allows feeding the boiler at 75+% solids
• Reduction of steam demand in evaporators

The plant team replaced the conventional vertical digestors with 3 new digestors of 80-tons/
day of BD pulp capacity, based on rapid displacement heating pulping process.
implementation of this project was taken up parallel to the old pulp mill, to ensure that, the
plant shutdown was kept minimal.
Benefits achieved
The operating parameters were as follows:
• Steam consumption = 0.70 tons / ton of FNP
• Batch time = 4 hours (avg. time)
• Kappa number = 12-13
• Yield = 46%
• Washing loss = 10 kg/ ton of pulp (as sodium sulphate)
• Black liquor conc. = 16%
• Ash retention = 10%
• Paper breakage = 1.5%
The reduction in chemical consumption was about 50%.

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Financial analysis
The total annual savings achieved was Rs.140 million. This required an investment of
Rs.500 million, which had a simple payback period of 42 months.

There is only one plant in India, which has installed the extended delignification pulping
process. Hence, the replication potential for this project is enormous.

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300
Case Study No.17
Improved Paper Machine Design to Improve Production
Background
The success of a paper mill is determined not only on the basis of quality and quantity of paper
produced, but also on productivity. Efficiency of paper machine plays a vital role in achieving
runnability and hence, productivity.
There are a number of limiting factors, which affect the efficiency and economics. Typically,
agro-fibres have lower strength, which in turn affect the machine runnability. Also, use of agro-
fibres results in lower water drainage and higher power consumption.
The identification of limiting factors and modifications to overcome them, becomes extremely
necessary to optimise the productivity of the paper machine, without affecting the quality of
paper.
Previous status
In an agro-residue based paper mill, renewable agro-waste, such as, wild grasses and straws
were being used for making high quality writing & printing paper.
This system had the following features:

• Stationary showers in head box
• Wire return roll driven by a separate motor, causing unequal tension, leading to creasing
of fabric
• Speed of machine restricted, due to lower diameter of dandy roll, only 700 mm dia leading
to limited production
• HDPE tops for paper machine
• Perennial problem of shadow marking in press part due to suction pickup roll
• SLDF screen for dryer part
• Static current problem in between calender and pope reel
A critical study was conducted to modify its paper machine, to improve its efficiency in terms
of quality and productivity.

The plant team applied various modifications, right from head box to dryer part in paper
machine.
The details of the modifications are as follows:

• Energy efficient rotary showers installed in head box, in place of stationary showers
• Wire circuit provided with an additional roll to improve wrap on FDR
• Motor used for wire return roll removed

301
• Diameter of dandy rolls increased to 1200 mm to increase speed of paper machine, enhance
production and provide for water-marks
• Ceramic tops installed in place of HDPE tops in paper machine
• Suction pick-up roll modified to suction cum BDR to avoid shadow marking and ensure
better sheet dryness
• Speed difference between wire and pickup roll reduced, resulting in improved life of pickup
felt life
• SLDF screen replaced with woven screen for better sheet flatness and prevent screen
marking
• Static current remover installed between calender and pope reel

The plant team carried out the modifications on the paper machine in phases. The measures
were taken up one-by-one to observe the benefits. On achieving satisfactory operating results,
the other measures were taken up. There were no major problems faced during the
implementation of this project.
Benefits achieved
The following benefits were achieved:
• Shower modification in head box resulted in better foam killing and reduced breaks due to
foam lumps
• Additional role avoided the wire slippage and consequent fabric damage
• Increase in speed of machine from 250 m/min with 115 RPM dandy roll to more than 350
m/min with 95 RPM dandy roll
• Elimination of fabric creasing, shadow marking problems
• Increased felt and wire life
• Increase in ash retention by over 1%
• Sheet dryness improved from 10.5% to 16% after suction box
• Constant moisture level at pope reel
• Consistency in grammage
Financial analysis
The total annual savings achieved on account of the various modifications was
Rs.18.30 million.
As about 31% of the paper mills are based on agro-residue, and also majority of the paper
mills are looking at capacity augmentation without any major investments, the de-bottlenecking
route could be a major opportunity to increase their competitiveness. Hence, this project has
very good replication potential, particularly in the older mills having multiple number of smaller
paper machines.

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303
9.0 List of Contractors/ Suppliers
Larsen & Toubro Limited Raw material handling & preparation

Industrial Machinery Heavy Engineering Division Pulping of wood & non-wood material
Kansbahal Dist. Sundargarh – 770034 Waste paper treatment & de-inking
Tel. : 0661 - 22280241/ 0101/ 0145 Secondary fibre generation
Fax : 0661 - 22280243/ 0557 Stock preparation & approach flow
Email : mktg-kbl@kbl.ltindia.com Paper & boards machine from headbox
Winder and auxiliary systems
Enmass Andritz Private Limited Design, manufacture, supply and service of

IV Floor, Guna Building Annexe Recovery boilers
New No. 443, Old No. 304 Falling film evaporators
Anna Salai Chennai – 600 018 Lime kilns
Tel. : 044 – 24338050/ 51 Recausticizers
Fax : 044 – 24322412 Desilication plant
Email : eal@vsnl.com
Web :
Kvaerner Pulping S.A. (Pty) Ltd Supplier of machines and systems to

Postnet Suite 235, Private Bag X504 chemical and recycled pulp industries
Northway 4065, Durban Republic Supplier of pollution control systems
South Africa ZA and specialised process technology
Tel. : +27 (0) 31 303 8940
Fax : +27 (0) 31 303 8949
Email : akerkvaerner@mweb.co.za
Web : www.akerkvaerner.com/fiberline
Mechano Paper Machines Ltd. Total solutions for pulp & paper
New Jessore Road Ganganagar machines
Kolkatta – 700 132
Tel. : 033 – 2538 3744
Fax : 033 – 2538 4952
Sulzer Pumps India Limited All types of centrifugal pumps

No.9, MIDCThane-Belapur Road, MC pumps
DighaNavi Mumbai – 400 708 Wear resistant pumps
Tel. : 022 – 55904321 Acid resistant pumps
Fax : 022 – 55904302
Web : www.sulzerpumps.com
Hindustan Dorr-Oliver Limited Pulp & paper mill equipment

Dorr-Oliver House Chakala, Liquid-solid separation
Andheri East Mumbai – 400 099 Environmental pollution control
Tel. : 022 – 2832 5541, 2832 6416/ 17/18 Water treatment
Fax : 022 – 2836 5659
Email : hdoho@hind-dorroliver.com

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The Eimco-KCP Limited Solids-liquid separation equipment like

Ramakrishna Buildings rotary vacuum filters, thickeners, clarifiers,
239, Anna Salai Chennai – 600 006 classifiers etc.
Tel. : 044 - 28555171 Water & waste water treatment plants
Fax : 044 – 28555863
Email: ekcp@md2.vsnl.net.in
Web : www.ekcp.com
FFE Minerals India Limited Material handling systems

FFE Towers, 27 G N Chetty Road Classification, filtration and
T Nagar Chennai – 600 017 thickening technologies
Tel. : 044 – 28220801/ 02, 28252840/ 44 Crushing and grinding
Fax : 044 – 28220803 Calcination, roasting, sintering, drying
Email : ffem@ffegroup.co.in
Alfa Laval India Ltd. Evaporators

Mumbai -Pune Road
Dapodi Pune - 411 012
Tel. : (020) - 24116100 / 27107100
Email : neeru.pant@alfalaval.com
Web : www.alfalaval.co.in
Contact : Mr Neeru Pant
Johnson India Steam engineering and consultancy

3, Abirami Nagar, G.N. Mills Post
Coimbatore – 641 029
Tel. : 0422 - 2442692
Fax : 0422 - 2456177
email: info@jsea.com.au
Elof Hansson (India) Pvt. Ltd. Paper plant machinery

Old No.11, New No.23, II Main Road Paper plant Chemicals
R A Puram Chennai – 600 028
Tel. : 044 - 24617901/ 902/ 903/ 904
Fax : 044 – 24617907/ 908
Email : elofin@vsnl.com
Pap-Tech Engineers & Associates Controls for paper machine pH, Flat
R-22/301, Khaneja Complex box vacuum, Couch pit, Dry end pulper
Main Market, Shakarpur and Refiner
New Delhi – 110 092 Consistency control
Tel. : 011 – 22232003, 22219130 QCS/PLC/SCADA automation
Fax: 022 – 22219130, 22422664 Basis weight control valve package
Email : sales@paptechinstruments.com Cascade control of steam & condensate
Web : www.paptechinstruments.com
Ruby Macons Limited Screening equipment

789/4, III Phase Road, GIDC
Vapi – 396 195
Tel. : 0260 – 2410901 to 908
Fax : 0260 – 2410910
Email : dnh@rubymacons.com
Web : www.rubymacons.com
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Rhetoric Technologies (P) Ltd. Turnkey projects

R-22/301, Khaneja Complex Suction pick-up roll cum press roll
Main Market, Shakarpur internals for bi-nip
New Delhi – 110 092 Auto guide for felt and wire
Tel. : 011 – 22232003, 22219130
Fax : 022 – 22219130, 22422664
Email : sales@paptechinstruments.com
Web : www.paptechinstruments.com
Porritts & Spencer (Asia) Ltd. Complete range of paper

113/114 A, Sector 24 machine clothing
Faridabad – 121 005
Tel. : 0129 - 25233721/ 22/ 23
Fax : 0129 – 25234424
Email : psa@porrittsandspencerasia.com
Parason Machinery (I) Pvt. Ltd. Stock preparation equipment

”Parasons House”, Venkatesh Nagar and systems
Opp. Jalna Road Hi-consistency pulper
Aurangabad – 431 001 Forming machine
Tel. : 0240 – 2339234/ 35/ 36/ 37
Fax : 0240 – 2332944
Email : parason_agd@sancharnet.in
Web : www.parasonmachinery.com
Ambica Paper Machineries Centri-cleaner system

7, Karunasagar Estate High density cleaner
Opp. Anil Starhc Prod. Ltd., Shower pipes & nozzles
Anil Road Ahmedabad – 380 025 Oscillating showers
Tel. : 079 - 22201089, 22201298
Fax : 079 – 22202668
Email : ampprmacad1@sancharnet.in
Web : www.ambicamachineries.com
Swetha Engineering Limited Drum chippers, chip screens, rechippers

121 – 133, Tass Industrial Estate Digesters, Blow tanks, Liquor preheaters
Ambattur Chennai – 600 098 Blow heat recovery system
Tel. : 044 - 26252191/ 3191 Screw presses
Fax : 044 – 26250836 UTM pulpers
Email : swethaengg@satyam.net.in Agitators Multi effect evaporators
Indo Gears and Machinery (India) Tri Disc refiners

48, New Arya NagarChowk Meerut Road
Ghaziabad – 201 001
Telfax : 0120 – 22714877

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Nash Water Technology Private Limited

67-UPS, Lake RoadKaggadaspura Extn.
C V Raman Nagar Bangalore - 560 093
Tel. : 080 – 25246374
Fax : 080 – 25246445
Nash International Company Water ring vacuum pumps

No. 1 Gul Link Singapore 629371
Rep. of Singapore
Tel. : (65) 861 6801
Fax : (65) 861 5091
Email : sales@nasheng.com
Web : www.nasheng.com
PPI Pumps Pvt. Ltd. Water ring vacuum pumps

4/2, Phase 1, GIDC Estate, Vatva
Ahmedabad – 382445
Tel. : 079 – 25832273/4, 25835698
Fax : 079 – 25830578
Email : sales@prashant-ppi.com
Web : www.prashant-ppi.com
Dandy Rolls India Pvt. Ltd. Dandy rolls

A – 179, 4th Cross, I Stage Industrial Estate, Auto guides
Peenya Bangalore – 560008
Tel. : 080 - 28394381
Fax : 080 -28398112
SWIL Limited Dandy rolls & brackets

27 –A, Camac Street Kolkkata – 700 016 Shower systems
Tel. : 033 - 22473375 to 78 Synthetic fabric clothing
Fax : 033 – 22473378 Metallic wire cloth
Gala Equipment Limited Vibro-screens

A-59, Road No.10 Wagle Industrial Area
Thane – 400 604
Tel. : 022 – 25820746/ 8934, 25800252
Fax : 022 – 25820771
Web : www.galagroup.com
Lathia Rubber Mfg. Company Pvt. Ltd. Blind drilled rolls

Saki Naka, Kurla-Andheri Road Industrial rubber/ ebonite rollers
Mumbai – 400 072
Tel. : 022 – 28519140
Fax : 022 – 28513797

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10.0 List of Consultants
Indian Companies v Project consultancy in paper plants &

SPB Projects and Consultancy Limited power plants
Esvin House, Perungudi v Management services
Chennai – 600 096
Tel. : 044 – 24961056/ 1079/ 0359
Fax : 044 – 24961625
Email : spbpc@md1.vsnl.net.in
TCE Consulting Engineers Limited v Preliminary planning

Tata Press Building v Detailed project reports
414, Veer Savarkar Marg v Basic and detailed engineering
Mumbai – 400 025 v Procurement, inspection & expediting
Tel. : 022 - 24374374, 24302419 v Project management
Fax : 022 – 24374402 v Construction supervision
Email : mgy@worli.tce.co.in v Assistance in start-up testing and
Web : www.tce.co.in commissioning
Contact : Mr M G Yagneshwara
Group Commercial Manager
Development Consultants Limited v Preliminary planning and surveying

24-B, Park Street Kolkata - 700016 v Detailed project reports
Tel. : 033 - 22267601, 22497603 v Basic and detailed engineering
Fax : 033 - 22492340/3338 v Procurement, inspection & expediting
Email : dcl@dclgroup.com v Project construction and management
v Structural engineering
v Technical management
Engineers India Limited v Preliminary planning

Engineers India Bhavan v Detailed project reports
1, Bhikaji Cama Place New Delhi – 110 066 v Basic and detailed engineering
Tel. : 011 - 26186732, 26102121 v Procurement, inspection & expediting
Fax : 011 – 26194760, 26178210 v Project management
Email : gupta.dk@eil.co.in
Web : www.engineersindia.com
Contact : Mr D K Gupta, General Manager – Mktg.
UHDE India Limited v Preliminary planning

UHDE House, LBS Marg v Detailed project reports
Vikhroli (W) Mumbai – 400 083 v Basic and detailed engineering
Tel. : 022 - 25783701, 25968000
Fax : 022 – 25784327
Email : uhdein@vsnl.com
Web : www.uhdeindia.com

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Kvaerner Pulping Pte. Ltd. v Providing engineering, design, fabrication

152 Beach Road #24-02/04 and project management services for
Gateway East Singapore 189721 • Fiberlines
Tel. : +65 6392 8500 • Recovery boilers • Power boilers
Fax : +65 6392 8511
Email : akerkvaerner@mweb.co.za
Web : www.akerkvaerner.com/fiberline
Chellam Project Consultancy and • Comprehensive consultancy services to

Technical Services Pvt. Ltd. pulp & paper industry
46, Krishna Complex, 4th Floor
Chevalier Sivaji Ganesan Road
T Nagar Chennai – 600 017
Tel. : 044 – 2430698/4491
Email : chellam@vsnl.com
International Companies • Project consultancy in paper plants &

Jaako Poyry OYP O Box 4, power plants
Jaakonkatu 3FIN – 01621 VANTAA Management services
Finland
Tel. : +358 – 9 – 89471/89472678
Fax : +358 – 9 – 8781818
Email : ari.runsten@poyry.fi
Contact : Mr Ari Runsten, Sr. Process Engr.
Pulping Process Dept.
AMEC Simons Forest Industry Consulting • Project consultancy in paper plants

111 Dunsmuir St, Suite 400
Vancouver, BCCanada, V6R 1R3
Tel. : 1- 604 – 6644402
Fax : 1- 604 – 6645381
E-Mail: phil.crawford@amec.com
Contact : Mr Phil Crawford, VP & GM
Forest Industry Consulting • Project consultancy in paper plants

Metso PaperSE – 85194
Sundsvall Sweden
Tel. : +46 – 60 – 1650 00 / 1651 77
Fax : +46 – 60 – 165500
Mobile : +46 – 70 – 653 3801
Email : yngve.lundahl@metso.com
Contact : Mr Yngve Lundahl
Regional Sales Manager - Fiberline

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EKONO Inc. • Project consultancy in paper plants

11061 NE 2nd Suite 107, Bellevue
WA 98004
Tel. : (425) 455 5969
Fax : (425) 455 3091
E-mail : ekono@ekono.com
Associated Professional Engineering • Engineering services

Consultants, Inc. (APEC) • Professional services
865 West Central Avenue • Consulting services
Springboro Ohio 45066 – 1115 • Feasibility studies
Tel. : 937 - 746 - 4600 • Scope developments
Fax : 937 - 746 – 5569 • Capital cost estimates
Email : ostberg.rh@apec.com • Construction progress monitoring
Contact : Mr. Richard Ostberg, President • Start-up assistance
• Extensive work in Pulp Mills, De-inking,
Fiber Preparation Systems, Paper Machine,
Utilities and Coating
Tavistock International • Mill management

Le Rondrais, 56350 Allaire France • Start-up assistance
Tel. : +33 (0)2 99 71 8069 • Integrated solutions
Fax : +33 (0)2 99 71 8069 • Non-wood speciality know-how
Email : TAVISTOCK.INT@wanadoo.fr • Feasibility studies
Voith Paper Holding GmbH & Co. KG

Corporate Marketing St.
Pöltener Str. 43D-89522
Heidenheim Germany
Tel. : +49 73 21 37-64 05
Fax : +49 73 21 37-70 08
Email : info.voithpaper@voith.com
Web : www.voith.com

Energy Conservation in Fertilizer
310
Fertilizers
Energy saving potential 2000 million (USD 40 million)
energy saving projects 6000 million (USD 120 million)

311
1.0 Introduction
Agriculture accounts for a third of India’s national income. The agricultural sector provides
direct employment to over 70% of the country’s population.
The issues of productivity and growth of agriculture are important indicators of the economic
growth of any country. Fertilizers play a key role in improving crop yield and hence are integral
to modern farming.
Growth in chemical fertilizer production and consumption therefore presents the single largest
contributor to agricultural progress, its technological transformation and commercialization.
2.0 About Fertilizer

The main primary nutrients that deplete with successive cropping are nitrogen (N), phosphorus
(P) and potassium (K). Fertilizers supplement the natural deficiency as well as the depletion
of nutrients.
Nitrogen is primarily provided by nitrogenous fertilizers, such as, urea (46%N) or ammonia
fertilizers, e.g. ammonium sulfate (20.6%N). Further shares of nitrogen are contained in
complex fertilizers that combine all three-plant nutrients (NPK).
Phosphate comes in the form of straight phosphatic fertilizers, such as, single super phosphate
(16%P2O5) or as part of a complex fertilizer. Potassic fertilizer is available as straight potassic
fertilizer, such as muriate of potash (60%K2O) or sulfate of potash (50%K2O) or as a complex
NPK fertilizer component.
3.0 Types of fertilizers

The key fertilizers used in India are:
Urea supplies around 83% of the total nitrogen requirements. It is manufactured from ammonia
in an energy intensive process. Natural gas is the preferred feedstock as it results in low
variable cost compared to naphtha. At present, only 50% of the total domestic capacity is gas-
based, about 30% is based on naphtha and rest on fuel, oil and coal.
Single super phosphate supplies 19% of the total phosphatic nutrients. It is manufactured by
treating rock phosphate with sulphuric acid and calcium. Both rock phosphate and sulphur are
imported.
Di-ammonium phosphate meets 50% of phosphatic and 8% of nitrogenous nutrients. Rock

phosphate is the main feedstock. Phosphoric acid is manufactured by treating rock phosphate
with sulphuric acid. It is then reacted with ammonia to manufacture DAP.
The integrated manufacturers have their own ammonia, phosphoric acid and sulphuric acid
plants, while sulphur and rock phosphate are imported.
Potassium fertilizers are not manufactured in India due to the non-availability of the basic
feedstock. Muriate of potash (MOP) is imported from countries like Canada, Jordan and
Germany.
Urea being the most affordable fertilizer, dominates the nitrogenous fertilizers, constituting
more than 80% of consumption. DAP is the dominant phosphatic fertilizer accounting for 58%

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of consumption, followed by SSP with a 20% share. During the year 2001-2002, the NPK ratio
deteriorated to 8.5:3.1:1 from 7.9:2.9:1 in 2000-2001.
4.0 Growth of Fertilizer Industry

Agricultural growth is mainly dependent on advances in farming technologies and increased
use of chemical fertilizers.
4.1 World Scenario

The capacity and production (in thousand tones of nutrients) of Nitrogen, Phosphate and
potash nutrients in the world are as follows:
Nitrogen Phosphate Potash
Capacity Production Capacity Production Production
125721 84616 40259 31704 25541
The world ammonia productions, increased by about 5% in 2002, while the world urea production
increased by about 4%.
The average per capita consumption of fertilizer is about 22.1 kg and 91.1 kg/ha.
4.2 Indian Scenario
4.2.1 Installed capacity

The first fertilizer-manufacturing unit was set up in 1906 at Ranipet near Chennai with a
production capacity of 6000 MT of Single Super Phosphate per annum. The 80’s witnessed
a significant addition to the fertilizer production capacity.
India is presently the second largest Nitrogeneous fertilizer manufacturer and third
largest Phosphatic Fertilizer manufacturer in the world, accounting for almost 10.9%
and 3.8% of the world production, respectively.
The present installed capacity of fertilizer production in India is about 120 lakh MT of
nitrogen and 51.37 lakh MT of phosphate nutrients.
In future, demand is expected to grow at a compound annual growth rate (CAGR) of

4%.
4.2.2 Capacity Utilization

External factors, such as, weather and monsoon conditions, as well as policy changes regarding
fertilizer production, use and agricultural output enhancement exert significant influence on
capacity utilization in the industry.
Against this background, there has been an overall improvement in the levels of capacity
utilization over the years. During 1999-2000, the capacity utilization was 100.7% in the case
of nitrogeneous and 94.0% in the case of phosphatic fertilizer plants.

313
The capacity utilization of the fertilizer industry is expected to improve as more modern plants
based on proven technology and equipment go on stream.
The existing plants in the private, public and co-operative sectors are improving their capacity
utilization, through revamping & modernisation and incorporation of dual fuel/ feedstock facilities,
wherever feasible.
4.2.3 Per Capita Consumption

The per capita consumption of fertilizer in India, which was a meager 1 kg in the early 50’s,
has increased substantially to about 16.3 kg in 2000-2001.
The per capita fertilizer consumption in different countries is highlighted in the table below:
Country Fertilizer Fertilizer

Consumption Consumption
(per capita) (kg/ha)
India 16.3 98.4
China 26.6 254.2
Japan 11.4 301.0
Egypt 18.4 385.8
Bangladesh 9.4 156.3
Pakistan 20.5 135.1
France 69.7 211.7
Russian Fedn. 9.8 11.2
UK 28.5 285.8
USA 64.7 103.4
World 22.2 91.1
Source FAI
5.0 Profile of Manufacturing Units

At present, there are 64 large size fertilizer units in the country, manufacturing a wide range
of nitrogenous and phosphatic/ complex fertilizers.
Of these, 39 units produce urea, 18 units produce DAP and 7 units produce ammonium
sulphate as a by-product. Besides, there are about 79 small and medium scale units producing
single superphosphate.
The fertilizer industries are categorised under public sector, cooperative sector and private
sector. The public sector units account for about 47% of the total installed capacity in fertilizer
industry in India. The private sector accounts for about 36% and the co-operative sector for
the remaining 17%.

314
While most of the nitrogenous fertilizer production capacity can be found in the public sector,
phosphatic fertilizer capacity is mainly installed in the private sector.
The table below highlights the sector wise installed capacity of fertilizer plants in India.
Sector Installed Capacity (‘000’MT)
Quantity N P
Public 12390.6 4319.8 827.0
Cooperative 6200.0 2348.4 519.2
Private 17589.6 4402.9 2301.7
Total 36180.2 11071.0 3647.9
5.1 Distribution of Manufacturing Units

The plants are located all over India. Also, the consumption of chemical fertilizers in the
country is unevenly distributed, being much higher in regions with assured irrigation.
The region-wise break-up of number of industries and capacity is highlighted below:
Nitrogeneous Fertilizers Phosphatic Fertilizers
Region Numbers % share to Numbers % share to

overall capacity overall capacity
East 10 4.00 6 29.86

West 15 45.72 43 41.97
South 12 1740 11 25.12
North 9 32.88 13 3.05
Total 46 100.0 73 100.0
5.2 Major players in India

The major fertilizer nitrogeneous and phosphatic fertilizer industries in India, are given below:
5.2.1 Nitrogeneous Fertilizer Units

• BVFCL, Namrup III ( Assam)
• CFL Vizag ( AP)
• Chambal Fert Garde, Kota ( Raj)
• Cyanides & Chemicals Surat ( Gujarat)
• Deepak Fert; Osers & Petro Chemicals Corpn. Taloja ( Maha)
• Duncans Industries ( Fomerly ICI India and later Chand Chhap Fert)
• EID Parry ( India) Ennore ( TN)
• FACT

315
a) Alwaye (Kerela)
b) Ambalamedu Cochin I (Kerala)
c) Ambalamedu Cochin II (Kerala)
• FCI Sindri (Jharkhand)
• Godavari Fertilisers & Chemicals, Kakinada ( AP)
• GNFC, Bharuch ( Gujarat)
• GSFC
a) Vadodara (Gujarat)
b) Vadpdara (Gujarat) Polymer Unit
c) Sikkar I (Gujarat)
• HLCL Haldia ( West Bengal)
• IFFCO
a) Kalol (Gujarat)
b) Kandla ( Gujarat)
c) Pulpur ( UP)
d) Aonla(UP)
• Indo Gulf Corpn. (Unit: Fertilisers) Pvt

a) Jagadishpur (UP)
b) Dahej( Gujarat)
c) KRISBHO, Hazira (Gujarat) 2 plants
d) MFL Manali ( TN)
e) MCFL, Mangalore ( Karnataka)
f) Nagarjuna Fetilizers & Chemicals, Kakinada ( AP)
NFL
a) Bhatinda ( Punjab)
b) Nangal I & II ( Punjab)
c) Panipat ( Haryana)
d) Vijaipur ( MP)
e) NLC, Neyveli ( TN)
Oswal Chemicals& Fertilisers

a) shajahanpur(UP)
b) Pradeep (Orissa)
Punjab National Fertilisers & Chemicals, Naya Nangal ( Punjab)
RCFL:
a) Thal Vaishet ( Maha) 2 plants
b) Trobay ItoIV (Maha)
Trombay V ( Maha)
Rashtriya Ispat Nigam, Visakhapatnam( AP)
SAIL
a) Bhilai ( Chattisgargh)

316
b) Bokaro ( Jharkhand)
c) Durgapur( WB)
d) IISCO, Burnpur –Kulti( WB)
e) Rourkela ( Orissa)
f) Rourkela ( Fert. Plant Orisa)
g) SFC, Kota ( Rajasthan)
SPIC, Tuticorin( TN)
Tata Chemicals Babrala( UP)
Tuticoring alkali Chemicals & Fertilisers, Tuticorin(TN)
ZIL, Zurai Nagar (Goa)
Under Implementation
BVFCL, Namrup II ( Assam) Revamp (Pun)
BVFCL, Namrup III ( Assam) Revamp ( Pun)
Gujarat State Fertilisers & Chemicals pvt Sikka II ( Gujarat)
Under Consideration
IFFCO, Nellore ( Andhra Pradesh)
KRIBHCO, a) Hazira, Phase II Guj) b) Gorakhpur ( UP)
RCFL,Thal Vaishet ( Maharashtra )III Stage
ICS Senegal
ICS, Senegal ( Expn)
Indo Jordan Chemicals Co
Indo Maroc Phosphore S A
SPIC Fert Chem Ltd
Oman India Fert. Co
5.2.2 Phosphatic Fertilizer Units

Andhra Sugars, Tanuku, W Godavari ( AP)
Arawali Phosphate, Umra, Udaipu (Raj)
Arihant Fertilisers & chemicals, Neemuch ( MP)
Arihand Phosphate & Fertilizers, Nimbaheda, Chittorgarh ( Raj)
Asha Phosphate, Jaggakhedi, Mandsaur ( MP)
Asian Fertilizers, Gorakhpur ( UP)
Basant Agro Tech ( India) Akola ( Mah)
BEC Fertilisers ( Unit of Bhilai Engg. Corpn. Ltd)
a) Bilaspur, (Chhattisgarh)
b) Pulgaon, Wardha, (Maj)
Bharat Fertilisers Industries ( Maharashtra) Kharivali, Thane ( Mah)
Bohra Industries Umra, udaipur (Raj)
Chemtech Fertilizers, Kazipalli, Medak ( AP)
Coimbatore Pioneer Fertilizers, Coimbatore ( TN)
Dharamsi Morarji Chemicals Co., Ambernath ( Mah)
Dharamsi Morarji Co., Kumhari ( Chhattisgarh)
Dharamsi Morarji Chemicals Co Amreli (Guj)

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Dharmsi Morarji Chemicals Co., Khemli ( Raj)

EID Parry (India) Ranipet ( TN)
Gayatri Spinners, Hamirgarh ( Raj)
HSB Agro Industries, Shahpur, Dist Hoshipur (PB)
Hind Lever Chemicals Ltd Haldia( WB)
Jairam Phosphates, Gudichiroli ( Mah)
Jayshree Chemicals & Fertiliser Khardah ( WB)
Jayshree Chemicals & Fertilizers Unit III Pataudi ( Haryana)
Jubilant Organosya Gajraula ( UP)
Kashi Urvarak, Jagadishpur Sultanpur ( UP)
Khaitan Chemicals & Fertilizers Nimrani, Khargone ( MP)
Khaitan Fertilizers, Rampur
Kothari Industrial Corporation Ennore (TN)
Krishna Industrial Corporation, Nidadavole (AP)
Liberty Phosphate
a) Madri Udaipur ( Raj)
b) Vadodara (Guj)
Madhya Bharat Agro products, Sagar ( MP)
Madhya Pradesh Orgochem, neemuch, Nayagaon ( MP)
Mahadeo Fertilizers fatehpur ( UP)
Maharastra Agro industrial development panvel ( mah)
Mangalam phosphates, hamirgarh, bhilwara ( Raj)
Mardia Chemicals Surendra Nagar ( Gujarat)
Mexican Phosphates Nimrani, Khargone ( MP0
Mukteswar Fertilizers, Narayankhedi, Ujjain (MP)
Narmada Agro Chemicalst, Junagadh( Guj)
Nirma Limited, Moralya (Guj)
Natraj Organics Muzaffarnagar( UP)
Oriental Carbon & Chemicals, Dharunhera( Har)
Phosphate Co, Rishra ( WB)
Pragati Fertilizers Vizag( AP)
Prem Shakhi Fertilizers, lakadwas, Udaipur ( Raj)
Prathyusha Chems and Fertilisers, Visakhapatnam (AP)
Priyanka Fertilizers & Chemicals, Anakapalli, Visakhapatnam ( AP)
Rajalaxmi Agrotech, Jalna ( Mahrastra)
Raashi Fertilizers Lakhmpur, Nasik ( Mah)
Rama krishi Rasayan, Lkoni Kalbhor ( Mah)
Rama Phosphates, Indore ( MP)
Rama Phosphates Udaipur (Raj)
Ravi Pesticides Bijnaur (UP)
Rewathi Minerals and Chemicals, Hirapur, Sagar ( MP)
Sadana Phosphates & Chem. Udaipur (Raj)
Shiva Fert. Nanded ( Mah)
Shree Acids & Chemicals Gajraula ( UP)
Shreej Phosphate, Kallipura, Jhabua ( MP)
Shri Bhavani Mishra Fertilizers Nanded ( Mah)

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Shri Ganpati Fetilizers, Muzaffarpur ( Bihar)

Sona Phosphates Sarigam, Valsad ( Guj)
Shurvi Colour Chem ( Raj)
Swastik Fetilizers, jhansi ( UP)
Sri Durga Bansal, Faizabad ( UP)
Subhodaya Chems, Gauri Patnam ( AP)
Teesta Agro Ind ( Fromely Suderban Fert. And Chem) Jalpaiguri ( WB)
TEDCO Granites, Bhilwar (Raj)
Tungabhadra Ferts. Chems Koppal Hospet (Karnataka)
6.0 Raw Material Profile
6.1 Nitrogeneous fertilizers

Domestic raw materials are available only for nitrogenous fertilizers. For the production of
urea and other ammonia-based fertilizers, methane is the major input.
Methane is obtained from natural gas/ associated gas, naphtha, fuel oil, low sulfur heavy
stock (LSHS) and coal.
Of late, production has switched over to use of natural gas, associated gas and naphtha as
feedstock. Out of these, associated gas is most hydrogen rich and easiest to process, due
to its lighter weight and fair abundance within the country.
However, demand for gas is quite competitive since it serves as a major input to electricity
generation and provides the preferred fuel input to many other industrial processes.
6.2 Phosphatic fertilizers

For production of phosphatic fertilizers, most of the raw materials have to be imported. India
has no source of elemental sulfur, phosphoric acid and rock phosphate.
Some low-grade rock phosphate is domestically mined and made available to rather small-
scale single super phosphate fertilizer producers.
Sulfur is produced as a by-product by some of the petroleum and steel industries.
7.0 Process description

The basic raw material for the production of nitrogenous fertilizers is ammonia, for straight
phosphatic fertilizers, phosphate and for potassic fertilizers, potash. Out of the three fertilizer
types, production of ammonia is most energy and resources intensive.
7.1 Ammonia production

The most important step in producing ammonia (NH3) is the production of hydrogen, which
is followed by the reaction between hydrogen and nitrogen. A number of processes are
available to produce hydrogen, differing primarily in type of feedstock used.

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The hydrogen production route predominantly used worldwide is steam reforming of natural
gas. In this process, natural gas (CH4) is mixed with water (steam) and air to produce
hydrogen (H2), carbon monoxide (CO) and carbon dioxide (CO2).
Waste heat is used for preheating and steam production, and part of the methane is burnt to
generate the energy required to drive the reaction. CO is further converted to CO2 and H2
using the water gas shift reaction. After CO and CO2 is removed from the gas mixture
ammonia (NH3) is obtained by synthesis reaction.
Another route to produce ammonia is through partial oxidation. This process requires more
energy (up to 40-50% more) and is more expensive than steam reforming. The advantage of
partial oxidation is high feedstock flexibility: it can be used for any gaseous, liquid or solid
hydrocarbon.
In practice partial oxidation can be economically viable if used for conversion of relatively
cheap raw materials like oil residues or coal.
In the partial oxidation process, air is distilled to produce oxygen for the oxidation step. A
mixture containing among others H2, CO, CO2 and CH4 is formed.
After desulfurization CO is converted to CO2 and H2O. CO2 is removed, and the gas mixture
is washed with liquid nitrogen (obtained from the distillation of air). The nitrogen removes CO
from the gas mixture and simultaneously provides the nitrogen required for the ammonia
synthesis reaction.
7.2 Nitogeneous fertilizers

A variety of nitrogenous fertilizers can be produced on the base of ammonia. Ammonia can
be used in a reaction with carbon dioxide to produce urea.
Ammonia nitrate can be produced through the combination of ammonia and nitric acid adding
further energy in form of steam and electricity.
Other fertilizer types produced on the base of ammonia include calcium ammonium nitrate
(ammonium nitrate mixed with ground dolomite) and NP/NPK compound fertilizers.
7.3 Phosphatic fertilizers

Phosphatic fertilizers are produced on the basis of phosphoric and sulfuric acids. Phosphoric
acid is produced, by the leaching of phosphate rock, with sulfuric acid. Sulfuric acid very often
remains as a waste product of the chemical industry.
7.4 Potash fertilizers

Potash fertilizers are produced from sylvinite salt. Sylvinite is diluted in a circulation fluid in
the flotation process. The potash fertilizer is separated, by skimming the solution.

The fertilizer industry is one of the major consumers of hydrocarbons. The fertilizer sector
accounts for 8.0% of total fuels consumed in the manufacturing sector.

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Energy costs account for nearly 60% of the overall manufacturing cost.
The absolute energy consumption by this sector has been estimated at 112 million
Giga calories.
The specific energy consumption per ton of urea varies between 5.79 Giga calories for
the most efficiently operating plant to 13 Giga calories for the most inefficient plant.
Energy intensity in India’s fertilizer plants has decreased over time. This decrease is
due to advances in process technology and catalysts, better stream sizes of urea
plants and increased capacity utilization.
8.1 Types of fuel used

Energy is consumed in the form of natural gas, associated gas, naphtha, fuel oil, low sulfur
heavy stock and coal for process. LDO, LSHS, HFO and HSD are also used in diesel
generators.
Large fertilizer plants generate part of their own power through cogeneration mode in TG sets,
while smaller plants depend exclusively on purchased power or power from DG sets.
With the ever-increasing fuel prices and power tariffs, energy conservation is strongly pursued
as one of the attractive options for improving the profitability in the Indian pulp and paper
industry.
8.1.1 Nitrogeneous fertilizers

Production of ammonia has greatest impact on energy use in fertilizer production. It accounts
for 80% of the energy consumption for nitrogenous fertilizer.
The feedstock mix used for ammonia production has changed over the last decade. The
choice of the feedstock is dependent on the availability of feedstock and the plant location.
The shares of feedstocks in ammonia production are as follows:
Feedstock 1980-1990 1990-2000
Natural Gas 54.2% 52%
Naptha 26.1% 19%
Fuel oil 18.2% -
Coke oven gas - 19%
Coal 1.5% 10%
The shift towards the increased use of natural/associated gas and naphtha is beneficial in that
these feedstocks are more efficient and less polluting than heavy fuels like fuel oil and coal.
Furthermore, capacity utilization in gas based plants is generally higher than in other plants.
Therefore, gas and naphtha are the preferred feedstocks for nitrogenous fertilizer production.

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8.1.2 Phosphatic fertilizers

The production of phosphatic fertilizer requires much less energy than nitrogenous fertilizer.
Depending on the fertilizer product, energy consumption varied from negative input for sulfuric
acid to around 1.64 GJ/tonne of fertilizer for phosphoric acid.
For sulfuric acid the energy input is negative since more steam (in energy equivalents) is
generated in waste heat boilers than is needed as an input.
8.3 Specific energy consumption

The specific energy consumption comparison of Indian fertilizer industry is as follows:
Parameter Units Indian Norms
Ammonia (incl. Off site energy)

For Naptha based G Cal/ MT 11.40
For Natural gas based G Cal/ MT 9.33
Urea
For Naptha based G Cal/ MT 8.32
For Natural gas based G Cal/ MT 6.84
9.0 Energy Saving Potential

The various energy conservation studies conducted by the CII – Energy Management Cell and
feedback received from the various industries through questionnaire survey and plant visits,
indicate an energy savings potential of 10% of the total energy use.
This is equivalent to an annual savings potential of about Rs.2000 million.
The estimated investment required to realize this savings potential is Rs.6000 million, with a
payback time of three years, depending on scale of operations and technology.
The fertilizer industry has an attractive cogeneration potential of atleast 100 MW, in addition
to the existing cogeneration plants.
9.1 Major factors that affect energy consumption in fertilizer units

The major factors that affect energy consumption in the Indian fertilizer industry are as
follows:
• Age of plant
• Technology used
• Capacity of plant
• Level of capacity utilisation
- Weather and monsoon conditions
- Use and agricultural output

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- Policy changes regarding fertilizer production
• Availability, storage and transportation
- Raw materials
• Finished products
• Availability, choice and cost of feedstock/ fuels
• Location of plant
• Reduction in raw material consumption
• Reduction in utility consumption
• Environmental impact abatement systems
• Level of safety and reliability controls
• Number and multiplicity of machinery
• Boiler type & pressure levels
• Level of cogeneration power generation
• Levels of instrumentation
• Extent of utilisation of variable speed drives, such as, variable frequency drives (VFD),
variable fluid couplings (VFC), DC drives, dyno-drives etc.
These are the various major factors, which affect the specific energy consumption in fertilizer
plants.
10.0 Energy saving schemes

An exhaustive list of all possible energy saving projects in the fertilizer industry is given below.
The projects have been categorised under short-term, medium term and capital-intensive
projects.
The projects which have very low or marginal investments and have an energy saving potential
of upto 5% has been categorised as short-term. The projects which require some capital -
investment having a simple payback period of less than 24 months and having an energy
saving potential of upto 10% has been categorised as medium-term.
and contribute significantly to improving the competitiveness of the fertilizer industry. However,
these projects require very high capital-investment and hence has been categorised separately.

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10.1 List of all possible energy conservation projects in a fertilizer plant
10.1.1House-Keeping Measures – Energy Savings Potential of 5%

A. Process areas
1. Avoid idle running of equipment, like conveyors and bag filters, by installing simple interlocks.
2. Providing timer control for agitators for sequential operation
3. Ensure optimum loading of all equipment
4. Avoid fresh water use for condensers, wherever possible, by maximizing use of recycled
water
5. Optimise fresh water consumption in process areas
6. Avoiding pump operation by utilisation of gravity head
7. Optimising excess capacity/ head in pumps by change of impeller or trimming of impeller
size
8. Optimising excess capacity/ head in fans/ blowers by RPM reduction or change of impeller
9. Optimise capacity of vacuum pumps by RPM reduction
B. Steam, Condensate Systems and Cogeneration

1. Monitor excess air levels in boilers and hot air generators
2. Arrest air infiltration in boiler flue gas path, particularly economiser and air preheater
section
3. Plug steam leakages, however small they may be
4. Always avoid steam pressure reduction through PRVs. Instead, pass the steam through
turbine so as to improve cogeneration
7. Monitor boiler blow down; use Eloguard for optimising boiler blow down
8. Monitor the blow-down quantity of water in cooling towers and the quality of water
C. Electrical Areas

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D. Miscellaneous
2. Optimise the pressure setting of the compressor, closely matching the requirement
5. Install level indictor controllers to maintain level in tanks
6. Install hour meters on all material handling equipment
10.1.2 Medium term Measures – Energy Savings Potential upto 10%

A. Process areas
1. Install new correct size high efficiency pumps for process pumps, scrubber circulation
pumps, recycled water, DM water and Soft water pumping
2. Install booster pumps for high head cooling water users (if they are only minor users) and
optimise overall head of cooling water pumps
3. Install VSD for process pumps, DM water pumps, soft water pumps, raw water pumps
and condensate transfer pumps
4. Install VSD for raw water, recycle water, effluent discharge and sulphur pumps
5. Optimising the capacity of vacuum pumps by RPM reduction or bleed-in control
6. Optimise the suction line size of water ring vacuum pumps
7. Install pre-separators for water ring vacuum pumps
8. Install new high efficiency fans & blowers in boiler
9. Install new high efficiency blowers for scrubbers in complex plant
10. Install VSD for scrubber blowers in complex plant
11. Mechanical unloading system in raw material handling area
B. Co-Generation, Steam & Condensate Systems

1. Install automatic combustion control system/ oxygen trim control system in steam boilers
and soda recovery boilers
3. Install boiler air preheater based on steam to enhance cogeneration
5. Install automatic blow down system for boilers
6. Install heat recovery from boiler blow down
7. Banking of boilers instead of cold start-up
8. Installation of flash vessels for heat recovery from hot condensate vapours
9. Condensate recovery and rinse water usage in complex plant

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13. Replace dyno-drives with VSD for coal feeder
14. Install chlorine dosing and HCl dosing for circulating water.
15. De-superheating station for low pressure steam users
16. Solar water heating for boiler feed water preheating
17. Installation of automatic debris filter at TG cooling water inlet
C. Electrical Areas
3. Installation of thyristorised rectifiers
5. Install energy efficient motors as a replacement policy
6. Thyristor room AC units provided wit timer control
7. Replace HRC fuses with HN type fuses
8. Replace 40 Watts fluorescent lamps with 36 Watts fluorescent lamps
10. Install SV lamps at wood and coal yard areas instead of MV lamps
13. Installation of neutral compensator in lighting circuit
14. Optimise voltage in lighting circuit by installing servo stabilisers
15. Minimising overall distribution losses, by proper cable sizing and addition of capacitor
banks
16. Replace V-belts with synthetic flat belts
D. Air Compressors
1. Segregate high pressure and low pressure users
2. Replace heater - purge type air dryer with heat of compression (HOC) dryer for capacities
above 500 cfm
E. DG System
1. Use cheaper fuel for high capacity DG sets
2. Increase loading on DG sets (maximum 90%)
3. Increase engine jacket temperature (max. 85°C) or as per engine specification
4. Take turbocharger air inlet from outside engine room
5. Installation of steam coil preheaters for DG set fuel in place of electrical heaters

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F. Miscellaneous
1. Install VFD for AHU fans with feed back control based on return air temperature
2. Install two port control valves for chilled water supply to AHU’s and install VFD for chilled
water pump
3. Install Variable Frequency Drive for ammonia transfer pump in atmosphere ammonia
storage system
4. Floating type aerator in place of fixed aerators
5. High efficiency diffuser aerators instead of conventional aerators
6. Treatment of effluent through activated sludge lagoon resulting in stopping of aerators
7. Use of ETP filter cakes in boilers
8. Solar water heating for canteen and guest house
9. Convert V-belt to flat belt drives
10.1.3 Long term Measures – Energy Savings Potential of 10-15%

1. Maintaining 42 kg/cm2 pressure at reformers outlet with the latest manurite 36M material
for reformer tubes and operating with low S/C ratio
2. Utilization of superior catalysts in reformer
3. Installation of pre-reformer
4. Utilization of latest and active HTS and LTS catalysts for shift conversion
5. Utilization of efficient CO2 removal process
6. Installation of radial flow converters with active catalysts in the synthesis conversion
7. Installation of purge gas recovery systems and Ammonia recovery systems
8. Installation of DCS control systems and process optimiser
9. Installation of modified total recycled process for maximum heat recovery at Urea plant
10. Installation of Urea hydrolyser stripper for reducing Ammonia losses in Urea plant
11. Installation of multi-stage high efficiency turbine in sulphuric acid plant
12. Installation of plate heat exchanger for cooling of sulphuric acid coming from drying tower
13. Installation of mechanical conveying system (Bucket-elevator or pipe conveyor) in place
of pneumatic conveying system for rock phosphate transportation
14. Install conical port high efficiency vacuum pumps in place of flat port vacuum pumps
15. Segregate high-vacuum & low-vacuum sections of the paper machine and connect to
dedicated systems
16. Segregation of high-head and low head users in cooling towers and process areas
17. Replacement of steam ejectors with vacuum pumps to enhance cogeneration
18. Install DCS controls for process automation in sulphuric acid, phosphoric acid and complex
plants
19. Install belt conveyor for conveying ground rock phosphate instead of pneumatic conveyors.
In case of space constraint, install pipe conveyors

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20. Installation of new correct size high efficiency pumps for sea water or raw water intake
21. Improvement of turbo-generator performance
22. Upgradation of utility boiler
23. Installation of waste heat recovery system in the process areas
24. Installation of hydraulic turbine
25. Install vapour absorption system to utilise LP steam and enhance cogeneration
26. Install vapour absorption system based on DG jacket water, if DG is run on a continuous
basis
27. Install steam-generating system from DG exhaust, if DG is run on a continuous basis
28. Installation of DCS monitoring and targetting system for better load management
29. Installation of harmonic filters
30. Replace multiple small size DG sets with bigger DG sets
31. Conversion to low NOx system for one 4 MW DG sets
32. Install Evaporative Condensers For The Atmospheric Ammonia Storage System

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Case Study No.1
Installation of High Efficiency Turbine for Air Blower in

Sulphuric Acid Plant
Background
The sulphuric acid plant generates substantial quantity of heat, which is converted to steam
in the waste heat boiler. The sulphuric acid plant also needs energy for operating equipment,
such as, fans and pumps. One of the major energy consumers is the air blower, which
supplies air at high pressure for burning sulphur in the furnace. The blower is either turbine
driven or motor driven.
Conventionally, the fans were turbine driven and the turbines were of single stage. These
single stage turbines have a low efficiency of 35 to 40 %.
The latest trend is to replace these single stage turbines with high efficiency multi-stage
turbines and reduce the steam consumption.
This project has greater benefits in a plant where there is venting of low pressure steam, as
any efficiency increase of the turbine results in reduction of high-pressure steam generation.
Previous status
In the sulphuric acid plant (1200 TPD capacity) of a huge fertilizer complex, the sulphur
furnace blower was driven by a single stage turbine operating between 35 kg/cm2 and 3.5 kg/
cm2. The turbine had a specific steam consumption of 16.9 tons per MW.
The turbine was consuming about 27 TPH of steam during normal operation. There was also
a mis-match of LP steam generation and requirement, resulting in an average venting of LP
steam (pressure of 3.5 kg/cm2) of about 4 TPH.
The plant also had taken up some modernising schemes to upgrade the capacity of the
sulphuric acid plant. This meant that there will be additional load on the turbine and hence
more venting of LP steam.

The single stage turbine was replaced with a new multi-stage steam turbine of higher efficiency.
The improvement in efficiency was about 15 % resulting in reduction of steam consumption
by about 3 TPH, even when operating at higher load.

The implementation of this project was taken up parallel, during the operation of the plant for
the stand-by fan. During a stoppage of the plant, the fan fitted with the new turbine was put
into service.
The implementation took about 1 month to complete. No problem was encountered during
implementation and subsequent operation of plant.

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The implementation of this project resulted in the saving of about 3 TPH of steam (35 kg/cm2).
Financial analysis
The implementation of this project resulted in an annual saving (@ Rs.400/ MT of steam) of
Rs 9.60 million. The investment made was about Rs 15.00 million, which had a simple
payback period of 19 months.

• Annual Savings - Rs.9.60 millions
• Investment - Rs.15.0 millions

The project has replication potential in all phosphatic fertilizer plants in the country, where, the
blower drive has a single stage turbine and plant has commercial cogeneration.
On a conservative basis, the project can be implemented in atleast 5 fertilizer units in the
country.

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Case Study No.2
Installation of Variable Frequency Drive (VFD) for Sulphur Pump
Background
The phosphatic fertiliser plants use sulphuric acid for reacting with rock phosphate to produce
phosphoric acid. The sulphuric acid is generated from elemental sulphur. The elemental
sulphur is melted and the molten sulphur is pumped to the furnace for oxidation.
The sulphur pump is generally rated for maximum capacity along with a safety margin. The
control normally followed is a re-circulation control, i.e., part of the molten sulphur from the
outlet of the pump is sent back to the melting pit.
The re-circulation method of control is highly energy inefficient as energy is wasted for
pumping extra liquid. The latest energy efficiency method is to install variable frequency drives
and control by varying the speed.
Previous status
In the sulphuric acid plant (1200 TPD capacity) of a huge fertiliser complex, the sulphur pump
was being driven by a steam turbine with inlet steam at 35 kg/cm2.
The pump was of 10.2 m3/h capacity and 265 m head and was being controlled by re-
circulation. Also, the turbine driving the pump was a small one consuming a maximum of
about 0.7 TPH of steam. Since the quantity of steam was less, the exhaust was let out into
the atmosphere.
This was an energy in-efficient system, as the pump was being operated with re-circulation
and the exhaust was also let into the atmosphere.

The steam turbine was replaced with a motor of 22 kW with a variable frequency drive. There
were two pumps and one was operated continuously.
The replacement was done for one of the pumps and other turbine driven pump was kept as
a stand-by. Consequent to the installation of the variable frequency drive, the pump was
controlled by varying the speed to meet the varying process requirement.

The implementation of this project was taken up
parallel during the operation of the plant for the
stand-by pump. During a stoppage of the plant, the
pump fitted with the VFD was put into service.
The implementation took about 1 month to complete.

No problem was encountered during implementation
and subsequent operation of plant.

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The implementation of this project resulted in the saving of about 0.4 TPH of steam. The motor
installed along with VSD was consuming about 15 kW.
Financial analysis
The implementation of this project resulted in a net annual saving (@ Rs.350/ MT of steam)
of Rs 0.75 million. The investment made was about Rs 0.50 million, which had a simple

• ISimple payback - 8 months
The installation of variable frequency drives for various critical applications is well proven. This
project has very good replication potential in several phosphatic fertilizer units, particularly the
smaller plants in the country.

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Case Study No.3
Installation of Right Size Hot Sump Pump
Background
In the phosphatic fertiliser plants, the phosphoric acid is produced from rock phosphate by
reacting with sulphuric acid. Subsequently, the weak phosphoric acid is concentrated in the
concentrators from a concentration of 28 % to 48 – 50 %.
These concentrators are maintained under vacuum with the help of steam ejectors. This
section consumes electrical energy for the cooling water pumps and the hot sump pumps.
These pumps need to be of the right size; otherwise, the pumps have to be operated with
valve throttling to meet the process requirement.
The installation of the right size pumps is therefore essential for operation of the plant at lower
energy consumption.
Previous status
In a fertiliser complex involved in production of complex fertilisers with ammonia plant and
phosphoric acid plant, two hot sump pumps of
1500 m3/h capacity and 25 m head are used for pumping hot water from the sump to the top
of cooling tower.
The motor driving the pump had a rating of 160 kW. The water requirement was around 1700
m3/h. Hence, one of the pumps was operating with the discharge valve throttled.

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The detailed study of the water requirement
indicated that the maximum requirement of hot
water to be pumped is around 1700 m3/h only.
Hence, one of the hot sump pump was replaced
with a smaller pump of capacity 250 m3/h and 30
m head and driven by a motor of 45 kW.
The system is schematically shown in the

diagram.
Consequent to the implementation of this project

the pumps were operated with discharge valve fully open.
Before After
2 pumps of 1500 m3/h capacity 1 pump of 1500 m3/h capacity
One pump with valve throttling 1 pump of 250 m3/h capacity

The implementation of this project was taken up during the operation of the plant. The
implementation took about 4 months to complete.
A pump, which was available in the plant as a spare, was used for this. No problem was
encountered during the implementation and subsequent operation of the plant.

The implementation of this project resulted in the reduction in the power consumed for hot
water pumping. The power consumption reduced by 32 kW, resulting in a saving of 2.5 million
units per year.
Financial analysis
This amounted to an annual monetary saving (@ Rs.3.1/unit) of Rs 0.78 million. As the pump
available in the plant was used for replacement, no significant investment was involved for
implementing this project.
The investment, which would have been made, had the pump been not available is Rs.0.50
million, which will have a simple payback period of 8 months.
The installation of correct size – capacity/ head pumps
find numerous applications in the fertilizer industry. This • Annual Savings - Rs. 0.78 millions
concept can be extended to all the various types of
pumps in a fertilizer industry, namely, raw water pumps,
soft water pumps, DM water pumps, scrubber circulation • Simple payback - 8 months
pumps, effluent water pumps, recycle water pumps etc.
Hence, this project has very high replication potential, with innumerable applications.

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Case Study No.4
Optimisation of Vacuum Pump Operation
Background
The vacuum pumps are used in different sections of the fertiliser plant for creating vacuum.
The choice of the right size of vacuum pump and maintaining of the system without leaks are
essential for achieving energy efficiency.
In the phosphatic fertiliser units, the Aluminium fluoride is produced as a
by-product. In the production of AlF3 , the final slurry comprising of silica and small quantities
of AlF3 is filtered in a long belt filter before discharging the dry cake (which is free of acid and
AlF3). The filtration requires a vacuum of
150 to 200 mmHg, which is produced by a vacuum pump.
Previous status
In a phosphatic fertiliser unit which is part of a bigger fertiliser complex involved in production
of complex fertilisers, a long belt filter was being used for final filtration of the slurry of silica
and AlF3.
Two vacuum pumps of 500 m3/h capacity and 0.3 kg/cm2 vacuum were being used for
creating vacuum. One of the vacuum pumps was being operated with valve throttling.

The detailed study of the system revealed the following:
• There were leaks in the vacuum line joints close to the belt filter.
• The capacity of the vacuum pump was reduced due to uneven wearing of the pump.

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During a maintenance stoppage of the plant, the leakges were arrested and a trial was taken
to operate the filter with one vacuum pump. The trial was satisfactory and the operation of one
vacuum pump per filter was made into a standard operating procedure.

The implementation of this project was taken up during the planned shut down of the plant. The
implementation took about 1 week to complete. No problem was encountered during the
implementation and subsequent operation of the plant.

The implementation of this project resulted in the reduction in the power consumed for vacuum
generation. The power saving was about 15 kW, which annually amounted to 1,20,000 units.
Financial analysis
This amounted to an annual monetary saving (@ Rs.3.1/unit) of Rs 0.37 million. As the
implementation of this project involved only some maintenance and change of operating
procedure there was no significant investment.

• Annual Savings - Rs.0.37 millions

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Case Study No.5
Installation of a Pipe Reactor in Complex Plant
Background
The complex fertiliser is produced by reacting the different components such as phosphoric
acid, sulphuric acid, ammonia etc. in specific proportions in a reactor. Subsequently, the
product from the reactor is granulated, dried, coated if required and sent for despatch.
Though these units are not highly energy intensive like the nitrogenous plants, there is
nevertheless a good potential to save energy by suitable modifications and technology
upgradation.
Previous status
In a phosphatic fertiliser complex, producing Ammonium sulphate and Mono-ammonium
phosphate, the final section of the plant had the following configuration:
• The phosphoric acid, sulphuric acid and ammonia are reacted in a tank reactor to produce
a melt of 85 % solids.
• This melt was then pumped to a granulator for converting to the form of granules. The melt
concentration had to be maintained below 85 % solids, so that the melt is pumpable. To
maintain this concentration water was being added to the system.
• The granules were then dried in a furnace oil fired rotary drier for removing the moisture.
• The average furnace oil consumption was 20 litres/ton of product.
The system is shown in the diagram.

The plant replaced the existing tank reactor with a pipe reactor. The new system after
implementation is indicated in the diagram.

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The implementation of this project was taken up during the annual maintenance of the plant.
The implementation took about 4 months to complete. No problem was encountered during
the implementation and subsequent operation of the plant.

The implementation of this project resulted in operation of the reactor at higher concentration.
The outlet of the reactor was directly inserted into the granulator. Hence the concentration of
the melt was maintained at about 95 %, as against < 85 % earlier.
The increase in concentration of the melt reduced the drying requirement in the dryer. The
furnace oil consumption came down from 20 litres/ton of product to 5 litres/ton of product.
Financial analysis
The implementation of this project resulted in a net annual saving (@ Rs.7.0/litre and a
production of 2.0 lakh tons) of Rs 21.00 million. The investment made was about
Rs.80.00 million, which had a simple payback period of 45 months.

Replication potential • Simple payback - 45 months
The replication potential is very high, particularly in the smaller size complex fertilizer
manufacturing plants.

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Case Study No.6
Installation of Right Size High Efficiency Sea Water Pumps
Background
The fertiliser plant consumes substantial power for cooling water pumping to different parts of
the plant. The installation of the right size and high efficiency pumps therefore is essential for
operation of the plant at lower energy consumption.
Previous status
In a fertiliser complex involved in production of complex fertilisers with ammonia plant and
sulphuric acid plant was using seawater for meeting a part of its cooling requirements.
The plant had three sea water pumps, out of

which two pumps were being operated for
pumping sea water. This was being used in the
Ammonia plant & Sulphuric acid plant for both
indirect cooling in various heat exchangers and
direct uses such as scrubbing and washing.
The pumps were of 15000 USGPM capacity and

4.5 kg/cm2 head driven by a
800 HP, HT (3.3 kV) motor. One of the pumps

was being operated with discharge valve throttled.

The detailed study of the water requirement and the pressure profile of the whole plant indicated
the following:
• The maximum water quantity requirement was around 20000 USGPM
• The maximum head requirement was only 2.5 kg/cm2
Hence, the plant replaced one of the pumps with 23000 USGPM capacity, 30 m head high
efficiency pump. The old motor was retained for driving the pump.

The implementation of this project was taken up during the operation of the plant. The
implementation took about 4 months to complete. No problem was encountered during the
implementation and subsequent operation of the plant.

• Reduction in the power consumed for sea water pumping

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• Only the new pump was operated. The other two pumps were kept as stand-by.
The above benefits resulted in the reduction of energy consumption by 11 lakh units per
annum.
Financial analysis
This amounted to an annual monetary saving (@ Rs.3.3/unit) of Rs 3.63 million. The investment
made was around Rs 4.00 million. The simple payback period for this project was 14 months.


The project has excellent replication potential in the raw water pumps of all fertilizer plants.

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Case Study No.7
Installation of Vapour Absorption System
Background
The non-process areas in a fertiliser plant also consume substantial electrical energy. The
various consumers include building & control room air-conditioning and lighting. The air-
conditioning requirement has been conventionally met through various vapour compression
machines.
The latest trend has been to install vapour absorption systems in plants where cheap LP
steam is available. These systems are quite reliable and less maintenance prone.
The fertiliser plant offers an excellent opportunity for installation of vapour absorption systems,
as huge quantities of cheap low-pressure steam is available.
Previous status
In a big fertiliser complex producing Urea and some phosphatic fertilisers, conventional vapour
compression systems with Ammonia as refrigerant and reciprocating compressors, were
used for meeting the air-conditioning requirement of the plant buildings and control rooms.
Three reciprocating compressors each of 100 HP were being operated to meet the requirement.
The average load was about 200 to 250 TR at an average power consumption of 1 kW/TR.

A vapour absorption system of 300 TR capacity was installed to meet the plant air-conditioning
requirement.
The vapour absorption system was based on steam at 3.5 kg/cm2 and had a specific steam
consumption of 7 kg/TR.

The implementation of this project was taken up
parallely during the operation of the plant. The
vapour absorption system was installed and was
hooked up replacing the vapour compression
system.
The implementation took about 12 months to

complete. No problem was encountered during
implementation and subsequent operation of
plant.

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The implementation of this project resulted in the following benefits.
• Reduction in power consumption by 7.0 lakh units per year
• Saving of Ammonia make-up costs – Rs. 4.0 lakh per year
• Reduction in maintenance costs – Rs. 1.20 lakh per year
Additionally the implementation also aided in continuous, trouble-free and reliable operation of
the air-conditioning unit.
Financial analysis
The implementation of this project resulted in an annual monetary saving (@ Rs.3.10/kWh) of
Rs 2.70 million. The investment made was about Rs 9.00 million. The simple payback period
is 36 months.


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Case Study No.8
Replacement of Old PRDS Valves with Superior Design Valves
Background
The nitrogenous fertiliser plant is a major consumer of thermal energy for meeting the various
heating requirements and mechanical energy for driving the different equipment such as
compressors, pumps and fans. To meet both power and steam demand, co-generation system
is installed.
The bigger equipment are driven generally by steam turbines and the smaller ones by electrical
motors. The steam extracted from the turbine is used for meeting the process steam
requirement.
To the extent possible, the flow of steam flow through the PRDS (pressure reducing and de-
superheating station) i.e., reduction of pressure without generating power, is avoided.
However, to take care of the ‘Power-steam’ mis-match, exigencies and start-up conditions, the
PRDS is installed. The effective operation and maintenance of the PRDS is therefore essential
for over-all efficiency.
Previous status
This case study pertains to a ammonia fertiliser complex producing 900 tons per day of Urea.
The PRDS system in the ammonia plant is described below.
• The entire demand of the ammonia plant at 40 ata, is met by the 40 ata extraction of the
synthesis gas compressor turbine. Two PRDS systems are installed to meet the 40 ata
steam demand during start-up and tripping of the synthesis gas compressor.
• The system is installed so that the PRDS comes in line, immediately when the synthesis
compressor trips.
• However, these PRDS valves need to be maintained with a minimum flow of 150 kg/h, so
that the valve opens immediately when required.
This continuous minimum flow caused high erosion of the valve internals leading to much
higher flow of steam through the valve, ultimately resulting in continuous venting of 40 ata
steam.

The plant installed a new PRDS system with drag type valves of superior design. These valves
needed little continuous flow of only 20 kg/h, for quick opening. The erosion of the valve at this
flow was almost nil.

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The implementation of this project was taken up when the plant was in operation. The installation
of the new system and successful commissioning took about one year. No problem was
encountered during the implementation and subsequent operation of the plant.

The implementation of this project resulted in reduction of 40 ata steam loss. The loss reduced
from 10000 kg/h to 20 kg/h. The total energy saved per year is about 63,360 GCal.
Financial analysis
The implementation of this project resulted in a net annual saving (@ Rs.350 / GCal) of
Rs. 22.00 million. The investment made was about Rs. 12.20 million, which got paid back
in 8 months.


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Case Study No.9
Replacing Reformer Tubes with Tubes of HPNb Material

Stabilised with Micro-Alloys
Background
The reformer is very important process equipment, used in the production of Ammonia. This
ammonia is consequently utilised, for the production of nitrogenous fertilisers.
The reformer is a major consumer of energy and

the efficiency of the reformer section has a major
bearing on the over-all energy consumption of a
fertiliser plant. Hence, the process of reforming
and the equipment used for reforming, needs
priority attention in a fertiliser plant.
Nitrogenous fertilisers use Ammonia as the basic

material for providing the nitrogen component.
Ammonia is synthesised by chemically combining
Hydrogen and Nitrogen under pressure, in the
presence of a catalyst. The Hydrogen requirement
is met by, catalytically reacting a mixture of steam and hydro-carbons, at an elevated
temperature, to form a mixture of Hydrogen and oxides of Carbon.
CnHm + nH2O ——>
<——- nCO + (m/2 + n) H2
CO + H2O ——>
<——- CO2 + H2
The first reaction is called the Reforming reaction. This is a highly endothermic reaction, and
hence needs energy input in the form of fuel firing, which is normally natural gas / naphtha.
One of the important factors which affects the performance of the reformer is the material of
construction of the reformer tubes.
Conventionally the HK40 or IN519 or equivalent material were being used for the reformer.
Presently, modified HPNb materials stabilised with micro-alloys are available and are being
increasingly considered for the reformer tubes. These materials have better strength and
stability at higher temperature and increased creep strength.
These aspects aid in:
• Possibility of operation of the reformer at higher temperature & pressure
• Reduced reformer wall thickness
• Increased quantity of catalyst packing in the same space – this aspect has been utilised
advantageously, for increasing the capacity and reducing the energy consumption of existing
Reformers.

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This has been taken up successfully in many fertiliser plants with substantial advantages.
Previous status
In a 357 TPD Ammonia plant involved in production of Urea and other Phosphatic fertilisers,
the reformer tubes were made of conventional material with 25 % Chromium & 20 % Nickel.

The Reformer tubes were replaced with ‘modified HPNb materials stabilised with micro-alloys’
with higher Chromium & Nickel and stabilised with Niobium (25 % Chromium, 35 % Nickel, 1.5
% Niobium and traces of Zirconium).

The implementation of this project was taken up as part of the Revamping exercise and took
about 9 week to complete. The implementation and consequently the operation did not pose
any problem.

The replacement of the reformer tubes with modified superior material resulted in the following
benefits:
• Reduction in thickness of tube from 20 mm to 10 mm
• Increase in internal diameter of tubes from 100 mm to 120 mm – Aided in packing additional
catalyst to the extent of 35 %
• Increase in capacity of the plant by 15 %
• Reduction in Reformer tube skin temperature
The above benefits together resulted in reducing the energy consumption for production of
Ammonia by 0.15 GCal / MT of Ammonia.
Financial Analysis
This amounted to an annual monetary saving (@ 1,00,000 MT production of Ammonia & Rs
1000 / Gcal) of Rs. 15.00 million. The energy saving alone has been considered. The investment
made was around Rs. 50.00 million. The simple payback period for this project was
40 months.


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Case Study No.10
Modernisation of the Ammonia Converter Basket
Background
The Hydrogen generated by reforming of hydro-carbons is reacted with Nitrogen in the
atmospheric air in the presence of a catalyst at
higher pressure to synthesise Ammonia. The
synthesis of Ammonia occurs in the Ammonia
converters.
The older Ammonia converters were all of axial

type which required higher pressure and resulted
in lower conversions. These have been replaced
in some of the plants with radial type / axial-
radial system with considerable benefits.
Previous status
In a 357 TPD Ammonia plant, the Ammonia converter basket had a conventional axial type
basket, as shown in the figure. This needed an operating synthesis loop pressure of 300 bar.
The catalyst used was Topsoe supplied of 10 mm size with a pressure drop of 5 bar.
The conversion per pass was around 16 %. In 1992, the bottom exchanger developed a leak,
leading to further reduction of ammonia conversion and increased loop pressure. The total
production loss was around 30 %.

The converter basket was modified to a axial-radial type system. The modified system is
indicated in the diagram.

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The implementation of this project was taken up as part of the Revamping exercise and hence
a separate stoppage of the plant was avoided. The implementation and consequently the
operation did not pose any problem.

The replacement of the old axial type converter basket with the modern axial-radial system
resulted in the following benefits:
• Loop pressure reduced to 250 bar – reducing compression energy
• Lower pressure drop in converter beds – 3 bar as against 5 bar before
• Higher Ammonia production ( about 10 TPD )
The above benefits resulted in the reduction of energy consumption by 0.35 Gcal / MT of
Ammonia.
Financial analysis
1000 / Gcal) of Rs. 20.00 million. The energy saving alone has been considered. The investment
made was around Rs 50.00 million. The simple payback period for this project was
30 months.


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Case study No.11
Installation of Waste Heat Boiler (WHB) at the Inlet of LTS

Converter in Ammonia Plant
Background
The reformer section converts the Hydrocarbons to a mixture of Carbon monoxide and Hydrogen.
The Carbon monoxide is converted to Carbon-di-oxide in the presence of a catalyst.
The conversion takes place in two stages i.e., one at a higher temperature and the other at
a lower temperature. The lower the temperature of conversion the higher is the heat recovery.
It is also advantageous from the process point of view, to operate the converters at a lower
temperature.
Previous status
In an Ammonia plant, the Low Temperature Shift
Converter (LTSC) was designed to operate at a
inlet temperature of 238°C.

As it is advantageous to operate at a lower
temperature of around 210°C from the process
and energy point of view, a Waste Heat Recovery
Boiler was installed to reduce the temperature of
the gases entering the LTSC to about 210°C.

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The implementation of this project was taken up during a major stoppage of the plant. The
implementation took about 4 week to complete. The implementation and consequently the
operation of both the WHRB & the LTSC did not pose any problem.

The installation of the WHRB resulted in the following benefits:
• Reduction of LTSC inlet temperature to about 210°C and generation of 2 TPH of steam at
14 kg/cm2
• Prolonged life of LTSC catalyst
• Increased process efficiency – Resulting in higher Ammonia production by 0.9 % ( about

3 TPD)
The above benefits resulted in the reduction of energy consumption by 0.082 GCal / MT of
Ammonia.
Financial Analysis
1000 / GCal) of Rs 8.20 million. The energy saving alone has been considered. The investment
made was around Rs 4.50 million. The simple payback period for this project was 7 months.

The fertiliser plant is a consumer of heat and power. The utilisation and integration of the plant
in terms of heating and cooling can lead to substantial energy saving. The projects as
mentioned above and variations of the above project have substantial replication potential in
many fertiliser plants.

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Case Study No.12
Installation of Make-up Gas Chiller at Suction of Synthesis

Gas Compressor at Ammonia Plant
Background
The compressor is the heart of nitrogenous fertiliser plant and is used for various purposes
such as compressing the synthesis gas, air, re-cycle gas and ammonia. The compressor
capacity is also one of the important parameters controlling the capacity of the plant.
Hence, the design of the compressor and its effective utilisation is essential for achieving
higher production and lower energy consumption.
The compressor is a constant volume equipment and hence the capacity of the compressor
can be increased by increasing the density of the gas at the suction of the compressor. As
the gas density is inversely proportional to the temperature, there is a good possibility of
increasing the capacity of the compressor by cooling the inlet gas.
Previous status
This case study pertains to a ammonia fertiliser complex producing 900 tons per day of Urea.
The plant was operating at about 920 TPD of ammonia production. The synthesis gas was
entering the compressor at about 39°C.
The plant installed a vapour absorption refrigeration system

with LP steam for cooling the synthesis gas.

The implementation of this project was taken up when the
plant was in operation. The hooking up of the new system
with the existing was done during the planned shut of the
plant.

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The installation of the new system and successful commissioning took about
18 months. No problem was encountered during the implementation and subsequent operation
of the plant.

The implementation of this project resulted in the following benefits.
Parameter Units Before After

Implementation Implementation
Ammonia Production TPD 920 944

Syn. gas temperature °C 39 13
Syn. gas compressor speed RPM 13,142 13,071
The implementation of this project resulted in a saving of 28,035 GCal per year, which amounted
to 0.09 GCal / ton of ammonia.
Financial analysis
The implementation of this project resulted in a net annual saving (@ Rs. 350/GCal) of
Rs. 9.80 million. The investment made was about Rs. 22.00 million, which got paid back in
27 months.


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Case study No.13
Replacement of Air Inter-coolers in the Ammonia Plant
Background
The Ammonia is synthesised by reacting Hydrogen generated by reforming of hydrocarbons
and Nitrogen in the atmospheric air in the presence of a catalyst at higher pressure to synthesise
Ammonia.
The atmospheric air is supplied to the reactor by a battery of air compressors. These
compressors are very important for the operation of the plant and hence are rightly referred
to as the heart of a fertiliser plant. The efficiency of these compressors therefore play a very
important role in efficiency of the whole plant.
Previous status
In a 1,00,000 ton per annum capacity Ammonia plant, the air requirements of the Ammonia
converter were being met by two numbers of oil lubricated 4 stage reciprocating compressors.
The compressors were provided with inter-coolers with finned tubes and were laid in a horizontal
fashion. The oil in the air from cylinders used to plug the gap between the fins and reduce the
heat transfer. The exit air from the inter-cooler used to be at 55 – 58°C as against the design
of 42°C. The capacity of the subsequent stages was getting reduced leading to loss of Ammonia
production.

The inter-coolers for the compressor was replaced with finless tubes and laid in a vertical
fashion.

The implementation of this project was taken up parallely
while the plant was operating. The replacement was done
for one compressor first and the second compressor
was taken up subsequently. The implementation and the
subsequent operation did not pose any problem.
The replacement of horizontal fin type cooler with vertical
finless coolers resulted in reduction of exit air temperature
to around 45°C. There was a reduction of power to the
extent of 45 kW.

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Financial Analysis
This amounted to an annual monetary saving of Rs 0.85 million. The power saving alone has
been considered. The investment made was around Rs 2.00 million. The simple payback


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Case study No.14
Routing of Ammonia Vapours from Urea Plant to Complex

Plant
Background
The fertiliser plant has many consumers of thermal and electrical energy distributed over the
entire complex. The energy consumption is for heating, cooling, compression, vaporising,
condensation etc,.
The system has to be balanced as a whole to ensure operation at the maximum efficiency.
Previous status
In an Urea & Phophatic fertiliser complex, the off-gases from the primary and secondary
decomposers contain NH3 and CO2. These gases are separated in re-cycle section where
CO2 is absorbed in MEA solution and NH3 is re-circulated.
There are two absorbers, one at 19 kg/cm2 and the other at 0.4 kg/cm2. The Ammonia vapours
from primary absorber is cooled in water cooled condensers while Ammonia vapours from
secondary absorber is compressed to 19 kg/cm2 in two reciprocating compressors and then
condensed.
At the same time in the complex plant, the liquid Ammonia (about 6 TPH) at 0°C was drawn
from the storage spheres was vapourised at 6 kg/cm2 and used for neutralisation of the
phosphoric acid. This process of vapourising needed LP steam at 3.5 kg/cm2.

In the above system, Ammonia is compressed from vapour to liquid form by compression
while in the other part of the plant, Ammonia is vapourised by heating. Both these operation
demand energy in the form of electricity for compression and steam for vapourisation.
The system was modified as below:

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• Ammonia was compressed to only 6 kg/cm2 in the Urea plant.
• The hot vapours were exported from the Urea to the complex plant.
The required controls and piping for the proposed arrangement were made for the transfer of
hot Ammonia vapours. The modified system is schematically shown in the diagram.

The implementation of this project was taken up while the plant was in operation. The hooking
up with the existing system was done with a stoppage of about 10 days. The implementation
of this project faced no problems.

• Reduction of electrical energy consumption for compression of Ammonia in the Urea plant.
• LP steam saving in the Complex plant
The above benefits resulted in the reduction of energy consumption by 6 lakh units per year
and 2000 MT of LSHS.
Financial analysis
This amounted to an annual monetary saving of Cost benefit analysis
Rs 4.00 million. The investment made was around
Rs 0.50 million. The simple payback period for this
project was 2 months. • Investment - Rs. 0.50 millions

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Case study No.15
Replacement of Pellet Type Catalyst with Ring Shaped Catalyst

in Sulphuric Acid Plant
Background
The Sulphuric acid plant is an integral part of the complex fertiliser unit involved in production
of phosphatic fertilisers. The sulphuric acid is produced by combustion of elemental sulphur
to its oxides and subsequently absorping in acid.
The conversion of the sulphur-di-oxide to sulphur-tri-oxide is one of the important reactions in

this plant.
This reaction is exothermic and is carried out in the presence of a catalyst. The geometry of
the catalyst affects the performance of the plant and the conversion. Presently, catalyst of
superior geometry are available. These have the advantage of longer life and reduced pressure
drop.
Previous status
In a sulphuric acid plant which was a part of the larger fertiliser complex plant, pellet shaped
V2O5 catalyst was being used.
The plant was frequently facing problems of dust accumulation and increase in pressure drop.
Additionally the plant had to be shut down once every six months for screening and re-charging
the catalyst.

The pellet shaped catalyst was replaced with ring shaped catalyst of the same material
composition.

The implementation of this project was taken up during the yearly stoppage. The implementation
took about 2 week to complete. The implementation and consequently the operation did not
pose any problem.

The replacement of the pellet type catalyst with ring type catalyst resulted in the following
benefits:
• Reduction in the pressure drop build up of the converter
• Reduction in the load of the main air blower
• Shut down (for screening and recharging catalyst) frequency reduced from two per year to
once per year

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The above benefits resulted in the reduction of energy consumption by 900 MT of LSHS and
additional production of 10,000 MT of sulphuric acid per year.
Financial analysis
This amounted to an annual monetary saving
(energy saving and additional acid production)
of Rs 7.80 million. The investment made was • Annual Savings - Rs. 7.80 millions
around Rs 40.00 million. The simple ayback

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Case study No.16
Installation of a Waste Heat Recovery Boiler for Generating

Set Exhaust
Background
The fertiliser plant is a huge consumer of electricity and steam. A part of the electrical energy
is supplied by the co-generation system comprising of the boilers and the back pressure
turbines. The balance power is met partly through condensing turbines, oil fired generating
sets and grid.
The increase in the cost of grid power has made many fertiliser plants to install condensing
turbines and oil fired generating sets. In the case of oil fired generating sets, about 30 to 35
% of the energy supplied goes out through the stack in the form of high temperature flue gas.
In many of the plants, waste heat boilers are installed to generate LP steam from generating
set exhaust, which can be connected to the LP steam header.
The implementation of this project results in greater benefits; in plants where some quantity
of LP steam is generated by passing HP/MP steam through pressure reducing valves. In such
plants, augmentation of LP steam through waste heat recovery system can lead to a saving
of HP steam and hence the fuel.
Previous status
In a big fertiliser complex producing Urea and some phosphatic fertilisers, the power requirement
of the plant was met through steam turbines, grid and oil fired generating sets. The cost of
different sources of power is as below:
Grid Rs.3.00/unit
Oil fired generating sets Rs.1.72/unit
As the cost of power generation with LSHS fired generator was lower, the plant was operating
two 4 MW capacity generating sets continuously. The generating set exhaust was going out
to the atmosphere at a temperature of 390°C.
This offered a good potential to install a waste heat recovery system. In the plant also, the
power steam balance was such, that nearly 4 TPH of LP steam was being generated by
reducing the pressure of HP steam (35 kg/cm2 pressure) through a pressure reducing valve.
Hence, any generation of LP steam from the generating set exhaust can aid in an equivalent
reduction of HP steam generation and reduce the fuel fired in the boiler.

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A waste heat recovery system was installed for generating LP steam from the generating set
exhaust.
Implementation methodology & time

frame
The implementation of this project was taken
up parallely during the operation of the
generating set. A waste heat recovery system
was installed for each of the sets. A provision
was also made for by-passing the waste heat
recovery system.
The implementation took about 12 months to

complete. No problem was encountered during
implementation and subsequent operation of plant.

The implementation of this project resulted in the saving of about 4 TPH of HP steam, which
need not be generated.
Financial analysis
The implementation of this project resulted in an annual monetary saving (@ Rs.300/ MT of
HP steam for 4000 hours per year) of Rs 4.50 million. The investment made was about
Rs 12.00 million. The simple payback period was 32 months.
Replication potential Cost benefit analysis

The project has excellent replication potential in all • Annual Savings - Rs. 4.50 millions
fertilizer plants, which operate large size DG sets on • Investment - Rs. 12.00 millions
a continuous basis

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Case study No.17

Coating of Pump Impeller and Casing with Composite Resins
Background
The pumps are major consumers of electrical energy in a fertiliser plant. Hence, the design,
operation and maintenance of pumps are essential for operating the plant at higher levels of
energy efficiency.
In any pumping system, the hydraulic passages of casings & impeller vane shape get damaged
due to wear, tear and corrosion. The clearances of wear rings also increases over a period.
This damage results in deterioration of hydraulic performance and reduces the efficiency of the
pumps, resulting in increased power consumption and frequent breakdowns.
The latest trend is to use composite resin coating on the pump impeller & casing, to restore
the geometric shapes, surface finish & clearances. This aids in restoring the original efficiency
and sustains over a longer period. The following organic based systems are being used for
refurbishing the impeller and casings:
• Bisphenol glass flake polyester resins
• Vinyl ester glass flake resins
• High build epoxy systems
The utilisation of these systems along with the standard engineering practises can
• Limit the extent of mechanical damage
• Resist chemically aggressive service environment
• Act as a barrier to prevent permeation of corrosion ions to the substrate (metal)
Previous status
In a sulphuric acid plant of 600 TPD capacity, there were 4 cooling water pumps of 2700 m3
/h capacity and 50 m head driven by a 500 kW motor. The pumps were operating at an
efficiency of 64.5 %, consuming about 430 kW.
The casing of the pump was coated with epoxy resin coating.
The implementation of this project was taken up during the planned shut down of the plant. The
over all implementation took about 10 days to complete. No problem was encountered during
the implementation and subsequent operation of the plant.
The implementation of this project resulted in the reduction in the power consumed for pumping
of cooling water for Sulphuric acid plant. Consequent to the coating the efficiency of the pump
had improved and there was a reduction of about 16 kW in the power consumed by each
pump. The total saving was about 0.13 million units.
Financial analysis
This amounted to an annual monetary saving (@ Rs.3.1/unit) of Rs 0.40 million. The investment
made was about Rs. 0.13 million and the simple payback period was 4 months.

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Case study No.18
Installation of a Second Turbo Alternator in Sulphuric Acid

Plant
Background
The sulphuric acid unit is one of the important sections of the phosphatic fertiliser plant.
Sulphuric acid is produced by burning elemental sulphur to produce sulphur- di-oxide, converted
to sulphur-tri-oxide and subsequently absorbed in a solution of 98 % acid. This is highly
exothermic resulting in generation of substantial quantity of heat, which is converted to steam
in the waste heat boiler.
In the older & smaller units, the steam is generated at 11 kg/cm2, reduced to a lower pressure
and used in the sulphuric acid plant and other areas. The sulphuric acid plant however needs
energy for operating equipment such as fans and pumps.
One of the major energy consumers is the air blower, which supplies air at high pressure for
burning sulphur in the furnace. In the subsequently installed plants, the steam is produced at
higher pressures, 24 kg/cm2 and expanded in a turbine to a lower pressure. This turbine is
used for generally driving the air blower.
The latest trend is to generate steam at much higher pressures and use it for increased power
generation. In this manner, the plant is able to increase the internal co-generation power.
The cost of co-generation power is much lower than the grid power cost, resulting in substantial
cost reduction for the plant.
Previous status
This case study pertains to a sulphuric acid plant in a phosphatic fertiliser complex producing
Ammonium sulphate and Mono-ammonium phosphate. The plant had two sulphuric acid units
of capacity 300 TPD and 400 TPD respectively.
The old plant of 300 TPD capacity had a waste heat recovery boiler of 24 kg/cm2 and the
steam was expanded to about 1.5 kg/cm2 in a turbine which was being used for driving the
air blower.
The second plant, which was installed subsequently, had a waste heat boiler of 40 kg/cm2
pressure. This steam was also being used for driving the air blower only, with the help of a
steam turbine operating with a backpressure of 1.5 kg/cm2.
Since the pressure was higher, only 70 % of the total steam generated (about 21 TPH at 400
TPD acid production), was being used by the turbine and the remaining steam was being
passed through a pressure-reducing valve.

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The plant did a detailed study of the steam system and implemented the following modifications.
• The LP steam coming out of the turbine was being used for de-salination of sea water in
multiple effect evaporators. The maximum pressure requirement in this section was only
0.5 kg/cm2.
Hence, the plant started operating the turbines with a back pressure of only 0.5 kg/cm2, after
confirming with the turbine supplier. This reduced the steam requirement for driving the blower
to about 50 % of the steam generation.
• Installed a 1.0 MW turbine alternator, so that the steam previously passing through pressure-
reducing valve could be used for generating additional power.

The implementation of this project was taken up parallely during the operation of the plant.
During a stoppage of the plant, the new turbine alternator was put into service.
The implementation and stabilisation of the second alternator took about 6 months to complete.
No problem was encountered during the implementation and subsequent operation of the
plant.

The implementation of this project resulted in additional average power generation of about 500
kW. Since the plant was buying power from the grid @ Rs.3.50/ unit, this project resulted in
substantial cost saving.
Financial analysis
The implementation of this project resulted in a net annual saving (@ Rs.3.50/ unit) of
Rs 14.00 million. The investment made was about Rs.10.00 million, which got paid back in
9 months.


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381
Case study No.19
Installation of Hydraulic Turbine in the CO2 Removal Section
Background
The Ammonia in a nitrogenous fertiliser plant is manufactured by synthesising Hydrogen and
Nitrogen in the presence of a catalyst. The Hydrogen is generated by reacting hydrocarbons
with steam in the presence of a catalyst, to produce a mixture of Carbon-di-oxide and Hydrogen.
The gas is stripped of Carbon-di-oxide in a solution of aqueous mono ethanol amine (MEA).
This MEA absorbed in the CO2 absorber which is at a pressure of 24 kg/cm2, enters the CO2
stripper operating at a lower pressure of around 0.4 kg/cm2. This pressure reduction is normally
effected through a pressure reducing valve.
There is a good potential to install a hydraulic pressure recovery turbine in such a system to
recover power to drive, say a pump. Some plants have installed this system and have benefited
substantially.
Previous status
In a particular nitrogenous fertiliser plant of about 1,00,000 tons per year capacity, the MEA
process was being used for CO2 removal. The absorption of the CO2 in the absorber is carried
out at high pressure and the rich MEA at the outlet of the absorber is at a pressure of 24 kg/
cm 2 .
This rich MEA exchanges heat with the hot lean MEA coming from the stripper, its pressure
reduced in a pressure reducing valve after which it enters the stripper. The rich MEA after
stripping of CO2 becomes lean and can be used for absorption of CO2 again.
This lean hot MEA after heating up the rich MEA coming out of the absorber is pumped through
a steam turbine driven pump to the absorber. This turbine has a BHP of 800 hp and operates
between pressures of 32.6 kg/cm2 and 5.5 kg/cm2.

A Hydraulic Power Recovery Turbine (HPRT) was
installed to recover the pressure energy being lost
across the valve.
The detailed calculations revealed that nearly 175

hp generation was possible by installing the turbine.
The nearest drive operating in CO2 removal section
was the lean MEA pump, which was being driven
by a steam turbine with a BHP of 800 HP.

382
Hence, the hydraulic turbine was installed in the same shaft as that of the steam turbine and
was being used for supplementing part of the power required to drive the lean MEA pump.
Implementation of the project, time frame

The following modifications were done during the implementation of this project.
• Piping was modified to route rich MEA through hydraulic turbine to the stripper.
• A second level control valve at the inlet of the hydraulic turbine was installed. The control
loop was modified so that the second level control valve operates on a split range basis.
This operates in parallel with the first level (i.e., original valve) valve, which is sized for
minimum pressure drop.
• The control system was made so that, the new second level control valve, controls the level
in absorber during normal operation. The original valve operates only when hydraulic
turbine is not in operation.
• Additional controls and instruments were installed so as to take care of various situations
like start up, shut down and other contingencies.
• A one-way clutch was also installed so that coupling and de-coupling take place automatically
between hydraulic turbine and pump.
The installation of the turbine and the successful commissioning took about 8 months to
complete. The hydraulic turbine has since then been operating successfully resulting in
substantial benefits.

The implementation of this project resulted in reduction of the load on the steam turbine driving
the lean MEA pump.

383
The steam saving on the steam turbine amounted to 2.5 TPH of high pressure steam, which
annually amounted to about 600 tons of LSHS. The reduction in specific energy consumption
amounted to about 0.06 GCal / MT of ammonia.
Financial Analysis
The annual saving achieved by the company on installing hydraulic turbine was
Rs. 3.80 million. The investment made was about Rs. 1.10 million with a simple payback
period of 4 months.


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385
Case study No.20
Installation of Plate heat exchangers for drying tower cooler in

sulphuric acid plant
Background
SO3 gas from “Converter” is absorbed in the Intermediate and Final Absorption Towers (IAT &
FAT) with sulphuric acid from the respective absorption tanks. The absorption of SO3 being an
exothermic reaction, the heat from the reaction has to be removed using a cooling medium.
The sulphuric acid from the drying tower tank is circulated to the drying tower or acid storage
tanks, through heat exchangers, which are of the serpentine type and made of cast iron
trombone. These heat exchangers use either seawater (depending on location of plant) or
cooling tower water for cooling.
These types of coolers are characterised by higher-pressure drops, lower approach temperature
and high maintenance costs (due to frequent scaling/ choking).
The plate heat exchangers are excellent substitution for serpentine coolers, as they are
characterised by lower pressure drops, approaches of upto 1°C and ease of maintenance.
Previous status
In one of the phosphatic fertilizer units, the sulphuric acid from drying tower was cooled in
conventional cast iron trombone serpentine coolers, using seawater as the cooling medium.
The distribution of seawater was always problematic on the lengthy coolers, due to frequent
scaling/ choking. The outlet acid temperature used to be higher by about 5°C than the design,
leading to reduced throughput.
There were also frequent problems of leaks in the coolers, necessitating stopping the plant for
attending on them. The downtime on account of this used to be about 5 days per year.

The serpentine coolers were replaced with 3 new sets of Plate Type Heat Exchangers (PTHE).
These PTHE’s are supplied with seawater, for cooling, using dedicated vertical submersible
pumps.

The plate type heat exchangers and connecting lines from the sulphuric acid pump (at bottom
of the drying tower) discharge header to the heat exchangers were kept ready and hooked
on during the planned maintenance shutdown.
There were no problems faced during the implementation of this project and this has been
operating successfully, resulting in substantial benefits.

386

The following benefits were achieved on installing the plate type of heat exchangers:
• Approach temperatures of upto 2°C, leading to better cooling
• Lower pressure drop, resulting in lower head requirement of cooling water pump
• Practically nil downtime, due to ease of cleaning and maintenance, on account of the
modular design
Financial Analysis
The annual saving achieved by the company on installing hydraulic turbine was
Rs. 12.00 million. The investment made was about Rs. 25.00 million with a simple payback
period of 25 months.


The installation of plate type heat exchangers for cooling applications has excellent replication
potential in almost all the fertilizer plants.

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388
Case study No.21
Installation of mechanical conveying system in place of

pneumatic conveying system for rock phosphate conveying
in phosphoric acid plant
Background
The basic raw materials required for phosphoric acid manufacture are sulphuric acid and rock
phosphate.
Raw rock phosphate, obtained from various sources, is ground in ball mills to a size of 60%
retention on –200 mesh screen. This ground rock is discharged into storage silos using a
pneumatic conveying system.
From the storage silos, the ground rock is extracted and conveyed to the phosphoric acid
plant also using a pneumatic conveying system.
Pneumatic conveying uses compressed or blower air as the material conveying media and is
hence, highly energy intensive. It is atleast 4 to 5 times power intensive than mechanical
conveying systems.
The latest trend among all industries is to replace pneumatic conveying systems to mechanical
conveying systems. There are mechanical systems, which are designed to convey fine powdery
material, over steep gradients and long horizontal distances, without spillage.
The replacement of pneumatic conveying systems with mechanical conveying systems is well
proven, in cement industries.
Previous status
In one of the complex fertilizer plants in the country, the ground rock from mill outlet was
conveyed to the storage silos using pneumatic conveying system, utilizing compressed air.
The power consumed by the compressors was 225 kW.
Similarly, the ground rock from the silos is conveyed to the phosphoric acid plant using
compressed air. The material is conveyed over a horizontal distance of 150 m and height of
25 m. The power consumption of system was about 320 kW.

The pneumatic conveying systems in the plant were replaced with mechanical conveying
systems.
In the rock grinding section, an air slide and bucket elevator combination was used to convey
material from the mill outlet to the storage silos. For ground rock conveying to the phosphoric
acid plant, an air slide and pipe conveyor combination was installed.

389

The entire project was completed over a period of 15 months. This did not require the stoppage
of the plant.
There were no major problems encountered during the implementation of this project, except
for routing of the conveyor, due to space constraint.

The major benefits of the modified mechanical conveying system are:
• Tremendous power savings
- 110 kW at rock grinding section
- 280 kW at phosphoric acid plant
• No material spillage
• Relatively low maintenance
Financial Analysis
The total annual savings achieved on conversion of pneumatic conveying system to mechanical
conveying systems is Rs. 7.00 million. The investment required for the system was Rs.23.00
million, which had a simple payback period of 40 months.

The installation of mechanical conveying systems has good replication potential in several
large and majority of the smaller size fertilizer plants.

390

391
Case study No.22
Replacement of steam ejectors with vacuum pumps
Background
In the concentration section of phosphoric acid plant, the evaporators are operated under
vacuum for concentrating phosphoric acid from 28% to 46%.
The vacuum maintained in the evaporators is about 580-600 mm Hg and is achieved using
steam ejectors. These steam ejectors use medium pressure or low pressure steam.
Vacuums of upto 680-700 mm Hg can be easily achieved with a water ring vacuum pump. The
installation of a water ring vacuum pump or steam ejector is decided based on cost of steam
and power.
The utilization of MP or LP steam in steam ejectors will offset an equivalent amount of power
generation in the turbine, if the plant has commercial cogeneration.
In such cases, there is a good potential to replace the steam ejectors with water ring vacuum
pumps, save MP/ LP steam and enhance power generation in turbines.
Previous status
In one of the complex fertilizer manufacturing units, there were five evaporators for concentration
of phosphoric acid. The evaporators were operated under vacuum using 2-stage steam ejectors.
These ejectors consume about 1.5 TPH each of 27 kg/cm2 pressure steam.

All the five steam ejectors in evaporator section were replaced with water ring vacuum pumps.
Implementation of the project and time frame

The replacement of steam ejectors with water ring vacuum pumps, were taken up one-by-one.
There was no stoppage required for the implementation of the project, as there was always
one standby evaporator available.
The entire project was completed over a period of 15 months. There were no major problems
encountered during the implementation of this project.

The steam saved by replacement was equivalent to about 7.5 TPH of 27 kg/cm2 pressure.
This can generate additional power equivalent to about 50 units/ ton of steam, thereby
offsetting equivalent power drawn from the grid.

392
Financial Analysis
The total annual savings achieved on replacing steam ejectors with water ring vacuum pumps
is Rs. 10.00 million. The investment required for the vacuum pumps was Rs. 7.50 million,


The replacement of steam ejectors with water ring vacuum pumps has excellent replication
potential in the large fertilizer units in the country. This project becomes particularly attractive,
when the plant has commercial gogeneration.

393

394
9.0 List of Contractors/ Suppliers
Alfa Laval India Ltd. • Evaporators

Mumbai - Pune Road
Dapodi
Pune - 411 012
Tel. : (020) - 24116100 / 27107100
Email : neeru.pant@alfalaval.com
Web : www.alfalaval.co.in
Contact : Mr Neeru Pant
FFE Minerals India Limited • Material handling systems

FFE Towers, 27 G N Chetty Road • Classification, filtration and thickening
T Nagar technologiesv Crushing and grinding
Chennai – 600 017 • Calcination, roasting, sintering, drying
Tel. : 044 – 28220801/ 02, 28252840/ 44
Fax : 044 – 28220803
Email : ffem@ffegroup.co.in
Johnson India • Steam engineering and consultancy

3, Abirami Nagar, G.N. Mills Post
Coimbatore – 641 029
Tel. : 0422 - 2442692
Fax : 0422 - 2456177
email: info@jsea.com.au
Hindustan Dorr-Oliver Limited • Liquid-solid separation

Dorr-Oliver House • Environmental pollution control
Chakala, Andheri East • Water treatment
Mumbai – 400 099
Tel.: 022 – 2832 5541, 2832 6416/ 17/18
Fax : 022 – 2836 5659
Email : hdoho@hind-dorroliver.com
Nash International Company • Water ring vacuum pumps

No. 1 Gul Link Singapore 629371
Rep. of Singapore
Tel. : (65) 861 6801
Fax : (65) 861 5091
Email : sales@nasheng.com
Web : www.nasheng.com

395
PPI Pumps Pvt. Ltd. • Water ring vacuum pumps

4/2, Phase 1, GIDC Estate,
Vatva, Ahmedabad – 382445
Tel. : 079 – 25832273/4, 25835698
Fax : 079 – 25830578
Email : sales@prashant-ppi.com
Web : www.prashant-ppi.com
Sulzer Pumps India Limited • All types of centrifugal pumps

No.9, MIDCThane-Belapur Road, • Wear resistant pumps
Digha, Navi Mumbai – 400 708 • Acid resistant pumps
Tel. : 022 – 55904321
Fax : 022 – 55904302
Web : www.sulzerpumps.com
The Eimco-KCP Limited • Solids-liquid separation equipment

Ramakrishna Buildings like rotary vacuum filters, thickeners,
239, Anna Salai clarifiers, classifiers etc
Chennai – 600 006 • Water & waste water treatment plants
Tel. : 044 - 28555171
Fax : 044 – 28555863
Email: ekcp@md2.vsnl.net.in
Web : www.ekcp.com
10.0 List of Consultants
Indian Companies
Development Consultants Limited • Detailed project reports

24-B, Park Street, Kolkata - 700016 • Basic and detailed engineering
Tel. : 033 - 22267601, 22497603 • Procurement, inspection & expediting
Fax : 033 - 22492340/3338 • Project construction and management
Email : dcl@dclgroup.com • Structural engineering
• Technical management

396
Engineers India Limited • Preliminary planning

Engineers India Bhavan1, Bhikaji Cama Place • Detailed project reports
New Delhi – 110 066 • Basic and detailed engineering
Tel. : 011 - 26186732, 26102121 • Procurement, inspection & expediting
Fax :011 – 26194760, 26178210 • Project management
Email : gupta.dk@eil.co.in
Web : www.engineersindia.com
Contact : Mr D K Gupta,
General Manager – Mktg.
FACT Engineering & Design Organisation • Project design

A Division of FACT Ltd. • Engineering
(A Government of India Enterprise) • Comprehensive turnkey project
Udyogamandal implementation
Kochi - 683 501 • Plant operation and maintenance services
Tel. : +91-484-545451 to 545458 • Feasibility reports
Fax : +91-484-545215
Email : fedohq@vsnl.com
Jacobs Engineering
Jacobs House, Ramkrishna Mandir Road
Kondivita, Andheri (East)
Mumbai - 400 059
Tel. : 022 – 2824 4873
Fax : 022 – 2820 8295
Web : www.jacobs.com
Monsanto India Limited

Ahura Centre, 5th Floor
96, Mahakali Caves Road
Mumbai - 400 093
Tel. : 022 - 2824 6450, 2690 2100
Fax : 022 - 2690 2111, 2690 2121
Projects & Development India Limited • Preliminary planning and surveying

PDIL Bhawan, A-14, Sector-I • Detailed project reports
Post Box No.125 Noida - 201301 • Basic and detailed engineering
Dist. Gautam Budh Nagar Uttar Pradesh • Procurement, inspection & expediting
Tel. : 011- 252 9842/ 843/ 851/ 853 / 854 • Project construction and management
Fax : 011- 252 9801, 254 1493, 2646 6199 • Structural engineering
Email : pdil.noida@smy.sprintprg.ems.vsnl.net.in • Technical management
• Cathodic Protection of Underground
Pipelines

397
TCE Consulting Engineers Limited • Preliminary planning

Tata Press Building • Detailed project reports
414, Veer Savarkar Marg • Basic and detailed engineering
Mumbai – 400 025 • Procurement, inspection & expediting
Tel. : 022 - 24374374, 24302419 • Project management
Fax : 022 – 24374402 • Construction supervision
Email : mgy@worli.tce.co.in • Assistance in start-up testing and
Web : www.tce.co.in commissioning
Contact : Mr M G Yagneshwara
Group Commercial Manager
UHDE India Limited • Preliminary planning

UHDE House, LBS Marg • Detailed project reports
Vikhroli (W), Mumbai – 400 083 • Basic and detailed engineering
Tel. : 022 - 25783701, 25968000
Fax : 022 – 25784327
Email : uhdein@vsnl.com
Web : www.uhdeindia.com
International Companies • Upgrades and builds

Casale • Fertilizer plants
via Sorengo, 76900 Lugano - Methanol plants
Switzerland - Ammonia
Tel. : ++41 91 9607200 - Urea
Fax : ++41 91 9607291/2 - Methanol derivatives
Email : urea@casale.ch • Speciality Chemicals
Web : www.casale.ch
Davy Process Technology Limited

20 Eastbourne Terrace
London W2 6LE
Tel. : +44 (0)207 957 4120
Fax : +44 (0)207 957 3922
E-mail : dpt@davyprotech.com
Web : www.davyprotech.com
Grande Paroisse S.A.

12, place de l’Iris 92062
Paris La Défense 2 Cedex
France
Web : www.grande-paroisse.fr

398
Haldor Topsoe A/S

PO Box 213 Nymøllevej 55DK-2800
Lyngby, Denmark
Tel. : +45 45 27 20 00
Fax : +45 45 27 29 99
Email : denox@topsoe.dk
Web : www.haldortopsoe.com
Contact : Mr Peter Søgaard-Andersen
Director – Mktg. & Sales- Technology Division
Tel. : +45 45 27 20 97
Email : psa@topsoe.dk
INCRO S.A
Serrano, 27 - 28001 Madrid Spain
Tel. : (34) 91 435 08 20
Fax : (34) 91 435 79 21
Email : incro@incro.es
Jacobs Engineering Group Inc.

1111 South Arroyo Parkway
P.O. Box 7084, Pasadena
CA 91109-7084
United State of America
Tel. : + 1 626 578 3500
Fax : + 1 626 578 6916
Email : contactus@jacobs.com
Kellogg Brown & Root (KBR)

KBR Tower, PO Box 4557601 Jefferson Street,
Houston, TX 77002
United States of America
Tel. : (+1) 713 - 753 20 00
Fax : (+1) 713 - 753 53 53
Emai : kbr@halliburton.com
Linde AG Coporate Center

Abraham-Lincoln-Strasse 2165189
Wiesbaden Germany
Tel. : +49 611 770 0
Fax : +49 611 770 269
E-Mail : info@linde.de

399
Monsanto Enviro-Chem Systems, Inc.

14522 South Outer Forty Road
St. Louis, MO 63017
United States of America
Tel. : +314 275 5700
Fax : +314 275 5701
Email : enviroch@na1.monsanto.com
Snamprogetti Sud Frazione

Triparni 89900 Vibo ValentiaItaly
Tel. : +39 0963 9611
Fax : +39 0963 961356
Contact: G. Carcano
Toyo Engineering Corporation

Tel. : (81)47-454-1113
Fax : (81)47-454-1160
Email : www@toyo-eng.co.jp
University Technologies Intl. Inc.

Suite 130, 3553 - 31st Street NW,
Calgary, AlbertaCanada, T2L 2K7
Tel. : +403-270-7027
Fax : +403-270-2384
Email : info@uti.ca

Energy Conservation in Foundry Industry
400
Foundry
Growth percentage 3-5%
Energy Intensity 25% of total manufacturing cost
Energy Costs Rs.45000 million (US $ 900 million)
Energy saving potential Rs.4500 million (US $ 90 million)

saving projects Rs. 5000 million (US $ 100 million)

401
1.0 Introduction
The Indian Foundry Industry plays a significant role in improving country’s economy. India is
currently among the 10 largest producers of ferrous and non-ferrous castings. India exports
annually above Rs.700/- Crores worth of castings to countries like USA, U.K., Canada, Germany
etc.
There are about 10,000 foundries in India inclusive of organised and unorganised sectors. Out
of 10,000 foundries about 90% are small-scale units. These foundry units are mostly in clusters
with a cluster size ranging from less than 100 to about 500 units. These plants have an
installed capacity of 4.5 million tonnes/ annum.
Majority of foundries in India produce grey iron castings. Annual production of Indian foundry
industry is about 3 million tonnes, consisting of 2.30 Million tonnes of grey iron castings, 0.4
million tonnes of steel castings and 0.3 million tonnes of malleable and SG iron castings.
Among the foundry units, more than 6000 are cupola based foundry units operating in small-
scale sector. The other units have rotary and induction furnaces.
The Indian foundry industry has been very responsive to energy efficiency. The latest plants
installed since early 90’s incorporate many energy saving measures by design. The older
plants also, continuously upgrading their technology and reducing their specific energy
consumption.
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.
2.0 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 medium and large scale foundry industry is the electrical energy
consumption for induction and Arc furnaces. Fuel oil is used for heat treatment furnaces. In
small foundry industry, coke is used for metal melting in the Cupola furnaces.
The energy costs contributes about 25% of the manufacturing cost in Indian foundry industry.
The total energy cost in Indian foundry industry is about Rs 4500 Crores.

402
3.0 ENERGY CONSUMPTION PATTERN
3.1 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.
Typical electrical energy consumption pattern in a foundry industry is depicted in a power tree
given below.
Power Input
100%
Melting Utilities Lighting Others

Moulding
86% 4.4% 1.4% 4.6%
3.6%
Furnace Auxiliary
Sand Mixer
83% 3%
Plant 2%
1.6%
Melting Holding
73% Cooling Crane &
10%
Pumps Hoists
2.5% 0.5%
3.2 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 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.

403
4.0 ENERGY SAVING POTENTIAL IN INDIAN FOUNDRY INDUSTRY

There are about 10,000 foundry units in India. The total annual energy bill of foundry industry
is about Rs 4500 Crores. The energy saving potential considering the short term and medium
term energy saving projects is 10-12 % of the total energy consumption.
Number of Annual Energy Saving Potential Investment

foundry units Bill Rs Crores required
Rs Crores % of Energy bill Rs Crores
10,000 4500 450 10-12% 500
The energy saving potential considering the long-term energy saving projects, which have
payback period of about 3-4 years, is in the range of 15-20%. The energy saving potential
amounts to Rs 650 – 700 Crores.
5.0 FOUNDRY UNIT - PROCESS DESCRIPTION

The manufacturing process of foundry industry is almost similar in all the units. The utilities
and auxiliary equipment varies depending upon the requirement. The manufacturing process
in foundry industry includes metal melting, sand preparation, pattern making, mould preparation
and casting.
5.1 Melting Section

The raw material is melted in melting furnace. The melting furnace can be an indication
furnace or rotary or arc furnace or cupola furnace. Molten metal from the melting furnace is
tapped in Ladles and then transferred to the holding furnaces.
Typically the holding furnaces are induction furnaces. The holding furnace is used to maintain
the required molten metal temperature and also acts a buffer for storing molten metal for
casting process. The molten metal is tapped from the holding furnace whenever it is required
for casting process.
5.2 Sand Plant

Green sand preparation is done in the sand plant. Return sand from the moulding section is
also utilised again after the reclamation process.
Sand Mullers are used for green sand preparation. In the sand mullers, green sand, additives
and water are mixed in appropriate proportion. Then the prepared sand is stored in bunkers
for making moulds.
5.3 Pattern making

Patterns are the exact facsimile of the final product produces. Generally these master patterns
are made of aluminium or wood. Using the patterns the sand moulds are prepared.

404
5.4 Mould Preparation

In small-scale industries still the moulds are hand made. Modern plants are utilising pneumatic
or hydraulically operated automatic moulding machines for preparing the moulds.
After the moulding process if required the cores are placed at the appropriate position in the
moulds. Then the moulds are kept ready for pouring the molten metal.
5.5 Casting
The molten metal tapped from the holding furnace is poured into the moulds. The molten
metal is allowed to cool in the moulds for the required period of time and the castings are
produced.
The moulds are then broken in the shake out for removing the sand and the used sand is sent
back to the sand plant for reclamation and reuse. The castings produced are sent to fettling
section for further operations such as shot blasting, heat treatment etc. depending upon the
customer requirements.
PROCESS FLOW DIAGRAM OF A FOUNDRY INDUSTRY
Raw
Sand Plant Mould Material
Preparation
Induction Furnace &

Arc Furnace
Casting
Molten
Metal
Mould
Cooling
Sand Shake out

Reclamation
Castings

405
6.0 EQUIPMENT IN FOUNDRY INDUSTRY
6.1 Cupola furnace

The cupola is a shaft furnace for continuous melting of cast iron
with new pig iron, return scrap iron and steel scrap. Coke is used
as fuel in cupola furnace. Cupola has not only an economic
advantage of low equipment cost but also has refining and self
purifying capability. This makes it possible to get good quality of
molten metal, even from inferior quality of raw material.
Cupola is divided into various zones such as preheating zone,

melting zone, and superheating zone from the functional point of
view. Metal charged through the charging door is first preheated
in the preheating zone by the exhaust gas going out of the furnace.
In the preheating zone the temperature is in the range of 500-
1000oC.
Then the metal is melted in the melting zone and superheated in the superheating zone. The
molten metal is tapped from the tapping hole through the trough. The temperature in the
melting zone is in the range of 1200-1500oC and 1600- 1800oC in the superheating zone.
The melting zone and the superheating zone are classified into the deoxidation zone and the
oxidation zone depending upon the combustion reaction. In cupola melting, the positions of the
deoxidation and oxidation zones are important, since they have great influence on the properties
of molten metal.
If the oxidation zone is expanded to the top of furnace, the solid metal is put in a strong
oxidation atmosphere. This leads to increased oxidation of molten metal and hence increased
metal loss.
Coke consumption in a single, cold blast cupola for molten metal temperature in the range of
1380 – 1410oC is about 150-200 kg/MT of molten metal. Many technological modifications have
been effected in cold blast cupola designs to increase operating efficiency and reduce specific
fuel consumption.
6.2 Divided Blast Cupola

In the divided blast cupola is blast is equally divided between two Tuyers in the cupola. The
divided blast cupola permits one to choose the best cupola process as required for the
particular production.
The advantages of divided blast cupola over cold blast cupola are as follows:
• 20% reduction in charge coke
• 40oC rise in tapping temperature
• No blocking or freezing of tuyeres
• 10% less loss in percentage of silicon
• 10% less loss in percentage of manganese

406
• Higher carbon pickup
• 20% increase in melting rate
• Reduction in exit gas temperature ( only 250oC as against 450oC in conventional cupola)
and hence reduced flue gas loss.
• Can take 100% bigger lumps of remelting scrap
• Conversion from single blast to divided blast is very low
6.3 Hot blast cupola

The temperature of exhaust gas of Cupola furnace is as high as 800oC. The high temperature
flue gas can be utilised for preheating the combustion air supply.
The combustion air supply can be preheated to a temperature of 300 or higher. This leads to
increase in combustion temperature and heat efficiency of the Cupola furnace.
Moreover in the upper part of the combustion zone, CO2 gas due to coke is deoxidised by high
temperature. This creates a reductive atmosphere and decreases the oxidation loss of metal.
Two methods, which widely used to preheat the blast air, are
1. The recuperative type which uses the heat of gases
2. The externally fired type which does not use any products of combustion in the cupola as
fuel, but instead utilises an independent heater fired by coal, gas or oil
The advantages of hot blast cupolas are:
• Increased melt rate
• Reduced coke consumption
• Increased melt temperature
• Increased usage of steel scrap
• Ensures little loss of Si and Mn in molten metal in a reductive atmosphere, saving ferro
alloys cost
• Energy savings of 25-30%
6.3.1 Oxygen enrichment in Cupola furnace

Oxygen enrichment is an established practice for increasing the operating efficiency of Cupola
furnace. This also raises the tapping temperature and increases the melting speed.
Though a method using an Oxygen enrichment membrane has also been developed recently,
generally pure Oxygen produced by evaporating liquid oxygen is added through inserting duct
in the air blast tube. Oxygen is diluted with blast air and enriched uniformly to 22 to 25%
blasted through tuyeres.

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6.4 Induction furnace

In induction furnace a magnetic field is generated by the current passed through induction coil.
Material to be melted is placed in the magnetic field. An electromotive force is induced by the
action of ectromagnetic Induction and the induced current flows to heat up and melt the
material placed in the magnetic field.
Induction furnace is classified into two types based on the operating frequency.
• Medium frequency induction furnace – 500 to 600 Hz
• Main frequency induction furnace - 50 Hz
The main features of the induction furnace are as follows:
• High efficiency due to direct heating of material by electromagnetic induction
• Improved temperature control.
• Uniform metal composition by agitation effect
• Heating is done without air. Hence no metal loss due to oxidation effect
6.4.1 Energy consumption pattern in induction furnace

Typical power consumption in induction melting furnace of capacity 12 – 15 tonnes is in the
range of 625 – 650 kWh/tonne of metal(cast iron) melted. In case of smaller furnaces the
specific power consumption increases.
The specific power consumption of induction furnaces of capacity 1 – 3 tonnes is in the range
of 700 – 725 kWh/tonne of metal melted.
In induction furnace the efficiency is expressed as total energy input detective electrical and
heat transfer losses.
The electrical losses consist of losses in transformer, frequency converter, capacitor banks
cable and coil losses. Heat losses in induction furnace consist of heat escaping from furnace
wall to coil side (carried away by cooling water0, radiation loss from melt surface and heat loss
due to slag removal.
Efficiency of medium frequency furnace is higher compared to efficiency of main frequency

furnaces. The operating efficiency of medium frequency furnace is in the range of 55-60%,
whereas the operating efficiency of main frequency furnace is in the range of 45 –50%.
In main frequency furnaces larger is the heat loss, whereas in case of medium frequency
furnaces. This is due to the fact that main frequency furnace has lower power density, longer
melting time and hence higher heat loss. Medium frequency furnace has higher electrical loss
due to frequency conversion and lower heat loss due to lower melting time.

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7.0 ENERGY SAVING MEASURES IN MELTING PROCESS

In foundry industry substantial reduction in energy consumption can be achieved by improving
the operational practices. Improvement of operational practices include the following:
• Improving melting process
• Reducing heat losses and heat input
This can be implemented irrespective of the type of melting furnace used for metal melting.
These measures do not call for any major investment. But these need to be closely monitored
for achieving reduction in energy consumption and sustaining the same.
7.1 Improving melting process

Energy consumption in melting furnace can be reduced by improving the charging practices,
quality of charge, reducing the time taken for transferring the molten metal etc.
7.1.1 Removal of rust, sand and oil from charge

Rust, sand and oil in the charging material form slag during the melting process. Majority of
time the slag formation is due to sand in returns such as runners & risers and rust in scraps.
Before the metal tapping from the melting furnace the slag is removed.
Due to slag formation both heat loss and material loss takes place. Typically in a melting
furnace, the heat loss due to slag formation is in the range of 1-2%.
The heat loss and material loss can be minimised by reducing the slag formation. This can
be achieved by shot blasting the charge and removing the sand, rust etc. In addition, attention
shall be paid to the material storage to prevent rusting.
7.1.2 Reducing the analysis time

Molten metal analysis is an important process through which, the quality of the castings is
established from material composition point of view.
Melting and holding time of molten metal can be reduced by reducing the time taken for metal
analysis. To realize this, it is necessary to put the melting furnace and analysis test place as
near as possible and attention should be paid for rapid and exact communication of the
analysis result.
The latest trend is utilizing spectrometer for molten metal analysis. This reduces the analysis
time substantially. Molten metal analysis can be done within 5-10 minutes.
Reducing the time taken for metal analysis directly reduces holding time of the molten metal
in furnace and hence the power consumption. Energy saving of 10-15 units per tonne of
molten metal can be achieved in furnaces, where holding is more than 30 mins.

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7.1.3 Reducing holding time of molten metal in furnace

The time taken for the mould preparation should be matched with the metal tapping time.
Molten metal should not weight for the moulds. This can be achieved by advanced planning
and close monitoring.
Matching of time taken for mould preparation and metal tapping from the furnace will lead to
reduction in holding time of molten metal in the furnace and hence reduction in power
consumption.
7.1.4 Reduction of residual molten metal

The weight of casting has to be calculated and the weight of material melted should be
matched with the weight of castings to be produced. This reduces the quantity of residual
molten metal and the associated energy consumption in the furnace.
7.1.5 Reducing time of slag removal

The slag formation takes place due to oxidation of molten metal and the unwanted material in
the feed such as rust, sand etc. The slag is removed periodically before tapping the molten
metal for the casting process.
Generally in a medium size foundry industry the slag removal is done manually. Each slag
removal takes minimum about 5 to 10 minutes.
The latest trend is going for back tilting mechanism for the induction furnace. The slag removal
can be done quickly. This leads to reduction in cycle time of the metal melting process and
reduction in energy consumption. Furnaces above 5 tons /batch capacity should be provided
with back tilting facility for de-slagging.
Quick slag removal using back tilting mechanism in the induction furnace results in atleast 1-
2% reduction in energy consumption.
7.1.6 Reduce the time of composition adjustment

Checking of composition of molten metal and again changing the composition during the
melting process leads to increased cycle time. The increased melting cycle time leads to
increased to energy consumption.
The right composition can be arrived at first check by correctly weighing and feeding the raw
material into the furnace. This can be achieved by installing load cells in the charge hopper.
Weighing and feeding of raw materials ensures right composition at first check.
7.1.7 Optimizing size of foundry coke

The size of foundry coke has a direct bearing on the coke consumption per ton of iron melted
as well as the melting rate. The use of come below 75 mm(3") in size reduces the metal
temperature for a given amount of coke charge. The decrease in coke size also increases
the blast pressure required to deliver a given volume of air.

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When the coke size decreases below 75 mm(3") the amount of coke in the charge must be
increased to ensure the required tapping temperature.
The following figures indicated, effect of coke size on metal temperature when using 62
mm(2.5") coke, 88 mm (3.5") coke in both 725 mm’ (29") and 1200 mm (48") cupolas
Additional coke amounting to about 2.5% of the metal charge would be required when using
2.5" (62mm) coke when compared to 3.5" (88mm) coke. This additional coke would reduce
the melting rate by about 20%
Coke saving in cupola furnaces can also be effected by:
• Undertaking repair and burn back of the linings to maintain the melting diameter to that
compatible with the melting rate required.
• Regularly checking the weighing equipment to ensure accurate weight
• Keeping the cupola full of charge upto the charging door, thereby the descending metallic
charge obtain maximum preheating from the ascending hot gases. This calls for adequate
height of stack above the bed till the charging door.
• Recovering the un burnt coke by water quenching the contents of the drop and using the
same for split charge after sorting
By adopting the suggestions mentioned above, it could be possible to effect a coke saving of
one lakh tonnes per annum at the national level worth Rs.500 million assuming about 90% of
grey iron production comes through cupolas and coke to metal ratio of 1:8.5. The energy
saving measures would also reduce air pollution as SO2 level in stack emissions come down.
7.2 Reducing heat losses and heat input
7.2.1 Lower metal tapping temperature

The energy consumption increases with increase in tapping temperature. The heat loss from
the furnace is also increases with increase in operating temperature. Hence, the temperature
of molten metal should be closely monitored to avoid over shoot in temperature and increased
energy consumption.
In gray iron melting, energy consumption increases by 20 kWh/ tonne for 100oC over shoot in
temperature.
To keep the tapping temperature lower, the parameters such as pouring temperature requirement,
the ladle traveling distance and drop in metal temperature during metal transfer etc should be
considered.
7.2.2 Provide furnace covers

In induction furnaces the molten metal is maintained at a temperature of about 1400-1450oC
depending upon the requirement. The furnace is kept open and the molten metal is directly
exposed to atmosphere. This leads to radiation loss.
In an induction furnace the radiation loss is estimated as about 3 to 5%. This radiation loss
could be minimised by providing closed hood for the furnace and a cover.

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8.0 LIST OF ENERGY SAVING PROPOSALS IN FOUNDRY INDUSTRY
8.1 Short-term energy saving proposals

1. Reduce the tapping temperature of the molten metal from the furnace to match with the
requirement
2. Insulate and provide insulated lid for the ladle to minimise heat loss during metal transfer
3. Provide insulated lid for the holding furnace to avoid heat loss due to radiation
4. Install oil fired ladle preheating to minimise heat loss from the molten metal during metal
transfer
5. Suitably size the ladle to match with the molten metal requirement for the casting process
6. Reduce the tap to tap time in the furnace
7. Utilise the entire quantity of molten metal in the furnace by optimal scheduling of pouring
8. Optimise the operating pressure of the compressor to match with the requirement
8.2 Medium term energy saving proposals

1. Improve combustion efficiency of cupola furnace
2. Optimise the size of the coke fed into cupola furnace
3. Practice oxygen enrichment in cupola furnace
4. Optimise combustion air supply to the oil fired heat treatment furnaces
5. Install blower air for sand cooling and avoid compressed air supply
6. Install temperature indicator control for induction furnace cooling tower fans
7. Install KWH indicator cum integrator for induction furnace
8. Segregate thick and thin section molten metal requirement and operate furnace at different
temperatures
9. Match the moulding time and melting time to minimise the holding time of the molten
metal
10. Monitor temperature of molten metal continuously using online infrared thermometer and
avoid overshoot in temperature
11. Bundle and improve the bulk density of the input material
12. Provide closed hood for the furnace and minimise the loss due to radiation and convection
13. Control of sintering cycle through automatic sintering cycle time
14. Optimise cooling water supply to the induction furnace
15. Apply ceramic coating on the inner walls of heat treatment furnace for improving heat
transfer

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8.3 Long term energy saving proposals

1. Install spectrometer for molten metal analysis and minimise testing time
2. Install automatic vibratory feeder for faster and continuous feeding of material
3. Charge hopper and furnace on load cells to achieve right composition at the first check.
4. Convert cold blast cupola furnace to divided blast cupola furnace
5. Replace electrical heating with thermic fluid heating for core baking oven
6. Install air pre heater for preheating the combustion air supply to the heat treatment furnaces
7. Install medium frequency induction furnace in place of main frequency furnace
8. Install dual track medium frequency furnace
9. Replace electrical Arc furnace with medium frequency furnace
10. Replace existing oil fired aluminium melting furnaces with gas fired furnaces
11. Segregate high pressure and low pressure compressed air users in the foundry industry
12. Install variable frequency drive for the screw compressor
13. Replace pneumatic operated tools with electrical tools

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Case study - 1
INSTALL KWH INDICATOR CUM INTEGRATOR FOR INDUCTION

FURNACE
Background
Medium frequency induction furnace is used for metal melting. The specific energy consumption
pattern for each batch is monitored. There is a huge variation in the specific energy consumption.
The variation in specific energy consumption is due to operational practices such as over
shoot in metal temperature, holding of molten metal in the melting furnace due to break down
in the moulding line, metal waiting for tapping and furnace waiting for raw material etc. The
lowest specific energy consumption is achieved in few batches due to adoption of the best
operational practices incidentally in those batches.
The latest trend is installing KWh Integrator for the furnaces. The power consumption required
for the melting has to be established based on the lowest specific energy consumption achieved
in the past. The established power consumption should be set as a target for each melt.
The KWh integrator measures the power consumption as the melting progresses and indicates
the units available to complete the batch as per the target. The KWh Integrator gives the signal
to the operators to tap the molten metal within the target power consumption.
The advantages of installing Kwh indicator cum integrator for the furnace are as follows:
• The furnace operators get an opportunity to take necessary steps online to complete the
metal tapping within set target power consumption
• The lowest specific power consumption in the furnace for metal melting could be sustained
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.

KWH indicator cum integrator was installed for the medium frequency furnace.
The power consumption per ton of molten metal is established based on past records. Target
for power consumption per ton of molten metal is set as 650 units/ton.
Implementation methodology

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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 10,000 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 25 Crores in Indian foundry
industry.
The investment opportunity for KWH indicator is about Rs 50 Crorers.

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Case study – 2
INSTALL MEDIUM FREQUENCY INDUCTION FURNACE

OF MAIN FREQUENCY FURNACE
Background
Induction furnace can be basically classified into two types depending upon the operating
frequency.
• Medium frequency furnace – over 500 Hz
• Main frequency furnace – 50 Hz
Heat efficiency of medium frequency furnace is higher than that of main frequency furnace.
The medium frequency furnace can be operated with three times higher power density than
the main frequency furnace. This speeds up the melting rate, reduces the cycle and the
associated heat losses. This leads to increased operating efficiency of the furnace.
Main frequency furnace has higher heat loss, where as medium frequency furnace has higher
electrical loss. This is explicable from the fact that low frequency furnace has lower power
density at melting and larger heat loss due to long melting time.
While medium frequency furnace has higher power density. Heat loss is less due to short
melting time and primary electrical loss is higher due to frequency conversion.
The other advantages of medium frequency furnace over main frequency furnaces are
• Absence of molten heel and hence increased productivity
• Reduced start up time
• Less melting time and hence reduced losses
Previous status
In a large size foundry industry a main frequency furnace of capacity 10 tons/batch was in
operation. The specific power consumption of main frequency furnace was 690 units/ton of
molten metal.

The main frequency furnace was replaced with medium frequency furnace of the same capacity.
The specific power consumption of metal melting has been reduced to 615 units/ton of molten
metal.

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The implementation of the project resulted in reduction of specific power consumption of about
95 units/ton. This saving annually amounted to about 9.0 Lakh units.
Financial analysis
The total benefits amounted to a monetary annual savings of Rs 3.15 million. The investment
made was around Rs 20.00 million. The simple payback period for this project was
76 Months.

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Case study - 3
INSTALL SPECTRO METER FOR ANALYSING THE MOLTEN

METAL
Background
Molten metal analysis is an important process through which, the quality of the castings is
established from material composition point of view.
Typically in a medium scale and large scale foundry industry the molten metal sampling is
done and then tested in the laboratory. The metal sampling and testing takes about 30 min.
This adds to the holding time of the molten metal in the furnace.
Melting and holding time of molten metal can be reduced by reducing the time taken for metal
analysis. This can be achieved by installing a spectrometer for analyzing the quality of molten
metal.
The spectrometer analysis takes only about 5-10 mins. This leads to significant reduction in
holding time of the molten metal in the furnace and hence reduction in energy consumption.
Present status
In one of the medium size foundry industry laboratory test method is followed for testing the
molten metal. Time taken for the molten metal testing is about 15-20 min.

The spectrometer was installed for molten metal analysis. This has minimised the time taken
for the analysis by 60-70%.
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 0.42 million. The investment
made was around Rs 0.80 million. The simple payback period for this project was 23 Months.


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Case study – 4
INSTALL ONLINE SHOT BLASTING MACHINE FOR CLEANING

THE RETURNS
Background
The returns such as runners and risers from the moulding section is again utilised for melting.
Typically in a small scale foundry industry the quantity of runners and risers accounts for about
30-40% of the quantity of total feed into the furnace.
The returns contain green sand, which leads to increased slag formation. Also if the feed is
rusted, the rust leads to slag formation. Before tapping the molten metal for the casting
process, the slag formed on the top of the furnace is removed.
The slag formation results in increased metal loss and also energy loss. The energy consumption
due to slag (1.2 units/kg of slag) is two times the power consumption of the metal melting. The
metal loss in the furnace is about 4-5% and the energy loss is about 2-3% of the energy input
to the furnace for melting.
The slag formation in the induction furnace can be minimised by cleaning the feed to the
furnace. This can be achieved by shot blasting the feed materials, specifically the returns
before fed into the furnace.
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.

Shot blasting machine was installed for cleaning the returns and fed into the furnace for
melting process.
Benefits
The slag formation was minimized and hence metal
loss was reduced from 6% to 2.5-3%. The power
consumption is reduced by 8-10 units/batch. Cost benefit analysis
Financial analysis
This amounted to an annual monetary saving (@
Rs 3.50/unit) of Rs 0.52 million. The investment • Simple payback - 46 months
made was around Rs 2.00 million. The simple
payback period for this project was 46 Months.

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423
Case study -5
REPLACE ARC FURNACE WITH MEDIUM FREQUENCY

INDUCTION FURNACE
Background
In the arc furnace the electric arc is produced between the electrodes. The heat generated due
to electric arc is utilised for melting the metal.
In arc furnace the melting heat efficiency in the process from ordinary temperature to melt
down is high. But the heat efficiency in superheating process after melt down is lower than half
of induction furnace.
The very low heat efficiency during superheating leads to increased specific power consumption
in the Arc furnace.
The typical specific power consumption between the Arc furnace and the induction furnace is
given below.
Arc furnace - 710 - 720 units/ton

Main frequency induction furnace - 680 - 690 units/ton
Medium frequency induction furnace - 590 - 600 units /ton
Hence there is a good potential to save energy by installing medium frequency furnace.
Additional benefits
• Cost savings due to elimination of electrodes
• Reduction in power consumption of exhaust system
• In some of the states an additional tariff to the extend of 25% is charged for the use of Arc
furnace for the melting process. This additional tariff can be totally eliminated.
Present status
In one of the large-scale foundry industry Arc furnace of capacity 14 tons is used for cast iron
melting process.
The specific energy consumption of the Arc furnace was in the range of 710-715 units/ton of
molten metal.

The arc furnace is replaced with two numbers of medium frequency furnaces of capacity 8
tons/batch each.

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The specific power consumption of medium frequency furnace is 610 units/ton of molten
metal.
Benefits
The implementation of the project resulted in reduction in energy consumption of about 110
units/ton of molten metal.
Financial analysis
Implementation of the proposal resulted in monetary benefit of Rs 6.5 million. Investment
made was Rs 50.00 million. The payback period was 92 Months.


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426
Case study - 6
MONITOR TEMPERTURE OF MOLTEN METAL CONTINUOUSLY

SUING ONLINE INFRARED THERMOMETER
Background
Molten metal temperature is an important parameter for the casting process. Lower molten
metal temperature will lead to defective castings. The tendency of the operators of the furnace
is to maintain higher molten metal temperature than the requirement considering all the
temperature drops during metal transfer.
The temperature of molten metal in the furnace is monitored periodically using contact type
thermocouple. This is done to ensure that the temperature of the molten metal is more than
the requirement.
This temperature measurement at intervals using contact type thermocouple leads to overshoot
in temperature. The overshoot in molten metal temperature leads to increased power
consumption in the furnace.
The latest trend is to install online infrared pyrometer. The pyrometer continuously monitors the
molten metal temperature and can be prominently displayed. This facilitates tapping of molten
metal within the required temperature and minimise overshoot in temperature.
Previous status
Temperature requirement for molten metal is 1460oC. The molten temperature overshoots
beyond 1480oC.

Online infrared pyrometer was installed for continuously monitoring the molten metal temperature.
The overshoot in temperature of molten metal was avoided.
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

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428
Case study – 7
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.

Air preheater was installed for preheating the combustion air supply. The combustion air was
preheated to a temperature of about 180oC.
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


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430
Case study -8
SEGREGATE HIGH PRESSURE AND LOW PRESSURE

COMPRESSED AIR USERS
Background
In foundry industry the compressed air pressure requirement varies depending upon the users.
For pneumatic actuators and cylinders the compressed air pressure requirement is about 5-
5.5 kg/cm2.
For other applications such as cleaning the compressed air pressure is not the criteria. The
volume of air flow is the criteria and not the operating pressure. The maximum compressed
air requirement is 2.5-3 kg/cm2.
In compressed air systems, the power consumption of a compressor is directly proportional

to the operating pressure of the compressor. The compressor power consumption increases
with increase in pressure and vice versa. Hence there is a good potential for energy saving
by segregating the high pressure and low-pressure compressed air (cleaning air) users and
supplying compressed air at lower operating pressure.
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 utilised for the pneumatic operations in the core
making m/c’s, pneumatic lifts, pneumatic grinders and cleaning operations etc.
The total number of cleaning points in core making sections is 32 and that in the Aluminium
Die Casting (ADC) section is 54. The quantity of compressed air utilised for cleaning operation
is estimated as 750 cfm in the core-making area and about 850 cfm in the Aluminium Die
Casting section.

The high pressure & low-pressure (for cleaning application) compressed air users were
segregated by laying a separate compressed air line.
Compressor of capacity 1500 cfm was dedicated for the cleaning applications and operated
at a pressure of 3.0 kg/cm2.
Benefits
Implementation of the project resulted in atleast 30% reduction in compressor power
consumption.

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Financial analysis


432

433
Case study -9
INSTALL VARIABLE FREQUENCY DRIVE FOR SCREW

COMPRESSOR
Background
In compressed air system once the required pressure is achieved the compressor is getting
unloaded. The loading unloading pattern indicate the quantity of compressed air requirement
in the plant. The higher unload time of the compressor indicates excess capacity available in
the compressor
During the unload time, the compressor does not deliver useful work, but operates only to
overcome its internal losses. The compressors should be so selected to operate with a
minimum unload time.
There is a good potential to save energy by minimising the unload time of the compressor.
This can be achieved by varying the speed of the compressor to match with the compressed
air requirement. speed variation can be carried out by installing a Variable Frequency Drive.
A Variable Frequency Drive (VFD) with the feed back as the receiver pressure, would constantly
sense even the slightest increase / decrease in the receiver pressure. Accordingly it would
vary the speed of the compressor.
This installation of the VFD would completely avoid the unload time and would hence result in
tremendous savings in power consumption.
Present status
A screw compressor of capacity 480 cfm is in operation for the compressed air requirement.
The load / unload pattern of the 480 cfm screw compressor is as below:
Description Power consumption (kW) Time (%)
Load 81.5 43
Unload 49.7 57
The load and unload timings of the compressor is recorded in the hour meter fitted to the
compressor. Over the past 1600 hours of operation of the compressor, the compressor is
loaded only for 43% of time.

The screw compressor was installed with variable frequency drive.

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Benefits
The implementation of the proposal resulted in the following benefits:
The unload power consumption of the compressor was totally eliminated.
The operating pressure is precisely maintained to match with the requirement. This has resulted
in reduction in operating pressure of 0.5 kg/cm2 and hence corresponding reduction in load
power consumption.
Financial analysis


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436
Case study -10
REPLACE PNEUMATIC TOOLS WITH ELECTRICAL TOOLS
Back ground
In foundry industry pneumatic tools are one of the major compressed air consumers. Pneumatic
tools are used for core dressing in the core shops and in the fettling shop for the grinding
operations.
Also pneumatic hoists are used for lifting the products. The compressed air pressure requirement
for operating the pneumatic tools is in the range of 5-5.5 kg/cm2. Use of compressed air for
operating the tools is energy intensive and costlier.
Electrical energy is used to generate high pressure air in the compressor, which has the
operating efficiency in the range of 35-40% i.e only maximum 40% of the energy input is
available in the form of compressed air.
If electrical energy is directly used for driving the tools, the inefficiency of the compressor can
be eliminated. Which will result in atleast 50% reduction in energy consumption.
Hence there is a good potential to save energy by replacing the pneumatic operated tools with
electrical tools.
Present status
In one of the medium scale foundry industry about 20 pneumatic tools are used for core
dressing and grinding operations in the fettling sections.
The quantity of compressed air utilised for operating the pneumatic tools is about 250 cfm

All the pneumatic operated tools such as grinding machines and the pneumatic hoists are
replaced with electrical tools and hoists.
One compressor of capacity 250 cfm, which was in operation for the compressed air supply
was stopped.
Benefits
Implementation of the proposal has resulted in 50% reduction in energy consumption of the
tools.
This has also resulted in avoiding maintenance of one compressor running for the pneumatic
tools.

437
Financial analysis
Implementation of the proposal has resulted in annual saving of Rs 0.75 million. The investment
made was Rs 2.30 million for converting the pneumatic tools to electrical tools. The payback
period was 37 Months.

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439
Case study -11
INSTALL OIL FIRED CORE DRYING OVENS FOR DRYING THE

CORES
Background
In medium scale and large scale foundry industry electrical energy is used for drying the cores
in the core drying ovens. the cores will be dried in batches by placing inside the electrical
heated ovens for a period of time.
Typically the operating temperature of the core drying oven is in the range of 175 –200oC.
Electrical energy is high grade energy. Cost of heating using electrical energy is very high
compared to cost of heating using low grade thermal energy.
The cost comparison between the electrical heating and thermal heating is given below.
• Cost of electrical heating @ Rs 3.50/unit - Rs 4283/MMkCal
• Cost of thermal heating (LDO fired) - Rs 1830/MmkCal
Cost of electrical heating is two times more than cost of thermal heating.
Hence there is a good potential to save cost by utilising thermal heating for the core drying
applications.
In the oil fired system, the fuel is fired using a burner and mixed with air. The hot gas is
circulated in a chamber through the cores are sent for the drying process. This system is a
continuous process unlike the electrical heated ovens. This leads to increased production also.
Present status
In one of the medium scale foundry industry electrical heated oven is used for the core drying
applications.
The operating temperature of the core drying oven is 200oC. The power consumption of the
core drying oven is 120 kW and the heaters are “switched ON” for atleast 50% of the operating
time.

The electrical heated oven was replaced with oil fired oven for the drying application.
This has resulted in 50% reduction in operating cost of the core drying oven

440
Financial analysis


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442
Case study -12
REPLACE EXISTING OIL FIRED ALUMINIUM MELTING

FURNACES WITH GAS FIRED FURNACES
Background
Typically for aluminium melting either electrical or oil fired furnaces are used. In oil fired
furnaces flue gas passes around the crucible in which metal to be melted is placed. The heat
transfer from the flue gas to the metal takes place through the crucible.
The melting furnaces the oil fired burners are fitted with a dedicated combustion air supply
blower. The exhaust flue gas from the melting furnace is in the range of 750 to 800oC. The
flue gas is directly sent to atmosphere. This results in increased flue gas loss.
In oil fired system, the quantity of excess air sent for the combustion process is in the range
of about 25-30% of the stoichiometric air requirement. The increased excess air supply leads
to increased flue gas loss.
The recent trend is installing gas fired system for Aluminium melting application. For gas fired
system the excess air requirement is only 3-5% of Stoichiometric air requirement, which is
very low compared to excess air requirement for the oil fired system. This results in lower loss.
In the gas fired system gas firing can be effectively controlled based on temperature. The
temperature of flue gas between the outside shell and crucible or molten metal temperature
can be given as a feed back to the gas firing control system. This eliminates over shoot in
temperature of molten metal.
In the gas-fired system, the quantity of combustion air requirement is less compared to
combustion air requirement for the oil fired system. Hence, the power consumption in the
combustion air supply fan is also significantly reduced.
There is a good potential to save energy replacing the existing oil fired system with gas-fired
system for all the melting furnaces in the aluminium foundry.
Present status
In one of the medium scale aluminium foundry oil fired furnaces are used for Aluminium
melting. Light Diesel oil and furnace oil are used as fuel for the melting furnaces. The details
of the melting furnaces available in the Aluminium foundry are as follows:
S No Furnace type No of furnaces Capacity Kgs Burner capacity lit/hr
1 Big Skelenar 1 500 62
2 Small Skelenar 4 250 30
3 Big tilting 3 300 32
4 Small tilting 5 150 20

443

The oil fired systems were replaced with gas fired system for all the melting furnaces in the
aluminium foundry.
Benefits
The implementation of the proposal has resulted in about 20% fuel cost saving.
Financial analysis
The benefits amounted to a monetary annual savings of Rs 2.01 million. The investment

• Investment - Rs. 2.50 million

444

445
List of Contractors / Suppliers
Name of the Company and Address Area of expertise

INDUCTOTHERM INDIA LTD Induction Furnaces,
Bopal, Ahmedabad - 380 058 Controls for the
Gujarat (India) furnaces
Tel:91-79-3731961 (8 Lines)
Fax: 91-79-3731266, 91-79-3731268
Email: iil@inductothermindia.com
URL: www.inductothermindia.com
M/S ENCON INTERNATIONAL (P) LTD. Induction furnaces
Mr. R.P. Sood
14/6, Mathura Road,
Faridabad - 121 003 (Haryana)
Tel: +91-129-2275307
Fax: +91-129-2276448
E mail: encon@ndb.vsnl.net.in
PILLAR INDUCTION (I) LIMITED Induction furnaces
EXPORTERS OF FURNACES.
A-13, 2nd Avenue Anna Nagar, Chennai - 600102,
India
Tel(44)6261703/26261704/2621705
Fax: +(91)-(44)-26260189
WESMAN GROUP OF COMPANIES Burners
"Wesman Center", 8, Mayfair Road,
Kolkata - 700 019,
Tel:(91)-(33)-22405320
Fax: +(91)-(33)-22478050
ADVANCE HEATING SYSTEMS Industrial furnaces,
d1/23 (back side) Mayapuri ind. area, phase-ii, New ovens, oil fired
Delhi -110064 systems, heat
Tel: 91-11-5139315 treatment furnaces
Email:advanceheat@yahoo.com
ASSOCIATED INDUSTRIAL FURNACES Shuttle & Tunnel

f-9, sector-xi, Noida -201301 kilns, pit type
Tel:91-11-84529169 annealing furnaces,
Fax: + 91-11-84555703 continuous ovens
E-mail: aifdli@vsnl.com and driers
Website

446
ENGINEERS ASSOCIATE Muffle furnaces,

10-d, Garpar road, Calcutta -700009 oven, drier, thermo
Tel: 91-33-3510690 couple
E-mail: exporter@exportersindia.net
HEATCON SENSORS (P) LTD. Temperature
mes road, bangalore -560013 controllers,
Tel:+ 91-80-8384564 thermocouples etc
Fax: + 91-80-8382914
E-mail: heatcon@bgl.vsnl.net.in
Website http://www.heatc onsensors.com
Electrical and oil
INDUSTRIAL FURNACE & CONTROLS
fired furnaces,
Vempu road, Bangalore -560021 temperature
Tel:+ 91-80-3329840 controllers,
Fax: + 91-80-3329840 thermocouples
E-mail: ifc1@vsnl.com
Website http://www.indfurnace.com
MACRO FURNACES PVT. LTD. Electrical and gas
16/2, mathura road, faridabad -121002 fired industrial
Tel:+ 91-129-5260004 furnaces
Fax: + 91-129-5260146
E-mail: aastha10@rediffmail.com
PYROTHERM ENGINEERS PVT. LTD. Aluminium melting
245/2b, 2b-vanagaram road, athipet, furnaces, ovens
Chennai -600058
Tel:+ 91-44-6358038
Fax: + 91-44-6358038
THERMOTHERM ENGINEERS Industrial furnaces,
455, 12th cross, 4th phase, heat treatment
peenya indl. area, furnaces and ovens
bangalore -560058
Tel:+ 91-80-8362507
Fax: + 91-80-8362919
E-mail:thermotherm@usa.net
PADAM ELECTRONICS Muffle furnaces,
electrical furnaces,
Plot No 1/103, diesel fired
West Kanti Nagar, St No 3, furnaces and heat
New Delhi - 110 051, India treatment furnaces
Tel:+(91)-(11)-22001791/22003581
Fax: +(91)-(11)-22003581
Website: http://www.indiamart.com/padam -electronics
NORTH-WEST INDUSTRIES annealing furnaces.
Opp. Indo Bulger, Meerut Road,
Sihani Chungi,
Ghaziabad - 201 001, India

447
Tel:+(91)-(120) -2736650/9810367173
Website: http://www.indiamart.com/northwest
Medium frequency
ALIDIA POWERTRONICS PRIVATE LIMITED
induction melting
Address: Shed 1, Computer Complex, DSIDC Scheme
and heating
1, Okhla Industrial Area Phase II,
furnaces, portable
New Delhi - 110 020, India
high frequency
Tel:+(91)-(11)-4963017/4963028/4963163
Induction heating
Fax: +(91)-(11)-26386602
equipment.
Website: http://www.indiamart.com/alidia
METROPOLITAN EQUIPMENTS & CONSULTANTS Roller hearth tunnel

PVT. LTD. furnaces, material
Plot No. A - 486, handling systems
Wagle Industrial Estate, Road 24, etc
Thane - 400 604, India
Tel:+(91)-(22)-5823294/5800799/5814654
Fax: +(91)-(22)-5800801
Website: http://www.indiamart.com/metropolitan
ENCON INTERNATIONAL (P) LTD. All types of
Address: 14/6, Mathura Road, furnaces
Faridabad - 121 003, India
Tel:+(91)-(129) -2275307/2275607
Fax: +(91)-(129)-2276448
Website: http://www.indiamart.com/enconindia
Precision Controls All types of

furnaces
Manufacturer & exporters of furnaces.
20, SIDCO Industrial Estate,
mbattur, Chennai - 600098, India
A
Tel: +(91)-(44)-26250370
Fax: +(91)-(44)-26257835
REFRACTORIES & FURNACES COMPANY Furnaces and
P.O.Box:80, Kezhakkenada, refractories
Chengannur - 689 121, India
Tel: +(91)-(479]-454310 Fax: +(91) -(479]-452481

Energy Conservation in Textile Sector & Technology in Textile Industry
448
Textile
Energy Intensity 10.4% of total energy consumption
Energy saving potential 506 MW
energy saving projects Rs 40000 million

449
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 mordanised.
Indian textile industry is worth around Rs 800 billion (US$ 22.05 billion) accounting for
approximately 20% of India’s total industrial output.
The textile industry is an important segment of the country’s economy, which contributes 3%
to country’s GDP and earns about 27% of the gross export earnings, totaling to 12.1 BN USD,
USD 50 billion has been set by 2010. Indian textile sector also employs 15 million people,
about 21% of the work force.
The cotton cloth production in the year 2001 – 02 was 40256 million sq. mtrs. Which 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%.

450
Process Flow Diagram for High Value Cotton Fabric
Raw Material
Blow Room
Carding
Yarn
Preparation
Combing
Draw Frame
Ring Frame
Yarn Dyeing Winding
Warping
Sizing
Weaving
Singeing
Bleaching
Mercerizing
Finishing

451
Process Flow Diagram for Denim Fabric
Raw Material
Blow Room
Card
Drawframe
Autocore
Dyeing & Sizing Processing
Weaving
Finishing
Folding
Packing
Dispatch

452
Textile Manufacturing
The manufacturing process in a composite textile mill involves three broad categories:
1. Spinning
2. Weaving
3. Processing
1.1 Spinning
a) Blow room
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.
b) Carding
During the carding process the laps are acted upon by a series of wire points set close
together and individual fibre separation is achieved. Residual trash in the opened cotton
is almost entirely removed in this process.
c) Combing
This is an additional process introduced between carding and drawing to parallelise the
fibres, remove short fibres and impurities so that yarn quality obtained is substantially
improved.
d) Drawing
In this operation the drawn fibres are made thinner and wound on to a bobbin after
introducing a small amount of twist.
e) Ring spinning
In this operation attenuation of the assembly of fibres takes place so as to obtain the
required count and the required twist is imparted to obtain the desired strength. The
resulting material is wound on a spindle.
f) Winding
The spinning packages obtained in ring frames contain a small quantity of yarn, which
are converted to bigger packages in winding.
g) Reeling
Certain markets required the yarn to be supplied in the form of hanks containing certain
lengths of yarn, which is on a reeling machine.
2.1 Weaving
a) Warping
The yarn from spinning frames is cleaned and obtained on a long length of cones. These
cones are placed on warping creel and the ends are drawn forward and wound on to a
warper beam placed on warping machine headstock.

453
b) Sizing
A number of warper beams as required are placed at the back of the sizing machine and
the layers of yarn are drawn forward and impregnated in a solution containing adhesive,
gum & lubricant and dried so as to withstand the rigors of weaving.
c) Weaving
The sized warped beams are mounted at the back of the loom and by suitably drawing
the ends through warp stop motion heads and the reed, they are made to interlace with
the weft, to produce the fabric. The woven fabric is collected in front of the loom.
3.1 Processing
a) Singeing
Singing is a process in which the protruding fibres and loose threads on both faces of
the fabric are removed. This is achieved by passing the fabric close to gas flames or
electrically heated hot plate.
b) Desizing
The fabric is given an enzyme treatment so that the impurities such as starch, gum etc.,
are degraded into water-soluble products, which are then easily removed by washing.
This carried out in jiggers.
c) Bleaching
Bleaching is a process where the natural colour of Grey fabric is removed and rendered
white by treating it with sodium hydrochlorite or hydrogen peroxide. The treatment time
varies depending on the fabric.
d) Mercerising
The purpose of mercerising is to impart luster and strength to the fabric. The process
consists of treating the fabric with concentrated caustic soda solution. Stretching prevents
the shrinkage of the material. Caustic is washed off while in the stretched stage.
e) Dyeing
During dyeing, a single shade is applied to the material, which can be a batch or continuous
process. There are different methods of dyeing – dyeing of yarn in cones, cheese, sheet
dyeing, rope dyeing, jet dyeing, jigger dyeing etc.
f) Printing
Printing is done on screen printing machine to impart designs to the bleached or dyed
fabric.
g) Curing
Curing is a treatment on curing machines to improve crease recovery properties of cotton
fabrics or to fix pigment colour on fabric. Curing is done on polymersing machine.
h) Heat setting
Heat setting is normally carried out in a stenter to impart dimensional stability to synthetic
fabric. The temperature and time for heat setting depends on the fabric count.
i) Finishing
Finishing process is done to improve the attractiveness of the fabric. Some of the major
finishing processes are anti shrink finishing, crease – resistance finishing, Shrinkage
finishing etc. Finishing is carried out on stenter or finishing machine.

454
Case study - I
Install High Efficiency Atomisers in Lieu of Nozzles in
Humidification Plants
Background
Humidification plays an important role in any composite textile unit. In composite textile units,
humidification is a major load.
In textile plants humidity is a critical parameter for the conditioning / stickiness of yarn. Humidity
varies with the type of yarn and type of application. Humidity varies from 50 – 75% based on
applications e.g. spinning, weaving and types of fabric.
Generally, all humidification plants are installed with conventional type nozzles. This requires
small nozzles in large numbers to meet the humidity requirement. This causes loss of force
due to friction for spraying water through small orifice. This also requires high head and high
flow of water.
Now a days better designed atomizer with high efficiency is available. One nozzle can replace
with 50 conventional type nozzles.
Advantages
• No cleaning / Maintenance
• Water flow : 1/3 flow of normal flow required
• Head : 1.45 times normal head required
• Lower flow due to better aomisation
• Substantial energy savings
• Density of atomised water could be adjusted according to the requirement
Recommendations
It is recommend to install atomisers in lieu of conventional type nozzles, where spray pumps
are running continuously.
AHU No Actual Power (KW) No of Nozzles No of Atomisers required
2 7.02 280 6
4 7.04 280 6
5 5.22 288 6
6 4.52 288 6
7 4.76 162 4
8 4.98 288 6
10 4.48 504 10
11 7.86 504 10

455
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
H
Spray u
Nozzle
m
i
D
i
Fan f
Air Flow
i
e
d
A
i
r
Wate
Water


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457
Case study - II
Install Energy Efficient Pnuemafil Fans in Ring Frames

Back ground
The main function of the pnuemafil fans in Ring frame machine is to remove fluff from cotton
/ fiber threads and preparing cones of yarn, which in further used for preparation of yarn
beams.
Normally 5 – 7.5 kW motor is installed for Pnuemafil fan of Ring Frame machine, and
conventional pnuemafil fan consumes 4.1 – 4.5 kW.
Now a day energy efficient fan with suction tube is available which are specially designed and
can reduce power consumption atleast by 20%
Comparison
• For G 5/1 Ring Frames
Sl no Special features Conventional Energy Efficient Fans

Pneumafil fans
1 Weight 14 kgs 6.5 kgs 6.2 kgs

2 Fan Diameter 490 mm 460 mm 420 mm
3 kWh consumed 5.00 3.97 2.41
• Comparative study on Impeller and Suction tube
Spindle no. Conventional fan Energy efficient fan Energy efficient fan
490 mm dia. fan with 490 mm dia. with 460 mm dia.
with suction tube and suction tube and suction tube
(OE) 505 *115 *150 *110
(Middle) 751 *50 *100 *70
(GE) 1008 *30 *85 *60
*Above suction results are in mm water column.
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
• Simple payback - 6 months paid back in 6 months.

458

459
Case study - III
Install VFD For Humidification Fans and Reduce Speed During

Favourable Condition
Background
Humidification, in the textile plants plays a very important role, as humidity plays an important
part in conditioning of the yarns and in turn in manufacturing of end product – fabric.
Humidification system comprises of fans and pumps for water spraying. It is one of the major
consumers of power in textile units.
It is customary to provide two fans adjacent to each other to meet the humidification requirement
and also to avoid complete shut down of humidification system in case of failure of one fan.
During unfavorable climatic condition all the pumps and fans will be running and during favorable
climatic condition, like – Monsoon & winter – when humidity in out side air is good (@90 – 98
% - Monsoon) and temperature is also less, some of the pumps and fans will be stopped.
During favorable condition, normally one fan is stopped and one fan is kept “ON”. This causes
recirculation of part of fresh air and this is energy inefficient method.
The operation is mentioned below:
Area Required condition Fresh Air Intake Power (KW)
Weaving
80 sulzer 28-30oC June – September 12.3

85 % Rh (24 Hrs)
16 sulzer 28-30oC June – September 10.6

85 % Rh (24 Hrs)
Spinning
Rope Race Carding 37-38oC March – September 15.0

50 - 54% Rh (7 Months)
Crosrol Carding 37-38oC 15.0

50 - 54% Rh
LR Section Plant -II 38oC 10.6

54% Rh
Ring Can I & II (LUVA) 38oC 10.3

54% Rh
LTG Plant No 4 38 – 40 oC 12.5

58% Rh

460
Good energy saving potential exists by installation of VFD for supply air fans with closed loop
control system and reducing the speed of the fan.
Recommendation
• Install VFD for supply air fans with closed loop control system.
• Providing feed back of Temperature and % Rh, close loop system can be made.
• Reduce the speed of the fans
• Then put the fans in operation
Good energy saving potential exists by installation of VFD for supply air fans with closed loop
control system and reducing the speed of the fan.
Benefits
Reducing the speed of the fan by installation of VFD will result in annual savings in the tune
of 25 – 30%.


461

462
Reducing the speed of the fan by installation of VFD will result in annual savings of
Rs. 0.36 million. This calls for an investment of Rs. 0.70 million for changing the pulley. This
has a simple payback period of 23 month.
Case study - IV
Convert V-belt Drives to Synthetic Flat Belt Drives For The

TFO Machines
Background
TFO (Two Folds One) machine is used for strengthening yarn by twisting. Generally, V-belt
drive is used for all TFO machines.
Belt is used for transmission purpose. “V” belt causes wedge – in and wedge – out losses.
Flat belt is crown at the center.
Replacement with synthetic flat belts will reduce
• Wedge-In and Wedge-Out losses
• Reduce the mass of the belt
Proven results show that there is a saving potential of 4% by converting V-belt drives to flat
belt drives. Flat belt drives are highly suitable for steady loads.
Motor of TFO machine is normally in the range of 20 – 25 kW and average power consumption
is @10 - 13 kW. Therefore very good potential can be tapped by converting “V” belt drives
to Flat belt drives.
Recommendation
It is recommend to convert V-belt drive to flat belt drive in the TFO machines.
This conversion should be done in phased manner, starting from installation on one or two
machines.
During implementation, it should be ensured that the area is free from oil or water spillage.
There should also be proper alignment between the drive and the driven equipment.
Benefits Cost benefit analysis

The annual savings potential will be @ 4% / machine.

463

464
The annual savings potential is Rs 0.73 million shall be achieved. This will require an investment
of Rs 1.45 million for new flat belts and pulleys and shall be paid back in 24 Months.
Case study - V
Install VFD For Autocoro Suction Motor
Background
In the spinning department, autocoro machine is used for manufacturing yarn. Autocore machine
draws cotton rope and prepares finer count yarn (7s / 16s / 2 X 50s / 2 X 40s etc…) which
is further used as raw material for processing in process department.
Autocoro machine is used to get required count of the yarn and in the process it removes fluff
and other impurities from the yarn. Normally, based on type of count, constant suction pressure
is maintained in the suction box of autocoro machine. Suction motor is used to maintain
suction pressure for removal of fluff and other impurities from yarn.
Suction pressure is varying with the count of the yarn. Maximum suction of 85 mbar is
sufficient for the process. But due to accumulation of fluff in suction box and choking of
suction net suction pressure is varied or maintained high.
Power consumption of suction motor is @ 20 kW because of high suction pressure.
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.


465

466
Case study - VI
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 • Annual Savings - Rs. 0.32 millions
back in 30 months.

467

468
Case study - VII
Reduce the Speed of Exhaust Fans in Stenters
Background
• In Stenters centrifugal fans are kept in continuous operation for removing the exhaust air
after the drying process. The air is collected from various zones and sent to atmosphere.
• It is observed that the dampers provided in ducts from various collection zones are heavily
throttled. The dampers are only 25 – 35% open. Due to damper throttling there is a
significant pressure loss and hence energy loss across the damper.
• Hence, there is a good potential to save energy by avoiding the pressure loss across the
damper control. This can be achieved by reducing the speed of the fan to match the
requirement and increasing the damper opening.
Recommendations
It is recommend to:
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.
Rs 0.03 million for changing the pulleys, which gets paid back in 3 Months.
C

469

470
Case study - VIII
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 re-started 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.
Sample calculation
LR Blow room single line

471
The following motors can be stopped
(Assuming 4500 kg process for 23 hrs running)

Stripper roller : 0.55 kW
Take off roller : 0.37 kW
Opening roller : 4.00 kW
Dust fan : 3.00 kW
De – Duster : 4.50 kW
Mono Cylinder beater : 2.20 kW
Ventilator : 4.00 kW
Total : 18.62kW
Power consumption @ 50% load / hr
18.62 kW X 50% Load = 9.31 kWh
Assuming motor idle time be 10 hrs out of 23 hrs of operation.
Units saved = 9.31 kW X 10 hrs

= 93.1 kWh/day
= 33516 kWh/Annum
Benefits
Rs 0.05 million for changing the pulleys, which gets paid back in 5 Months.


472

473
Case study - IX
Install Transvector Nozzle for the Cleaning Applications
Background
Generally for cleaning application same air pressure is used as air required for plant. For
cleaning application compressed air tapping from main header is taken and same air is used
for cleaning of machines. The observations on compressed air generation and utilization for
cleaning application are as below:
• Three screw air compressors of capacity 1475 cfm is in operation to supply compressed
air for the plant requirements. The compressed air is supplied at an average pressure of
7.00 kg/cm2.
• In weaving section about 10 -15% of the compressed air is used for cleaning the weaving
looms and removal of fluff fabric. There are about 8 numbers of such air cleaning points
available in the plant.
• For cleaning operations the volume of the airflow is the criterion, not the pressure. Air at a
pressure of 2.0-2.5 kg/cm2 can effectively clean the products.
• The following observations were made in cleaning of cabinet section:
1. Total 8 cleaning points in operation
2. 1/ 2 “ hose- pipe is used for cleaning
3. Header pressure is 7.0 Ksc
4. Cleaning points are without guns.
• The recent trend is using Transvector nozzles for cleaning applications. The Transvector
nozzles can be fitted at the user ends. It works based on venturi principle. When the
compressed air flows through the nozzle, the atmospheric air is sucked in through the
holes provided in the periphery of the nozzle.
• The atmospheric air is mixed with compressed air and supplied for cleaning at lower
pressure (2-3 kg/cm2). The atmospheric air replaces 50% of the compressed air.
There is a good potential to save energy by installing Transvector nozzles for cleaning operations.
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.

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475
Case study - X
Install Waste Heat Recovery Systems for Stenters
Background
The stenters located in the processing sectionare major consumers of steam in any textile
unit. The stenters are being used for drying, stretching and finishing. The fabric enters the
stenters after the pre-drying cylinders with moisture of about 60 – 65 %. This moisture needs
to be dried and vented out in the stenters. The stenters have normally two exhaust blowers
which are operating continuously venting hot air & moisture at temperatures around 100 deg
C. At the processing plant the jigger dyeing section needs hot water at temperatures ranging
from 40 degC to 80 degC. Presently steam is being used for supplying this heat. There is a
good potential to install waste-heat recovery systems for stenter exhaust and utilise this
recovered heat for dyeing machines.
Recommendation
It is recommend to install waste-heat recovery systems for stenters.
Benefits
The total annual savings that can be achieved by implementing this project is Rs.0.85 million.
The investment required is estimated at Rs.1.50 lakhs with a payback period of 22 months.


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477
Case study - XI
Install FO Based DG Set to Meet Power Requirement of the

Plant
Background
Composite textile units are power intensive and require huge power demand. Normally, power
requirement of the plant is met through SEB power. Normally, power frequency of the grid
varies between 48 Hz to 50 Hz.
Composite textile unit comprises of Ring frames, Autocoro, TFO machines. These machines
are power sensitive machines i.e. production varies with the change in frequency of incoming
power. Also any interruption in power will cause breakage of yarn. This causes down time of
the machine for almost 2-3 hrs and loss of production. Production of entire unit depends on
these machines i.e. lesser the production out put from these machines, lesser the production
of finished fabric.
If, it is possible to maintain stability of the power i.e. constant frequency and no interruption
then there will be increase in production by 1 – 1.5% and less breakage of yarn result into good
quality of product.
This can be achieved by installing FO based DG set to meet power requirement of the plant.
Recommendation
It is recommended to install 4.2 MW FO based DG set to meet power requirement of the plant.
This will result in drastic reduction in cost of power. Cost of power generated through FO
based DG set is Rs 2.50 / kWh.
Benefits
The total annual savings that can be achieved by implementing this project is Rs. 40 million.
The investment required is estimated at Rs.120 million with a payback period of 36 months.
While calculating annual savings, rise in output by 1 – 1.5% is not considered.


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479
Case study - XII
Replace Chain Stroker Boiler to FBC Boiler System
Background
• A composite textile industry is having IJT Chain stroker boiler of 30 TPH at 30 kg / cm2.
Efficiency of boiler is about 70%. Boiler is generating high pressure steam at 30 kg/ cm2,
350 deg C super heat, passes through back pressure turbine and generating about 2000
kW power. Out let of steam turbine at 10.50 kg / cm2 is used in process. Requirement of
process is @ 24 – 26 TPH at 8.50 kg/cm2.
• At present imported / indigenous coal is used. Average calorific value of coal is 4500 kcal
/ Kg. Landed cost of coal is Rs 2700 / MT. Average consumption of coal is 6.0 MT / hr.
• Power generation through STG is 12 Lakhs kWh / Month.
• There is a possibility of improving efficiency of the boiler from existing 70% to atleast 79%.
• Work out possibilities of using cheaper fuel, which will lead to differential cost saving of
fuel, without compromising capacity and quality of steam.
Recommendation
• Convert existing boiler to multi fuel fluidised bed combustion system, by which efficiency
can be increased from existing 70% to atleast 79%.
• Also this conversion will have facilities of using multi fuel like agro waste, saw dust, lignite,
rice husk having calorific value more than 3000 kcal / kg.
• This will give flexibility of using cheaper and available fuel.
• Expected lignite consumption is 5625 MT / month considering average CV of lignite 3200kcal

/ kg.
• Cost of lignite at site is Rs 1400 / MT
• Power generation will remain same i.e. 12 Lakhs kWh / Month
Benefits
The total annual saving that can be achieved by implementation of this project implementation
of this is Rs 52.38 million. The investment required is estimated at Rs 12.50 million with a
payback period of 4 Months.
Project cost for conversion of existing boiler to FBC
1) Estimated conversion cost : Rs 1,16,10,000/-
2) Approximate cost of ESP : Rs 50,00,000/-
Total cost : Rs 1,25,00,000/-

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Cost Savings
Cost of coal consumption of : Rs 1,16,10,000/-
4300 MT /month at 72% efficiency @ Rs 2700 / MT
and CV 4500 Kcal / kg
Equivalent cost of lignite consumption of : Rs 78,75,000/-

5625 MT / Month at 72% efficiency
@ Rs 1400 / MT and CV 3200 Kcal / kg
Additional savings in lignite consumption with : Rs 6,30,000/-

increase in efficiency from 72% to 80%
Net savings in fuel cost / month : Rs 43,65,000/-
Estimated Savings / Annum : Rs 5,23,80,000/-
Payback : 03 months


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Case study - XIII
Replace Old Conventional Motors with Energy Efficient Motors
Background
The conventional standard induction motors have efficiencies of 75 to 88% depending on the
size and the loading of the motors. The Energy Efficient Motors (EEM) are designed with low
operating losses. The efficiency of Energy Efficient motors is high when compared to
conventional AC induction motors, as they are manufactured with high quality and low loss
materials.
The efficiency of Energy Efficient motors available in the market range from 80 to 95%,
depending on the size.
The efficiency of energy efficient motors is high due to the following design improvements:
• More copper conductors in stator and large rotor conductor bars, resulting in lower copper
loss
• Using a thinner gauge, low loss core steel and materials with minimum flux density reduces
iron losses.
• Friction loss is reduced by using improved lubricating system and high quality bearings.
Windage loss is reduced by using energy efficient fans.
• Use of optimum slot geometry and minimum overhang of stator conductors reduces stray
load loss.
Efficiency of a motor is proportional to the loading of the motor. Conventional Motors operate
in a lower efficiency zone when they are loaded less than 60%. At all loading ranges of the
motor, efficiency of EEM is higher than conventional motors.
There is a good potential to replace these inefficient motors with energy efficient motors.
Replacing with energy efficient motors would result in at least 8-10% efficiency improvement.

In a textile plant, the old conventional motors, which were rewound for more than 5 times were
replaced with energy efficient motors.
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.


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Energy Conservation in Engineering Sector
484
Engineering Sector
Energy Intensity 3.7% of the manufacturing cost
Energy Costs Rs. 25000 Million
Energy saving potential Rs. 5000 million.
energy saving projects Rs.10000 million

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About the sector

India has a well-diversified general engineering goods sector. It consists of automobiles and
auto components, power plant/prime mover equipment, industrial processing machinery,
domestic goods, pumps, construction machinery, engines and other special purpose machines,
pumps, domestic goods, etc
Energy Intensity in the Engineering sector

In the engineering sector, fuel and power costs vary from 3% to 7% of the total manufacturing
cost. The energy bill of the engineering industry in India amounts to Rs 2500 Crore per annum.
Energy Saving Potential

The energy savings potential in this sector ranges from 6% to 18 % of the total bill for fuel and
power. The energy saving potential in engineering sector is Rs 2500 millions. The total
investment potential for energy savings in the sector is Rs 5000 million.
For any investments made in energy saving projects in the general engineering sector, the pay
back is less than 2 years.
Growth potential
The sector represents a market of Rs 1250 billion, with annual growth averaging nearly
6% during the last five years. The sector is expected to maintain the same levels of growth
in the coming years also.
Major Players
The engineering sector in India is a very diverse sector, having a number of major and midsize
players - Telco, Ashok Leyland, Bajaj Auto, Hero Honda, TVS group, LML, Kinetic Engineering,
Escorts group, TI (Tubes India) Group, Bharat Heavy Electricals Ltd (BHEL), Godrej & Boyce
Manufacturing, Kirloskar Group, Bharat Forge etc to name a few.
Manufacturing Process
In engineering sector, the processes are diverse in nature and vary from industry to industry
depending on the final end product being manufactured.
In the case of automobile industry, the processes vary from sheet metal cutting, moulding, heat
treatment, pressing, machining, drilling, milling, grinding, electroplating, induction heating, welding,
painting, pneumatic applications etc.
Utilities in the sector, account for almost 70% the whole of the energy being consumed. The
main utilities are Compressor, Pump, Fan, air conditioning, refrigeration etc. Also present are
some common processes like painting, drying, heat treatment, electroplating etc. There is no
single process in the sector that can be generalised.
The process equipment involved in the engineering sector offer only a minimum potential for
energy savings. This study on energy saving potential in engineering sector therefore mainly
focuses on utility loads like Compressors, dryers, Pumps, fans, blowers, heat treatment
equipment (furnaces), air-conditioning equipment, lighting etc.

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Short, Medium and The Long term Projects
Long term projects
Compressors
1. Replace old energy inefficient compressors with new energy efficient compressors
2. Install variable Frequency Drives for Screw compressors catering to varying demands of
compressed air
3. Segregate high pressure and low-pressure compressed air users
4. Replace the refrigeration /Desiccant type air dryer with Heat of Compression type (HOC)
air dryers, in case of reciprocating air compressors
Short-term & Medium-term

1. Arrest compressed air leakages by vigorous maintenance
2. Optimise overall operating pressure of compressors based on the system requirement
3. Provide ball valves at the user ends of compressed air cleaning hoses and other similar
points where the exiting control exists at a distance from the user.
4. Replace compressed air with blower air for agitation in effluent treatment plants,
phosphating tanks and in similar applications
5. Install Transvector nozzle for cleaning applications involving compressed air
6. Replace pneumatic tools with electrical tools where ever possible
Pumps
Long-term
1. Install VFD for Oil pump in Hydraulic power pacs and reduce idle operation
2. Install Variable Frequency drives (VFD) for pumps catering to varying demand instead of
operating with recirculation / valve throttling

1. Optimise the excess capacity / head of the pump by installing next lower size impeller for
pumps and avoid throttling / recirculation
2. Switch “OFF” the main circulation pump in the curing press hydraulic power pacs during
the idle cycle
3. Install LIC (Level Indicator Controller) for water over head tank pump to avoid recirculationi
/ over flow
4. Install correct size pumps for cooling tower based on the system head / flow requirements

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Fans
Long-term
1. Replace low efficiency exhaust fans with new fans of higher efficiency.
2. Install variable Frequency driveS (VFD) for hot air circulating fans in preheating furnaces
Furnaces
Long-term
1. Provide ceramic fibre insulation for batch operated furnaces
2. Install Radiant tube recuperative burners in place of electrical heaters for applications
involving temperatures less than 1000 deg C.

1. Optimise the overall loading of furnaces by better planning of jobs
2. Improve the combustion efficiency of furnaces, by optimizing the combustion air supply
3. Install pneumatic operated door for push type furnaces
4. Install Air curtains at exit / entry of drying ovens to reduce heat loss.
5. Replace refractory bricks with ceramic fibre in furnaces
6. Improve the over all Insulation levels and close the openings in furnaces, so as to minimize
heat losses.
7. Use ceramic coating for achieving improved insulation levels
8. Install KWH integrator controller for induction furnaces
Electrical
Long-term
11. Replace Motor – Generator sets (Ward – Leonard System) with Static Inverters.
12. Replace High pressure Mercury vapour (HPMV) lamps with High pressure Sodium
vapour (HPSV) lamps

1. Switch-off primary of idle transformers
2. Replace faulty capacitor banks
3. Relocate capacitors to the machine ends, or from the MSBs to the SSBs (at the substation
ends), to minimise voltage drop in cables.

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4 Improve the over all power factor and Surrender excess demand
5. Install automatic voltage stabilizers for lighting circuits and other precision electronic circuits.
6. Install lighting transformers in all major lighting feeders and operate the lighting circuit at
210 V
6. Optimse the Operating voltage and frequency in DG sets
7. Avoid night time lighting at where lighting is not required
8. Replace the conventional fluorescent tubes with slim fluorescent lamps
9. Replace conventional chokes with electronic HF ballast
10. Replace 40 watts fluorescent lamps with 28 watts T-5 lamps where lights are kept “ON”
through out.
11. Replace filament indication lamps in control panels and with LED lamps.
12. Install translucent sheets at identified places to avoid day time lighting, where ever feasible
13. Install neutral compensator at unbalanced lighting feeders
14. Replace the delta connection with permanent star in case of motors, which are lightly
loaded permanently.
15. Install Automatic - Star - Delta - Star converter in the lightly loaded motors which handle
fluctuating loads
16. Replace old inefficient motors with energy efficient motors
Other Projects
1. Recover waste heat from flue gas of furnaces, by installing air pre heater.
Cooling Tower- Chilled water system
Short term & medium term

1. Install temperature indicator control (TIC) for cooling tower fans
2. Replace aluminium blades with FRP blades at all cooling tower fans
3. Convert the 2-well system to a single well system in the chilled water system, where ever
possible
4. Improve the insulation levels of the chilled water distribution system
5. Optimise the Operation Of Chilled Water Pumps In Vapor Absorption Machine based on
the head/capacity requirements of the system.
Thermopacs

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1. Improve the combustion efficiency of the thermopac by reducing the excess airflow.
2. Replace inefficient burners in the thermopacs with energy efficient burners.
3. Install variable frequency drives (VFD’s) for Thermic fluid pumps catering to multiple users
Boiler

1. Improve combustion efficiency of boilers by optimizing the combustion air supply,
2. Install condensate recovery system for the boiler
Dust collection systems
1. Clean Scrubber Regularly and optimise the operation of Sand Dust Collection Blower
2. Replace inefficient dust collection systems improve the dust collection system
Refrigeration & Air conditioning

1. Install Micro processor based Temperature Indicator Controller (TIC) for window air
conditioners
2. Use polyester sun film controls in the areas exposed to direct sunlight and optimise the
temperature settings of the cooling system.
3. Optimise temperature settings of AHU’s and install thermostat controls for chiller
compressor
4. Replace air-cooled condensers with water-cooled condensers. In case of higher TR

capacities, go for evaporative condensers.
Vapour Absorption Machine

1. Optimise Combustion Air Supply To Vapour Absorption Machines (HSD fired)

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Electroplating
1. Install polymer balls for reducing the heat loss in Phosphating systems
2. Replace the inefficient Auto Plating Scrubber Blower With energy Efficient Blower
3. Replace Electrical heating with Thermal heating (Aquatherm) at Phosphating / Electroplating

section
Miscellaneous
1. Replace Eddy current controls with VFD
2. Convert V Belt to Flat Belt drives in equipments like Compressors and Blowers etc

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Case Study 1
REPLACE OLD INEFFICIENT COMPRESSORS WITH NEW ENERGY EFFICIENT

COMPRESSORS
Background
Air compressors are very commonly used in engineering
Industry. In a typical engineering Industry, the power
consumption of the air compressors is as high as
30 % of the total energy consumed.
The most common type of compressors used in the

industry is the reciprocating compressor. Off late, there
is a growing inclination for companies to go in for screw
compressors, mainly due to their flexibly in operation
as well as due to their low noise characteristics.
Centrifugal compressors are used for high capacities
or base loads, greater than 1500 CFm.
A typical comparison between the different types of compressors at 7-kg/cm2 pressure,

is given below.
Description Reciprocating Centrifugal Screw
Specific Power 4.9 4.65 5.8
(kW/m3/min)
Specific Power (kW/Cfm) 0.139 0.132 0.164
Whenever there is a significant variation in the power consumption of the compressor

from the above-mentioned values, it signifies that the compressor may be energy
inefficient.
The reason s 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.

492
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 Actual volume Power consumption
(Cfm) (Cfm) (KW)
744 565 103
It was observed that the volumetric efficiency of the compressor was about 75% and that 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.

There was an option to replace the existing reciprocating compressor with an energy efficient
compressor either of the reciprocating type or of the screw type. Since the compressor was
catering to a steady base load and since the comparative capital investment was lower for a
reciprocating compressor, the existing compressor was replaced with new energy efficient
reciprocating compressor, having a lower SEC of 0.13 kW/cfm.
Project Implementation Strategy

The project was implemented during the preventive maintenance period in the plant. No stoppage
of the plant was needed. The plant team did not face any problems during the implementation
of the project.
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 Cost benefit analysis
payback period of 20 Months • Annual Savings - Rs. 0.95 millions

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.

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494
Case Study 2
INSTALL VARIABLE FREQUENCY DRIVE FOR SCREW COMPRESSOR

CATERING TO VARRYING 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 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.

495
Package screw compressor

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 an unload 22 kW during unload
mode.

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 Cost benefit analysis
The annual savings achieved amounted to • Annual Savings - Rs. 0.43 millions
Rs 0.43 million . The required an investment of • Investment - Rs. 0.7 millions
Rs 0.7 million for installing variable frequency drive
with feed back control, was paid back in 20 Months.

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This project can be implemented across all the sectors of the engineering industry, wherever
a screw compressor is operating in the loading /unloading mode. Considering that at least 50
% of the installed base of Screw compressors in the industry still operate in the load/unload
mode, without a VFD there is a tremendous potential for them to be retrofitted.

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Case Study 3
SEGREGATE HIGH PRESSURE AND LOW PRESSURE COMPRESSED AIR

USERS
Background
In compressors the power consumption is directly proportional to the operating pressure. The
power consumption increases with increase in operating pressure and vice versa.
There is a good potential to save energy by dedicating compressors for the individual users,
which need compressed air at a lower pressure. This eliminates the pressure loss due to
distribution and hence energy loss.
Previous status
IIn 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- Receiving end Quantity
Kg/cm 2 Cfm
Unit1 4.0 1900
Instrumentation in unit 2 4.5 600
The fall in pressures at the receiving end was mainly due to the losses, which were taking
place in the transmission line, which had a length of about 1.5 Km.
Energy Saving project

The compressed air supply from the main header to the units 1 and 2 was segregated.
Dedicated screw compressors of following specifications were installed and operated.
For unit 1
• Capacity - 2000 Cfm
• Operating pressure - 4.0 kg/cm2
For unit 2
• Capacity - 600 Cfm
• Operating pressure - 4.5 kg/cm2

499
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
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.

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

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Case Study 4
REPLACE REFRIGERATION / DESSICANT 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 utilised for regeneration
of the dissicant, which otherwise needs an electrical heater.
Heat of Compression type air dryer is a breakthrough in compressed air drying technology.
Thus the need for a heater is eliminated and also there is no purge loss.
An atmospheric dew point of (-) 40 deg C can be easily achieved using HOC dryer. There is
considerable power saving in this type of Air Dryers
Heat Of Compression (HOC) dryer
Previous status
In an engineering unit, the compressed air to the plant was broadly classified into 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.

502

Heat of Compression (HOC) dryers were Installed in place of the desiccant / heatless type
dryers.
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.


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.

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504
Case study 5
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 reciculation 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.
Case Study
Previous status
In a pipe-manufacturing unit, there were 12 hydraulic power packs in the foundry section and
at any point in time 7 were being operated, for actuating the die casting machines. For about
60-70% of the operating time, oil was being recirculated.

Variable Frequency Drives (VFDs) were installed for the oil pumps with feed back control using
a pressure sensor provided at the discharge side of the pumps.
The VFD was operated in closed loop with a pressure sensor on the pump discharge header.
The pressure sensor senses the process requirement and the pressure signal is given as 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.
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, • Annual Savings - Rs. 0.3 millions
which got paid back in 15 Months. • Investment - Rs. 0.35 millions
The project can be replicated in all the units where
oil pumps are installed for pumping oil in the hydraulic power packs.

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506
Case Study 6
INSTALL VARIABLE FREQUENCY DRIVES (VFD’s) 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.

A Variable Frequency Drive (VFD) was installed for the thermic fluid circulation pump.

507
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 Rs0.20 Million was paid back in 12 months.

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.

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Case Study 7
REPLACE THE LOW EFFICIENCY EXHAUST FANS WITH NEW FANS OF HIGHER
EFFICIENCY
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.
Axial fan
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%.

Axial fans are capable of meeting head requirements upto 75 mm WC. These fans have
better operating efficiency than the centrifugal fans, both in full loads and in partial loads. The
minimum operating efficiency of an axial fan is about 65%.
The existing plating section exhaust fan was replaced with a new axial fan of higher efficiency,
having a capacity 15 m3/s and capable of developing a pressure head of 40 mm WC.

510
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.

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.

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Case study 8
INSTALL VFD’s for HOT AIR CIRCULATION 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 optimise energy savings.
VFDs find applications in optimising 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 530°C (minimum). After accounting for the ingot
rolling time and temperature loss from preheating furnace outlet to the hot rolling mill of about
40 – 60°C (between top ingot & bottom ingot), the metal is heated upto a temperature of 590-
600°C. The air temperature required to maintain this metal temperature is 620°C.
Once the furnace charging is complete and the batch time starts, the heaters and fans are
switched “ON” automatically. It takes about 2 – 3 hours for the air temperature to be raised
from a starting temperature of 360 – 380°C to 620°C. The total time taken for heating the metal
from the ambient temperature to 580-590°C 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.

513
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.

VFDs were installed for the air circulating fans. All the circulating air fans were operated at a
lower RPM during the soaking period using programmed PLC controls. A 30% speed reduction
(speed was reduced from 50 Hz to 35 Hz) was achieved.
Implementation of the Project

VFDs for the circulating fans were installed during the normal operation of the plant itself. The
plant team did not face any problems at any stage during implementation of the project.
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.

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.

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Case study 9
PROVIDE CERAMIC FIBRE INSULATION FOR BATCH FURNACES
Background
The surface temperature of a furnace is an indicator of the insulation levels in the furnace. For
an electrical furnace the surface temperature should not be more than 50 degree C and for
a thermal furnace the surface temperature could be around 60 degree C.
The heat loss due to radiation from the surface increases exponentially with the surface
temperature. For eg in the radiation loss due to a surface temperature of 150 °C is 1500 Kcal/
m2/hr as compared to 450 Kcal/m2/hr, at a surface temperature of 70 degree C.
Ceramic fibre is a lightweight material featuring low thermal conductivity and low heat capacity,
making it a superior Insulating material. A furnace lined with this form of material provides
excellent thermal properties. Ceramic fibre is supplied in various forms; blanket, bulk, paper,
and vacuum formed products as shown below.
Ceramic fibre material
Given below is a table, which gives a comparison between refractory brick, insulation brick and
ceramic fibre.
Property Refractory brink Insulation Brick Ceramic fibre
Specific heat
kCa/Kg Deg C 0.2 0.22 0.27
Themal conductivity
kCal/m Deg C 0.22 0.20 0.20
Density kg/m3 2000 1000 125
It is the low density of the ceramic fibre that makes it an excellent insulation material. Because
of the low bulk density the space occupied by the ceramic fibre is also minimal compared to
the other two. This leads to a significant drop in the power consumed by the furnace, especially
during cold starts in case of batch furnaces.
Ceramic fibre can hold a temp of up to 1450 deg C and are not affected by chemicals.

516
The limitations of ceramic fibre are that it cannot take direct flame impingements and mechanical
stresses. So in case of any of these a layer of ceramic fibre can be sandwiched between
insulation bricks for achieving better insulation levels.
The best practise that is followed is to have a ceramic coating above the ceramic fibre
insulation so as to minimise the surface temperature.
Previous Status
In an auto components manufacturing unit, a bell furnace was used for heat treatment of the
material. The material was heated to a temperate of 650 deg C, using electrical heaters. The
furnace was lined with refractory bricks for insulation. The measured surface temperature on
the outer sides of the furnace was around 150OC.
Batch operation was employed in this case and the cycle time for the process lasted to about
12 hours.
The specific energy consumption of the furnace was around 250 kWh per ton of material.

The inner sides of the Annealing furnaces were insulated using ceramic fibre. Ceramic coating
was also provided both in the inner surface area as well as in the outer surface area. The outer
surface temperatures were maintained at around 50OC — 60OC.
Implementation
The implementatin of the project was carried out during the scheduled preventive maintanance
of the plant. The plant team did not face any hurdles in implementing the project.
Benefits
Insulation of the furnace with ceramic fibre and ceramic coating resulted in the specific energy
consumption coming down to 185 units per ton.
Financial Analysis
The annual savings achieved was Rs 0.75 million. The investment required for ceramic fiber
and ceramic coating was 15 was Rs. 0.15 million, which got paid back in 3 months.

The project can be replicated in all furnaces,
• Investment - Rs. 0.15millions
which are using either refractory bricks or
• Simple payback - 3 months insulation bricks. In case there is a chance of
direct flame impingement, a layer of ceramic
fibre can be sandwiched between the inner and
outer layer of the refractory.

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Case study 10
INSTALL RADIANT TUBE RECUPERATIVE BURNERS IN PLACE OF ELECTRICAL

HEATERS FOR APPLICATIONS REQUIRING TEMPERATURES LESS THAN 1000
deg C
Background
Electrical energy is a high-grade energy and costlier as compared to thermal heating. In almost
all cases, electrical heating is being done since the stock should not come in contact with the
exhaust gases.
The cost comparison of thermal and electrical energy is given under:
• Cost of electrical energy - Rs 4773 / MM Kcal
• Cost of thermal energy - Rs 1966 / MM Kcal
Electrical energy is 2.4 times costlier than thermal energy. Hence there is a potential
of 50% of savings by replacing the electrical heating with thermal heating.
Before the advent of radiant recuperative heaters, electrical heating was the only viable alternative
for any applications involving temperatures greater than 300 deg C.
Radiant tube recuperative burners (ref fig below) are now available which are fired with oil and
the exhaust gases do not come in contact with the stock. The heat transfer is through radiation
from the tube, which is at a high temperature of 900 to 1100 deg C. The exhaust heat is used
to preheat the combustion air.

519
Previous status
In a bicycle-manufacturing unit, annealing furnaces were used to for heating the components.
Electrical heaters were being used in the annealing furnace to heat the material up to a
temperature 900 deg C. The total rated capacity of the heaters was 2000 KW.
Radiant tube recuperative burners with LDO firing were installed in place of Electrical heaters.
Implementation Strategy
The implementation of this project took about 3 months.
Benefits
The implementation resulted in reducing the cost of energy used for the furnace.
Financial Analysis
The installation of Radiant tube recuperative burners resulted in an annual savings of Rs 6.0
million. The investment required was Rs. 10.00 million, which got paid back in 20 months.

Prior to the radiant recuperative heaters, there was no reliable technology for applying thermal
heating to achieve temperatures beyond 300 deg C. The replacement of electrical heating with
thermal heating involving radiant recuperative heaters has a tremendous potential of replication.
This proven technology can be easily replicated at least in 50 installations in India.

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Case study 11
REPLACE MOTOR – GENERATOR SETS WITH STATIC INVERTORS
Back ground
Ward-Leonard drives are very popular among the engineering industry, especially in machine
shops. The system provides very smooth and reliable speed control, which is the basic
requirement for any application involving cutting tools. They are highly complex systems.
Ward-Leonard systems were introduced in 1890s. Schematically, the operation of the system
is as follows:
The synchronous AC motor drives the generator. The generator generates the terminal voltage
for the DC motor. This voltage can be modulated by modulating the field current on the
Generator. The field current is varied to achieve the speed control and direction reversal of the
DC motor.
Solid-state converters and rectifiers have become available in recent years even in high-power
circuits. Such devices are gradually replacing the Ward-Leonard systems based on dedicated
motor generator sets.
These controlled rectifiers are commonly referred to as Silicon Controlled Rectifiers or SCRs.
By chopping the supply voltage, they produce a pulse train for the armature voltage rather than
a continuous supply. This pulse train controls both the speed and the direction of operation of
the DC motor.
Previous Status
In an automobile manufacturing unit, across different machine shops, there were 30 numbers
of M-G sets.

All the Motor – generator sets were replaced with static invertors, in a phased manner.
Implementation
The project was implemented during the preventive maintenance periods. The plant team
faced no hurdles in implementing the project. All the drives where replaced in a phased
manner in a period of over 2 years.

522
Benefits
The benefits were two fold -
- Energy Saving
- Easier maintenance as the thrysiter drives were easier to maintain than motor generator
sets.
Financial Analysis
Replacement of ward Leonard drives with Thyrister drives resulted in an annual savings of
Rs. 0.48 million. The investment required of Rs.1.0 million, got paid back in 26 months.

The project can be implemented across all industries where Ward Leonard systems are in
use. The replication potential is quite high in particularly the medium scale engineering industries.

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Case Study 12
REPLACE HIGH PRESSURE MERCURY VAPOUR (HPMV)_ LAMPS WITH HIGH

PRESSURE SODIUM VAPOUR (HPSV) LAMPS
Background
High Pressure Sodium Vapour (HPSV) lamps are more efficient than HPMV lamps. Butt the
Colour property (Colour rendering index) of HPSV lamp is poor compared to HPMV lamp.
Wherever colour is not a critical requirement the HPSV lamps can used.
The comparison is shown below.
S.No Lamp Watts Efficacy Illumination
1 HPMV 250 54 lumens/Watt 13,500 lumens
400 57.5 lumens/Watt 23,000 Lumens
2 HPSV 150 90 lumens/Watt 13,500 Lumens
250 100 lumens/Watt 25,000 Lumens
Comparison of mercury & sodium vapour lamps
HPSV lamp HPMV lamp
• Efficacy of HPSV lamps is double than HPMV lamps
• Colour Rendering properly of HPSV lamp is poor compared to HPMV lamp
• Wherever colour is not a critical one, we can replace HPMV lamps with HPSV
lamps
There is a good potential to replace 400 Watt and 250-Watt HPMV lamp with 250 Watt and 150
Watt HPSV lamps respectively.

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Case study
In an automobile manufacturing unit, there were three plants in which 60 HPMV lamps, of
250W were used for lighting. The color was not a criterion in the above areas. Also about 20
lamps were used for street lighting also.

Since colour was not a criterion in these areas, it was recommended to replace the 250-watt
HPMV lamps with 150-watt HPSV lamps.
Implementation
The projects were implemented in all the 3 plants during the scheduled preventive maintenance.
The plant team did not face any problems due to the implementation of the project.
Benefits
The potential resulted in lower energy consumption of the lighting systems.
Financial Analysis
Replacement of HPMV lamps with HPSV lamps resulted in annual savings of Rs.0.09 million.
This required an investment of Rs. 0.08 million, which got paid back in 10 months.

• Investment - Rs. 0.08 million
The project can be implemented in all the areas where the colour-rendering index is not critical
to the plant operations.

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Case study 13
RECOVER WASTE HEAT FROM THE FLUE GAS OF FURNACES BY INSTALLING

AIR PREHEATER
Background
Typically, oil fired furnaces are used in engineering units for almost applications like melting,
heat treatment, forging, billet reheating etc. The major losses that take place in the furnaces
are the radiation losses and the flue gas losses. Among these, flue gas losses amount to
almost 70% of the total losses in a furnace.
The waste heat recovered from the flue gas can be used for various applications like Air pre
heating, oil preheating and metal preheating.
The flue gas temperature can be bought down to the range of 150 – 170 deg C before it is
finally let out into the atmosphere. The final temperature to which the flue gas can be bought
down depends on the sulphur dew point of the type of fuel being used.
Present Status
In an engineering unit, a Marconi furnace was used to melt aluminium ingotsconsuming about
20 lit/hr of furnace oil. The flue gas from the furnace was directly let off into the stack. The
exhaust flue gas temperature was measured and is about 875oC.
Based on oil-firing rate and excess O2%, total flue gas quantity was estimated to be about
445 kg/h. The total quantity of recoverable heat present in flue gas was estimated to be
63421 kCal/h.
The Combustion air supplied to the furnace entered the furnace at an ambient temperature of
about 35 deg C.
Also the furnace oil fired into the furnace was preheated to a temperature of about 80 deg C
using electrical heaters. The total power consumed by these heaters was 6 kW.

An air Preheater was Installed to preheat combustion air to the Marconi furnace to a temperature
of 180°C.
An aquatherm system was installed to preheat the furnace oil to the required temperature of
80oC. The operation of electrical heaters was totally avoided and they were used only in case
of cold start-ups.
The system was modified accordingly as shown:

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Flue gas Flue gas to

stack
Air to
Preheated
preheat Air
Aquatherm
F.O
Heater
Pressurised
water to
preheat oil
Benefits
- Reduction of oil consumption
- Saving of power used for heating furnace oil
Financial Analysis
The implementation of the waste heat recovery scheme led to an annual savings of Rs.0.30
million. The investment of Rs. 0.60 million (for installing heat recovery equipments) had an
attractive payback period of 24 months.

• Annual Savings - Rs.0.30 million
• Investment - Rs.0.60 million
Project implementation
Project implementation required modification in the exhaust flue gas line and the installation of
an air Preheater in the flue gas system. The aqua therm system was installed.
All these modifications where carried out during the normal course of operations itself, with a
minimal shut down of operations. The plant team did not face any problems in implementing
the project.
The potential for replicating the project exists in the case of all furnaces where the flue gas
is directly let out into the stack, at high temperatures.

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Energy Conservation in Sugar Industry
530
Sugar
Per Capita Consumption 17.75 kg/annum
Growth percentage 7.5%
Energy Costs Rs. 14000 million (US $ 290 million)
Energy saving potential Rs. 4200 Million (US $ 84 Million)
energy saving projects Rs. 6000 Million (US $ 120 Million

531
1.0 Introduction
India is the largest consumer and second largest producer of sugar in the world. With over 450
sugar factories located throughout the country, the sugar industry is amongst the largest agro
processing industries in India, with an annual turnover of Rs. 150 Billion (US $ 3.3 Billion).
Sugar is a controlled commodity in India under the Essential Commodities Act, 1955. The
government controls sugar capacity additions through industrial licensing, determines the price
of the major input sugarcane, decides the quantity that can be sold in the open market, fixes
the prices of the levy quota sugar and determines maximum stock levels for wholesalers, etc.
Sugar prices are the lowest in India when compared to the leading sugar consuming countries
in the world. Converted in Indian rupees the price equivalent in China Rs. 25.78 per kg, in
Indonesia Rs. 18.62 per kg and in Brazil and Pakistan it is Rs. 17.9 per kg. The price of sugar
in India is Rs. 12.68 per kg.
With the price being lowest in India, the competitiveness of the industry lies in lowering the
cost of production. One of the major area, almost all the major sugar industries have focused
on, is energy efficiency.
2.0 Historical Industry Development

India has been known as the original home of sugarcane and sugar. Indians knew the art of
making sugar since the fourth century.
The Indian sugar industry has not only achieved the singular distinction of being one of the
largest producer of white plantation crystal sugar in the world but has also turned out to be
a massive enterprise of gigantic dimensions.
Over 45 Million farmers, their dependants and a large mass of agricultural labor are involved
in sugarcane cultivation, harvesting and ancillary activities constituting 7.5% of the rural
population. The sugar industry employs over 0.5 Million skilled and unskilled workmen, mostly
from the rural areas.
The average capacity of the sugar mills in the industry has considerably moved up from just
644 ton per day in SY1930-31 to 2656 ton per day. But still the growth in the Indian sugar
industry was driven by horizontal growth ( increase in number of units) compared to the
vertical growth witnessed in other countries (increase in average capacity).
3.0 Energy consumption in Sugar Industry

Sugar industry is energy intensive in nature. The power & fuel consumption in the Indian sugar
industry is in the order of Rs. 124.0 Crores. This is the contribution of sugar plants operating
without co-generation facility.
The average energy consumption in an Indian sugar mill is about 38 units / ton of cane
crushed. The average cane crushing in Indian mills is about 2700 TCD. The total power
requirement in a standard sugar mill is in the order of 4.25 MW.
The total cane crushed in Indian sugar industry is about 360 Million tons. The total power
consumption for this requirement is about 13.68 Billion kWh. This corresponds to equivalent
power of about 3250 MW (considering average crushing of 175 days).

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Energy efficiency in sugar industry offers the following benefits:

• In plants having cogeneration facility and where the state utility is able to purchase additional
power generated from sugar plants, any improvement in energy efficiency levels of the
plant results in increased export to the grid. This reduces the equivalent reduction in power
generation from fossil fuel based power plants. This has a significant reduction in carbon
emissions.
• In plants having cogeneration facility, but the state utility is not ready to purchase power,
improvement in energy efficiency in the plant results in saving in bagasse. This either
could be exported to other sugar plants, having cogeneration facility with state utility ready
to purchase power, or can be sold to paper plants.
• In plants which do not have cogeneration facility, energy efficiency directly results in reduced
power demand from the state utility. This results in higher profitability to the plant as well
as significant reduction in GHG emission. These plants, however, are very few in number.
The Indian sugar industry offers good potential for energy saving. The estimated energy
saving potential in the Indian sugar industry is about 20%. This offers potential of about 650
MW of electrical energy. This corresponds to about Rs. 2600 Crores investment, in newer
power plants.
The investment opportunity in the Indian sugar industry is estimated to be in the tune of about
Rs. 5000 Crores.
Per Capita Consumption of sugar in India

Indians by nature have a sweet tooth and sugar is a prime requirement in every household.
Almost 75% of the sugar available in the open market is consumed by bulk consumers like
bakeries, candy makers, sweet makers and soft drink manufacturers.
The per Caipta sugar consumption in India is about 17.75 kg/annum. This is growing at a
rate of 7.5% every year, on an average.

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4.0 Cogeneration
The sugar industry by its inherent nature can generate surplus energy in contrast to the other
industries, which are only consumers of energy. With liberalization and increased competition,
the generation and selling of excess power to the electricity board, offers an excellent source
of revenue generation to the sugar plants. This is referred to as commercial cogeneration and
has been only marginally tapped in our country.
Integrated approach and Co-generation

Co-generation in sugar plant
The sugar plants have been adopting co-generation right from the beginning. However, the
co-generation has been restricted to generating power and steam only to meet the operational
requirements of the plant. Only in the recent years, with the increasing power demand and
shortage, commercial cogeneration has been found to be attractive, both from the state utility
point of view as well as the sugar plant point of view.
The sugar plant derives additional revenue by selling power to the grid, while the state is able
to marginally reduce the ‘demand-supply’ gap, with reduced investments.
The sugar plant co-generation system can be in the one of the following ways
i. Conventional system
The old sugar plants, installed particularly in the sixties in India, have this type of system.
These plants are characterized by
• 20 kg/cm2 boiler
• Mill drives and shredder driven by individual turbines
• One or two back pressure power turbines, for meeting the remaining power requirements
These systems have low operating efficiency and result in little bagasse saving, after
meeting the plant requirements. The non-season power requirement is met from the grid.
ii. Partly modified system
This type of system is prevalent in the plants installed in the eighties. These plants are
characterised by
• 32 kg/cm2 or 42 kg/cm2 boiler
• Mill drives are partly steam driven and partly DC motor driven
• One / two back pressure turbines, meeting the power requirements of the plant.
These systems have slightly higher operating efficiency and result in little bagasse saving,
after meeting the plant requirements. The non-season power requirement is met from the
grid.
iii. Commercial co-generation system-only season
This type of system is prevalent in the plants installed in the early nineties. These plants
are characterised by
• 42 kg/cm2 / 64 kg/cm2 boiler with bagasse and auxiliary fuel firing

534
• Mills are DC motor driven
• One/two back pressure turbines, for meeting the power requirements and the excess
power is sold to the grid.
These systems have much higher operating efficiencies and result in excess energy
being generated and sold to the grid during the season. The non-season power requirement
of the plant is met from the grid.
iv. Commercial co-generation system – Both season and non-season
These are the latest systems installed very recently and operating in the sugar plants,
predominantly in the state of Tamil Nadu.
These plants are characterised by
• 42 kg/cm2 / 64 kg/cm2 / 82 kg/cm2 boiler
• Bagasse firing during season & firing with other fuel during non-season
• Mill drives are hydraulic or DC drives
• One / two extraction - cum - condensing turbine
• Turbine operates with nil condensing during season and maximum condensing during
non-season. This scheme can be a very attractive alternative, if some cheap source
of fuel is available.
These plants have the highest operating efficiency and the excess energy generated is
sold to the grid during the season. During the non-season, the boilers are fired with the
auxiliary fuel and the turbine is operated in the condensing mode. The excess power after
meeting the plant requirements, is sold to the grid.
This alternative results in maximum revenue generation for the sugar plant and is very
attractive if the auxiliary fuel is available at a cheaper cost.
5.0 Manufacturing Process & Target energy consumption

The target electrical and thermal energy consumption of a new sugar plant should be as given
below
Specific Electrical Energy consumption 30 units/ton of cane with electric

motors & DC Drives
24 units / ton of cane with diffusers
Specific Thermal Energy steam consumption 38% on cane
5.1 Electrical energy

Cane preparation
The cane preparation is the first operation in the production of sugar. The preparatory equipments
include kicker, leveller, cutter, fibrizers and shredders. The degree of preparation has a major
effect on the cane crushing capacity and extraction. The efficiency / capacity of the utilisation

535
of the cane carrier system can be increased, with parallel loading of cane. The parallel loading
of cane is possible with sling type unloading and hydraulic tipper unloading.
The typical cane preparation devices suggested are kicker and cutter followed by a fibrizer /
shredder. The cane carriers need a variable speed mechanism, to regulate the flow of cane
to the shredders. The shredders also need a variable speed mechanism, to take care of the
varying load. The shredders have, either a steam turbine or a dynodrive for varying the speed,
while the cane-carriers have a dynodrive. Both these systems are energy inefficient.
Hence, it is recommended to install DC motors or AC variable speed drives for the cane
carriers.
Target energy consumption in cane preparation section – 4.00 kWh / ton
Milling – operation
The prepared cane is crushed, to separate the juice and bagasse. The crushed juice is then
taken up for further processing, while the bagasse is despatched to the boiler house.
The milling energy requirement, depends on the efficiency of conversion at the prime mover
and the actual shaft power required at the mills.
The scrapper power and the pinion loss

are standard for all mills, while the Breakup of Energy Consumption
other three depend on the hydraulic Compression of
bagasse
pressure applied and the fibre loading.
64% Bearing loss
The bearing loss of 15% in the case
of white metal bearings, can be totally Trash plate
avoided, by replacing them with anti-
5% Scrapper
friction roller bearings.
2% 14% 15%
The power spent for compression of Pinion loss
bagasse and power absorbed by trash
plate due to the friction with bagasse, depends on the power applied to the top roller and trash
plate setting.
A latest development in this regard, is the development of a Low-Pressure Extraction (LPE)

system. This new system comprises of, a long train of two roller bearings, operating under
low hydraulic pressure. The trash plates are eliminated, resulting in substantial reduction of
power upto 35%.
Target milling power consumption – 9.5 units/ton of cane for conventional milling system.
Milling – prime mover
The installation of the right prime mover also has a major bearing on the energy efficiency
of a sugar plant. In the Indian sugar industry, presently 3 types of prime-movers are being
used as below
• Steam turbines
• Electric DC motors
• Hydraulic drives

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Steam turbines
These have been used in all the older sugar units for driving the mills. These low capacity
turbines are single stage turbines and have very low efficiencies of the order of 35-40%. The
lengthy transmission also involves additional losses, making it more inefficient. Hence, steam
turbines are not recommended for prime movers in the milling section.
Electric DC motors
These have much higher efficiency than the steam turbines and with better control & cleaner
operations, are easily adaptable into any system. The DC drive also avoids the primary high-
speed reduction gearbox, resulting in a higher overall efficiency of 51%. The steam turbines
have been replaced with electric DC drives, resulting in considerable benefits in many sugar
plants.
Hydraulic drives
The utilization of hydraulic drives for the prime-moves in the mill section, is also gaining rapid
popularity among the sugar units. This involves a combination of an electric motor driven
pump and a hydraulic motor, which operates by the displacement of oil. The speed is controlled,
by varying the flow in a fixed displacement pump and by changing the pump swash angle,
in a variable displacement pump. The over-all efficiency of a hydraulic system is nearly about
53%. The cost of hydraulic drives is higher than that of the DC drives. However, if the total
cost, comprising of the building, transformer etc. are taken into account, the cost of installation
of a hydraulic drive and a DC drive are nearly comparable.
5.2 Latest development in manufacture of sugar

Cane Diffusers
Cane diffusers have been the latest and the most energy efficient method in cane preparation.
Modern sugar mills have adopted cane diffusion, in lieu of conventional milling tandem,
considering the multi-pronged advantages, diffusion process offers over conventional milling
process.
In Cane Diffuser, prepared cane is directly sent to Diffuser, which acts both as primary and
secondary extraction equipment. Sugar in the prepared cane is systematically leached with
water and thin juice. At the end of the diffusion process, diffused bagasse discharged from
the diffuser is conveyed to De watering mill where moisture is reduced to 50%. De-watering
mill outlet bagasse is sent to boiler and the mill juice is sent to Diffuser.
Cane diffusion Process
The Juice extraction process in the cane diffuser system is as follows:
i. Cane is prepared up to a Preparation Index (PI) of over 85 %.
ii. Prepared cane is delivered to the diffuser. The cane is heated at entry to the diffuser to
a temperature of 83 Degree C by scalding juice. Scalding juice is the juice from the initial
compartment of the diffuser and is heated from a temperature of about 69oC to 90oC.
iii. The diffusion percolation bed is a moving conveyor on which the cane bed height is
between 1200 mm to 1400 mm.

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iv. The diffuser is divided in 13 circulation compartments. Juice from each compartment is
re-circulated in counter current direction to cane blanket movement, from low brix area
to high brix area.
v. The scalding juice is limed in order to maintain a pH of about 6.5 in the diffuser in order
to prevent inversion of sucrose.
vi. Average temperature of the material inside the diffuser is about 78oC
vii. Draft juice from the diffuser is at about 69oC and is sent directly to the sulphitation vessel
viii. Diffusion bagasse at exit of the diffuser is at supersaturated moisture and is de-watered
in a single six-roller mill. Final bagasse moisture is about 51 %.
ix. Imbibition is applied directly in the diffuser. Hot condensate at 84oC from the evaporator
last effect is used for imbibitions.
Draft juice is measured by a mass flow meter. Screening of draft juice is not necessary
because the bagasse bed through which the juice percolates, itself acts as a screen.
Mill section – auxiliaries
The auxiliaries in the milling action are the juice transfer pumps, in between the drives and
the imbibitions water pump. In majority of the plants, the pumps are designed for the maximum
capacity, with a large cushion. This results in either the discharge valve being throttled or the
inlet tank of the pump becoming empty at regular intervals. Both these are energy inefficient
operating methods.
Hence, it is recommended to install –
• High efficiency centrifugal pump and
• Variable Frequency Drive (VFD) for controlling the flow to the system for the juice transfer
pumps and imbibition water pumps.
Juice preparation
The juice preparation involves the weighing & heating of juice, sulphitation and clarification,
to make it fit for the process of evaporation. The juice preparation section, comprising of the
juice pumps, is also a major electrical energy consumer.
Final juice heater Tubular/Plate heat exchanger (PHE)
The juice heaters over a period of time get scaled up and the pressure drop increases. To
take care of this, stand-by juice heater is to be installed for each of the primary and secondary
juice heaters. In the case of the final juice heater, the stand-by is optional. Target energy
consumption in juice preparation section - 2.00 units / ton of cane.
Evaporator, crystalliser & pans
These are minor consumers of electricity primarily in the form of transfer pumps and recirculation
pumps in FFE. The aspect that needs to be taken care is the installation of the right capacity
& head pumps with high efficiency.
Target energy consumption - 1.00 unit / ton of cane

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Pump house (Evaporator and Vacuum Pans)
The juice after preparation goes to the evaporator, for further concentration into syrup, which
gets further concentrated in the vacuum pans. The evaporators and the vacuum pans are
maintained at lower pressures, through injection water pumps.
It is recommended to use multi-jet condensers with hot water spray for jet water. The water-
cooling system can be one of the following
• Cooling tower
• Mist cooling/spray pond cooling
Target energy consumption for pump house - 3.50 units / ton of cane
Boiler house
The boiler and its auxiliaries are also major consumers of power in a sugar plant. The major
power consumers in the boiler house are the I.D, F.D, P.A & S.A fans and the BFW pumps.
The energy consumption can be kept at a bare minimum, by adopting the energy efficiency
aspects at the design stage itself.
Target energy consumption for boiler house - 2 units/ton of cane
Centrifugals
The centrifuge section, where the sugar is separated and washed from molasses, is also a
major consumer of power. Presently, two types of centrifuges are in operation in the industry
– batch and continuous centrifugals.
Target power consumption in centrifugals – 6.00 units/ton of cane
5.3 Steam Consumption

The sugar industry is a major consumer of steam, with the evaporators and vacuum pans
consuming substantially quantities for concentration of juice and manufacture of sugar. Apart
from these, the juice heaters, centrifuges, sugar dryers and sugar melting also consume some
steam. The washing of pans and other equipment need some marginal steam.
Evaporator
The evaporator is the major steam consumer in a sugar plant. The evaporator concentrates
the juice from a level of 14 – 16 Brix to a level of 60 – 65 brix. The exhaust steam is used
for this purpose. Further to the concentration to a higher level, the concentrated syrup is
transferred to the vacuum pan section, for evapo-crystallisation, to produce sugar.
Several types of evaporators are used in the sugar industry. The commonly used are the
quadruple and quintuple-effect short-tube evaporators. Typically, the steam enters the first
effect at a pressure of 1.1 kg/cm2, at a temperature of 105oC and the vacuum in the last effect
is around 650 mm Hg.
The multiple effect evaporators have higher steam economies of 3 to 5, depending on the
number of effects.

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Falling film evaporators (FFE)
This is another popular evaporator, which is being considered by many sugar industries. In this
type the juice travels from top to bottom and as it descends, it takes the entrained vapour along
with it to a lower chamber, where the vapour and liquid are separated.
The falling film evaporators have many advantages over the conventional evaporators as below
• The FFE’s have better heat transfer, as there is no elevation in boiling point due to hydrostatic
pressure.
• The average contact time between juice and steam in a falling film evaporator is about 30
seconds as against 3 minutes in the Kestner evaporator and 6-8 minutes in the conventional
short tube evaporator.
• The design of the evaporators is such that, the juice is in contact with the heating surface
in a thin layer over the length of the heating surface.
The installation of falling film evaporator has therefore, immense potential for installation in
the Indian sugar industry for achieving substantial savings in steam. Hence, all new plants
should strongly consider installation of FFE for the first three effects and at-least for the first
two effects to begin with.
Target steam consumption in evaporators – 34% on cane
Vacuum pans
The vacuum pans are used for further concentrating the massecuite produced in the
evaporators, to finally produce sugar and molasses. Conventionally, the Indian sugar industries
have been using the batch pan. With the recent introduction of the continuous pans, there has
been a reduction in the steam consumption to the extent of 15 – 20%.
Apart from the steam reduction, the utilization of continuous vacuum pans also result in
• Improved grain
• Reduced sugar loss
• Better control and systems.
• Reduced power consumption for injection water pumps.
Hence, by design all new plants should install only continuous vacuum pans. Other steam
consumers The other miscellaneous steam consumers in a sugar plant are
• Sugar dryers
• Sugar melter
• Centrifuge wash water super heater
• Other washing /cleaning application

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6.0 Energy Saving Projects in Sugar Industry

The energy saving projects in sugar industry are detailed below:
Cane Preparation & Juice Extraction
Short Term Projects
• Avoid recirculation in the filtrate juice by installing next lower size impeller
Medium Term Projects
• Install lower size pump for weighted juice pump/Install VFD for weighed juice pump
• Install correct size pump for crusher
• Install correct size pump for imbibition water pump
• Install lower capacity pump for juice transfer at III mill and minimize recirculation
• Install lower head pump with VFD for raw juice pump
• Install next lower size impeller for mill IV juice transfer pump
• Install right size pump for imbibition water pumping
• Install Variable Frequency Drive for Imbibition Water Pump
• Install variable frequency drive(VFD) for cane carrier drives
• Install VFD for weighed juice pump
Long Term Projects
• Install DC drives/hydraulic for mill drives & shredder
• Install electronic mass flow meters for all three mills and avoid use of weighed juice transfer
pump.
Juice Heating, Sulphitation, Clarification & Crystallization
Short Term Projects
• Reduce rpm of existing reciprocating compressors (centrifugal house) by 20%
• Utilize L P steam for sugar dryer and sugar melting
• Avoid condensate water pumps at juice heaters and evaporators
• Commission load/unload mechanism for sulphur air compressors
• Improve flash steam utilization for S K condensate and quad-1
• Improve sealing of the stand-by blower, avoid damper control and reduce impeller size of
the sugar drier blower

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• Install lower size pump for clarified pumping/install VFD for clarified juice pump
• Install lower size pump for sulphite juice tank/install VFD for sulphite juice pump
• Install right pump for filter condenser water pumping
• Install rotary blower in place of Compressor for supplying air to syrup sulphur burner
• Install thermic fluid /pressurized hot water heat recovery system for utilizing sulphur furnace
exhaust steam for sulphur melts
• Install Variable Frequency Drive for super heated wash water pump
• Install VFD/small size pump/lower size impeller for mill IV juice transfer pump
• Optimize operation of spray pump
• Provide VFD for booster vacuum pump of vacuum pans (1-12)
• Provide VFD for rotary blowers of sulphur burner
• Reduce RPM of sulphur burner compressor
• Reduce rpm of vacuum pumps for drum filter
• Segregate high vacuum and low vacuum requirements of Oliver filter
• Segregate spray water and jet water and use cold water only for spray
Long Term Projects
• Modify new injection pumping system and avoid use of cooling tower pumps
Cogeneration system
Short Term Projects
• Arrest air infiltration in boilers
• Arrest identified steam leaks and improve the working of steam traps in identified areas
• Avoid recirculation of boiler feed water pump in WIL boiler
• Down size impeller of SA fan
• Improve combustion efficiency of all the boilers
• Improve insulation in identified areas
• Rationalize condensate collection system
• Reduce RPM of power plant air compressor
• Replace feed water make-up pump with low duty ump
• Use exhaust steam for deaerator water heating
• Convert identified MP steam users to LP steam users

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• Install a flash vessel to recover the flash from the boiler continuous blow down & HP steam
header traps drain and connect to exhaust header
• Install correct size pump for the condensate transfer pump
• Install L P steam heater in delivery of boiler feed water pump
• Install steam jet ejectors in place of vacuum pumps for vacuum filters
• Install thermo compressors with 150 psi steam for compressing 8 psi and 12 psi exhaust
vapors to 16 psi
• Install variable fluid coupling for boiler ID fans
• Install Variable Frequency Drive for Auxiliary Cooling Water (ACW) pump
• Install Variable Frequency Drive for Condenser Water pump
• Install Variable Frequency Drive for SA & PS fans and operate in open loop control
• Install VFD for Boiler feed water pump
• Optimize capacity of boiler house compressor
• Replace identified fans with correct size high efficiency fans
Long Term Projects
• Commission de-aerator and utilize L P steam for heating condensate water in de-aerator
• Install heat exchanger to preheat boiler feed water
• Install small turbine for utilizing 43/8 ata steam
Distillery
Short Term Projects
• Increase the temperature of fermented wash from 83 degree C to 90 Degree C by installing

Additional plates
• Install additional standby PHE for fermented wash heating
• Install lower head pump for fomenter circulation pump
Long Term Projects
• Install steam ejector and utilize LP steam for distilleries
Auxiliary areas
Short Term Projects
• Avoid/reduce over flow of cold water OH tank by installing next lower size impeller for pump
• Install level based ON / OFF control for service water pumps

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• Install LIC for service tank/Install correct size pump for service tank
• Install temperature cut-off switch for cooling tower fans
• Arrest compressed air leakages at packing section
• Convert ‘V’ belt to flat belt drive at the identified equipment
• Install auto drain valve for instrument air compressor
• Install correct size pumps for hot water pumping at cooling tower
• Install FRP blades for process Cooling Tower fans
• Install next lower size impeller for hot water process cooling tower pump
• Install Variable Frequency Drive for Cooling Tower fans
• Install Variable Frequency Drive for service water pump
• Provide cooling tower for identified equipments and stop use of fresh water
• Segregate the low vacuum and high vacuum of Oliver filter
Electrical
Short Term Projects
• Convert delta to permanent star connection for the identified lightly loaded motors
• Install automatic star - delta - star converter in the identified lightly loaded motors
• Optimize the plant operating frequency, if operating in island mode
• Optimize the plant operating voltage
• Improve the P.F of the Identified feeders and reduce the cable loss
• Install automatic slip ring controller for the cane leveler
• Install soft starter cum energy saver at the lightly loaded motors
• Replace filament lamps installed in panel on/off indications with energy efficient led lamps
• Replace identified faulty capacitor banks
Energy Efficient Equipment

• Replace dyno drives with variable frequency drives in identified equipments
• Replace eddy current drive in cane carrier with variable frequency drive

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• Replace old rewound motors with Energy Efficient motors
Lighting
Short Term Projects
• Avoid daytime lighting in identified areas
• Increase the natural lighting by installing translucent sheets and switch off the identified light
• Install 50 KVA step down transformer at the main lighting circuit
• Convert the 100 incandescent lamps with 40W fluorescent lamps
• Convert the existing 200 W 300W & 500 W incandescent lamps with 160W choke less LML
lamps
• Convert the existing 40W fluorescent tubes with 36 W slim tubes
• Covert the 400 W high pressure mercury vapor lamps (HPMV) with 250 W energy efficient
high pressure sodium vapor lamps (HPSV)
• Install automatic voltage stabilizer in lighting feeder and operate at 205 -210 volts
• Install energy efficient Copper chokes for identified fluorescent lamps
7.0 Detailed description of capital intensive energy saving projects

13 no of capital intensive energy saving projects are described in detail. These projects have
been chosen as they have high saving and investment potential with high replication possibility.

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Case study 1
Install diffusers in lieu of milling tandem

Background
Installation of milling tandem is practiced conventionally
in sugar plants in India. Milling is highly power and
labour oriented equipment. The present trend is to
adopt diffusion as an alternative to Milling, considering
several advantages diffusion offers over milling.
It is a low cost extraction process. In conventional

milling mass transfer operation is by leaching followed
by high pressure squeezing. In diffusion process, the
physico-chemical principle of diffusion is adopted. Here
sugar molecules moves from higher concentration to
lower concentration due to concentration gradient.
Rate of diffusion is proportional to the temperature, concentration gradient and the area of
liquid and solid contact.
The Juice extraction process in the cane diffuser system is as follows:

1. Cane is prepared to a Preparation Index (PI) of 85 %+, ensuring long fiber preparation.
The heavy duty swing hammer fibrizor described above is suitable for meeting this
requirement.
2. Prepared cane is delivered to the diffuser. The cane is heated at entry to the diffuser to
a temperature of 83oC by scalding juice, which is at a temperature of about 90oC.
3. The diffusion percolation bed is a moving conveyor on which the cane mat height is
between 1200 mm to 1400 mm.
4. The diffuser is divided in 13 circulation compartments. Juice from each compartment is
re-circulated in counter current manner to cane blanket movement, from low brix area to
high brix area.
5. The scalding juice is limed in order to maintain a pH of about 6.5 in the diffuser in order
to prevent inversion of sucrose.
6. Average temperature of the material inside the diffuser is about 78 Degree C
7. Draft juice from the diffuser is at about 69 Degree C and therefore is sent directly to the
sulphitation vessel because it is already at the required temperature for sulphitation.
8. Diffusion bagasse at exit of the diffuser is at supersaturated moisture and is de-watered
in a single six-roller mill. Final bagasse moisture is 51 % plus.
9. Imbibition is applied directly in the diffuser. Hot condensate at 84 Degree C from the evaporator
last effect is used for this. Imbibition quantity at Andhra Sugars is 320 % on Fiber.
10. Draft juice is measured by a mass flow meter. Hence the juice is delivered to the sulphitation
vessel in a closed pipe without appreciable loss of temperature. Screening of draft juice
is found to be not necessary because the bagasse bed through which the juice percolates,
itself acts as a screen.

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A 2500 TCD plant in India has installed cane diffuser by design. The power consumption in
a standard sugar mill, utilizing a milling tandem for juice extraction is 17.8 kWh / ton. In the
plant under discussion, the average power consumption in the juice extraction section is 11.4
kWh / Ton. This results in a decrease of 6.4 kWh / Ton of cane crushed.
The other spin off benefits on installation of diffuser are:
• Increased extraction
• Lower power consumption
• Lower maintenance cost
• Reduction in Unknown loss
• Reduction in Lubrication Cost
• Reduction in Sugar Loss in filter cake
• Availability of More Bagasse
Financial Analysis
The additional .. saving benefit was Rs 8.0 million. Considering an average crushing of 2500
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.
This project has tremendous replication potential. In India, the number of sugar mills over 2500
TCD capacity is more than 320. Considering an average crushing of 150 days and power
export cost of Rs. 2.75 / kWh, the total energy saving potential is over Rs. 2.112 Billion/
season.
Considering an investment of Rs. 90 Million per diffuser, the investment potential for installation
of diffusers in Indian sugar industry is Rs. 28.8 Billion.


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Case study 2
Utilisation of Exhaust Steam for Sugar Drier and Sugar Melter
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 by
passing the live steam generated from the
boiler, through a pressure-reducing 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
The temperature requirements for sugar drier blower and sugar melter are about 80°C and
90°C respectively. The centrifuge hot water was to be heated to a temperature of about
115 - 125°C.

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Exhaust steam generated by passing live steam through a turbine was available at around
1.2 ksc.

The exhaust steam was utilised in place of live steam for sugar melting (blow-up) and sugar
drying.

The sugar melting requires a temperature of 90°C and sugar drying needs about 80°C. The
heat required for these two process users, can be easily achieved by exhaust steam.
Replacement of live steam with exhaust steam in these two users can increase the co-
generation. Every ton of medium pressure steam replaced with exhaust steam can aid in
generation of additional 120 units of power.
Implementation Methodology, Problems faced and Time frame

The steam distribution network was modified, to install steam line from the exhaust header
to sugar melter and sugar drier blower.
There were no problems faced during the implementation of this project, as the modification
involved only the laying of new steam pipelines and hooking it to the main steam distribution
system. The entire modification was carried out in 15 days time.
Benefits
The live steam consumption, amounting to about 0.3 TPH, in the sugar melter and sugar 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 -125°C.
Exhaust steam can be used for heating the centrifuge wash water to atleast 105°C. The
heating, from 105°C to 125°C can be carried out by live steam. This will partly substitute the
use of live steam and will increase the cogeneration power.

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Case study 3
Installation of Conical Jet Nozzles for Mist Cooling System
Background
The spray pond is one of the most common type
of cooling system in a sugar mill. In a spray pond,
warm water is broken into a spray by means of
nozzles. The evaporation and the contact of the
ambient air with the fine drops of water produce
the required degree of cooling. There are many
types of nozzle onfigurations available for different
spraying applications. Most of them aim to give a
water spray the form of a hollow cone. A good
spray nozzle should be
of simple design, high capacity and high efficiency. Of the various types of spray nozzles, the
conical jet nozzles have been found far superior on all the above parameters. Hence, the
recent trend among the new sugar mills is to install the conical jet nozzles, to achieve maximum
dispersion of water particles and cooling.
Mist Cooling System

Previous status
In a 4000 TCD sugar mill, the cooling systemconsisted of a spray pond. There were 5 pumps
of 75 HP rating operating continuously, to achieve the desired cooling parameters. The
materials of construction of the spray nozzles were Cast Iron (C.I). These nozzles had the
disadvantages of low capacity and high head requirements (of the order of 1.0 - 1.2 ksc or
10 -12 m of water column). The maximum cooling that could be achieved with the spray pnd
was about 34 - 35 °C. To achieve better cooling, higher efficiency and energy savings, the
conical jet nozzles were considered.

The spray pond system was modified and conical jet nozzles were installed to achieve mist
Cooling.
The water particle dispersion is so fine that, it gives a mist like appearance. The surface area
of the water particles in contact with the ambient air is increased tremendously. Hence, better
cooling is achieved with the mist cooling system.
The material of construction of the latest conical jet nozzles is PVC, which enables achieve
better nozzle configuration. They will also help attain the same operating characteristics as the
cast iron nozzles, but at a much lower pressure drop or head (0.5 - 0.8 ksc) requirement.

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This reduces the cooling water pump power consumption substantially.
Implementation Status, Problems faced and Time frame

The earlier CI nozzles of 40 mm diameter were replaced with PVC conical jet nozzles of 22
mm diameter, in phases. There were no problems faced during the implementation of this
project.
As the project was implemented in phases, it was implemented in totality over 2 sugar
seasons.
Benefits Achieved
The cooling achieved with the mist cooling system was about 31 - 32 °C (i.e., a sub-cooling
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 minimised 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.


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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 crystallisers. From the
crystallisers, 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 many 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 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 4000 TCD 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.

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The regenerative type of braking system was installed for all the flat bottom high speed
centrifugal used for A - massecuite curing.

One of the most important characteristics of a regenerative braking system in an electric
centrifugal is that, it permits the partial recovery of the energy expended, during the discharge
cycle.
With AC current, this is obtained by means of a motor of double polarity, which can work with
half the normal number of poles. This regeneration is effective only down to about 60% of the
normal speed. 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.

The regenerative type of braking system was installed for one of the flat bottom DC motor
driven high-speed centrifugal on a trial basis. Once, the satisfactory and stable operating
parameters were achieved, it was extended to the remaining centrifugal also.
There were no particular problems faced during the implementation of this project. The
implementation of the project was carried out over two sugar seasons.
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 upgradation measure.
This project has a high replication potential of implementation in more than 75 plants in the
country.

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Case study 5
Installation of Jet Condenser with External Extraction of Air
Background
The evaporators and pans are maintained at low pressures,
through injection water pumps. These are one of the highest
electrical energy consumers in a sugar mill. The multi-jet
condenser, which are presently used in the sugar plants, do both
the jobs of providing the barometric leg, as well as removing the
non-condensibles.
The water injected into these condensers comprise of, spray

water for condensation and jet water for creating vacuum. The
water used for condensation needs to be cool, while the jet water
can be either hot or cold. So only a part of the water used in the
condenser needs to be cooled.
However, the vacuum levels which they give is less uniform and varies slightly with the
temperature of the hot water, which in turn depends on the quantity of vapour to be condensed.
of 3200 TCD.
With the expansion plans, for increasing the installed crushing capacity to 4000 TCD, the
installation of jet condensers with external air extractor was considered.
They have a higher water consumption and require more powerful pumps, with consequent
high electric power demand.
To overcome these disadvantages, the latest trend among the major sugar mills has been to
replace these multi-jet condensers with a jet condenser with external extraction of air.
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 of jet condenser with external extraction of air Reduction in injection water pump
power consumption

Along with the expansion plans of 4000 TCD crushing capacity, the multi-jet condensers were
replaced with jet condensers having external air extractor facility

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The jet condensers with external extraction of air also works on the same principle as that
of the jet condensers. The nozzle is placed at such a height that the water discharged by it
can be aspirated into the condenser. Since the quantity of air is very small, the water leaves
the nozzle at a temperature, practically equal to that at which it enters. The difference is not
easily detectable, by a thermometer.
Hence, a pump of low head can be utilised and it may be arranged, so that, it is not necessary
to pump the water, leaving the water actuated ejector condenser (which is used to ensure
condensation in the barometric column).
For this, it is sufficient that the water level in the intermediate channel below the ejector should
be about 4 m above the level in the channel at the foot of the barometric column.
The water in the intermediate channel is, thus aspirated into the condenser, as soon as the
vacuum approaches its normal value.
Implementation status, problems faced and time frame There were no problems faced during
the implementation of this project, except for the initial problem of identifying the ideal layout.
The entire project was taken up during the sugar off-season.
Benefits achieved
There was a significant drop in water consumption in these condensers, inspite of an increase
in crushing capacity (average maximum crushing of 4800 TCD). This resulted in reduction in
the number of injection water pumps in operation.
The new injection water pumping system includes - 5 nos. of 100 HP pump and 1 no. of 250
HP pump. Thus, there is a net reduction in the installed injection water pumping capacity of
about 350 HP (30% eduction). 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 120
days of sugar season and saleable unit cost of Rs.2.50/kWh). This required an investment of


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Case study 6
Installation of 30 MW Commercial Co-generation Plant
Background
The Indian sugar industry by its inherent nature, can generate
surplus power, in contrast to the other industries, which are
only consumers of energy. This is mainly possible because
of the 30 % fibre content in the sugar cane used by the
sugar mills. This fibre, referred to as bagasse, has good
fuel value and is used for generation of the energy required,
for the operation of the sugar mill.
The bagasse is fired in the boiler, for producing steam at

high pressures, which is extracted through various back-
pressure turbines and used in the process. This
simultaneous generation of Commercial
co-generation plant steam and power, commonly referred to as Co-generation. Conventionally,

the co-generation system was designed to cater to the in-house
requirements of the sugar mill only. The excess bagasse generated, was sold to the outside
market.
In the recent years, with the increasing power‚ Demand-Supply™ gap, the generation of power
from the excess bagasse, has been found to be attractive. This also offers an excellent opportunity
for the sugar mills to generate additional revenue. Co-generation option has been adopted in
many of the sugar mills, with substantial additional revenue for the mills. This also contributes
to serve the national cause in a small way, by bridging the ‚Demand- Supply™ gap.
This case study describes the installation of a

commercial co-generation plant in a 5000 TCD mill.
Previous status
A 5000 TCD sugar mill in Tamilnadu operating for about
200 days in a year had the following equipment:
Boilers
• 2 numbers of 18 TPH, 12 ATA
• 1 number of 50 TPH, 15 ATA
Turbines
1 number 2.5 MW
1 number 2.0 MW
1 number 1.5 MW

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Mill drives
• 6 numbers 750 BHP steam turbines
• 1 number 900 BHP shredder turbine
The plant had an average steam consumption of 52%. The powerrequirement of the plant
during the sugar-season was met by the internal generation and during the non- season from
the grid.

The plant went in for a commercial co-generation plant. The old boilers and turbine were
replaced with high- pressure boilers and a single high capacity turbine. The new turbine
installed was an extraction-cum- condensing turbine. A provision was also made, for exporting
(transmitting) the excess power generated, to the state grid. The mill steam turbines, were
replaced with DC drives. The details of the new boilers, turbines and the steam distribution
are as indicated below:
Boilers
• 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
Implementation methodology, problems faced and time frame

Two high capacity, high-pressure boilers and a 30 MW turbine was installed in place of the
old boilers and smaller turbine.
While selecting the turbo-generator, it was decided to have the provision for operation of the
co-generation plant, during the off-season also. This could be achieved, by utilising the surplus
bagasse generated during the season, as well as by purchasing surplus bagasse, from other
sugar mills and biomass fuels, such as, groundnut shell, paddy husk, cane trash etc.
The shortfall of bagasse during the off-season was a problem initially. The purchase of biomass
fuels from the nearby areas and the use of lignite solved this problem.
The entire project was completed and commissioned in 30 months time.
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 for
exporting to the grid.

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The following operating parameters were achieved:
Typical (average) crushing rate = 5003 TCD
Typical power generation
• During season = 5,18,321 units/day
• During off-season = 2,49,929 units/day
Typical power exported to grid
• During season = 3,18,892 units/day (13.29 MW/day)
• During off-season = 1,97,625 units/day (8.23 MW/day)
Typical no. of days of operation = 219 days (season) = 52 (off-season)
The summary of the benefits achieved (expressed as value addition per ton of bagasse fired)
is as follows:
Financial 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.


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Note :
Critical factors affecting power generation
The efficient operation of a co-generation system depends on various factors. This has a direct
bearing on the loss in power generation and the power exported to the grid. Some of these
critical factors affecting the power generation (quantified as loss in generation per day) are as
follows:
• 1% drop in bagasse % in cane : 18300 units
• 1% increase in moisture content of bagasse : 6800 to 10200 units
• 1% increase in process steam consumption : 4200 units
• 1% drop in crushing rate : 5000 to 7400 units
• 1 hour downtime : 20600 units
• Drop in 1 ton of cane availability : 60 units
The above figures are based on the following operational parameters:
• Crushing rate : 5000 TCD
• Steam to bagasse ratio : 1 : 2.2
• NCV of bagasse (50% moisture) : 1804 kCal/kg
• Bagasse content, in % cane : 27%
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 alteast say about 50 plants is Rs 4000 million.

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Case study 7
Replacement of Steam Driven Mill Drives with Electric DC

Motor
Background
Conventionally, steam turbines, are used as the prime
movers for the mills, in a sugar industry. These steam
turbines are typically, single stage impulse type turbines
having about 25 - 30% efficiency.
The recent installation of commercial cogeneration

system, with provision for selling the excess power to
the grid, has made the generation of excess power in a
sugar mill, very attractive. One of the methods of
increasing the cogeneration power in a sugar mill, is to
replace the smaller Previous status A 5000 TCD sugar
mill had six numbers of 750 HP mill turbines and one number of 900 HP shredder turbine.
The average steam consumption per mill (average load of 300 kW) was about 7.5 TPH steam
@ 15 Ata. The steam driven mill drives had an low efficiency mill turbines, with better
efficiency drives, such as, DC motors or hydraulic drives.
The power turbines (multi-stage steam turbines) can operate at efficiencies of about 65 - 70%.
Hence, the equivalent quantity of steam saved by the installation of DC motors or hydraulic
drives, can be passed through the power turbine, to generate additional power.
This replacement can aid in increase of net saleable power to the grid, resulting in additional
revenue for the sugar plant. This case study, highlights the details of one such project,
implemented in a 5000 TCD sugar plant.
Benefits of electric DC drives for mill prime movers

• Increased drive efficiency
Previous status
A 5000 TCD sugar mill had six numbers of 750 HP mill turbines and one number of 900 HP
shredder turbine.
The average steam consumption per mill (average load of 300 kW) was about 7.5 TPH steam
@ 15 Ata. The steam driven mill drives had an efficiency of about 35%, in the case of single-
stage turbine and about 50%, in the case of two-stage turbines.
The plant team was planning to commission a commercial cogeneration plant. This offered an
excellent opportunity for the plant team to replace the low efficiency steam turbine driven mills,
with DC motors or hydraulic drives and maximise the cogeneration potential.

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The plant team contemplated the replacement of the steam driven mills with electric DC
motors, along with the commissioning of the cogeneration plant.

The conventional single stage impulse type steam turbines have very low efficiencies of 35%.
Hence, the steam consumption per unit of power output is very high.
A single high capacity steam turbine is more efficient as compared to multiple number of
smaller capacity steam turbines. Hence, the steam can be passed through the larger capacity
steam turbine to generate more saleable power.
The latest drives, such as, DC drives and hydraulic drives have very high efficiencies of 90%.
The steam saved by the installation of DC drives, can be passed through the larger capacity
power turbines of higher efficiency (about 65 - 70%), to generate additional saleable power.

The steam turbine mill drives were replaced with DC drives, once the cogeneration plant was
commissioned. The modifications carried were as follows:
• Four numbers of 900 HP and two numbers of 750 HP DC motors were installed in place
of the six numbers of 750 HP mill turbines
• Two numbers of 1100 kW AC motors were installed for the fibrizer, in place of the single
900 HP shredder turbine
• There were no major problems faced during the implementation of this project. The
implementation of the project was completed in 24 months.
Benefits achieved
The comparative analysis of the operational parameters before and after the modification is as
follows:

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The steam consumption indicated, is the equivalent steam consumption in a power turbine, for
generation of additional power
The equivalent power saved (850 kW/mill) by the implementation of this project, could be
exported to the grid, to realise maximum savings. This amounts to about
Financial analysis
Rs.42.00 million, which had an attractive simple payback period of 9 months.


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Case study 8
Installation of an Extensive Vapour Bleeding System at the

Evaporators
Background
The sugar industry is a major consumer of thermal
energy in the form of steam for the process.
The steam consumers in the process are -
evaporators and juice heaters (mixed juice,
sulphited juice and clear juice).
Out of these consumers, the evaporators which

concentrate the juice, typically from a brix content
of 10 - 11 to about 55 - 60 brix, consume the
maximum steam. The evaporators are multiple
effect evaporators,with the vapour of one stage
used as the heating medium in the subsequent stages. In the older mills, the evaporators are
triple/quadruple effect and the vapour from the first effectis used for the vacuum pans and
from the second effect for juice heating.
In the modern sugar mills, efforts have been taken to reduce the steam consumption. The
following approach has been adopted in the boiling house for reducing the steam consumption:
Increasing the number of evaporator effects the higher the number of effects, the greater will
be the steam economy (i.e., kilograms of solvent evaporated per ton of steam).
Typically, the present day mills, use a quintuple effect evaporator system.
Extensive vapour bleeding - the extensive use of vapour coming out of the different effects of
the evaporators are used for juice heaters and vacuum pans. The later the effect, the better
is the steam economy in the system.
Additionally, the following aspects were also considered in the cane preparation section and
milling section:
• Installation of heavy duty shredders, to achieve better preparatory index (> 92+ as compared
to the conventional 85+) for cane
• Installation of Grooved Roller Pressure Feeder (GRPF) for pressure feed to the mills. This
allows for better juice extraction from the cane.
• Lesser imbibition water addition, on account of the better juice extraction by the GRPF,
resulting in reduction of boiling house steam consumption
This case study pertains to a sugar mill of 2500 TCD, where the above approach has been
adopted at the design stage itself, resulting in lower steam consumption.

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Conventional system
In a typical sugar mill, the most commonly used evaporators are the quintuple effect evaporators.
The typical vapour utilisation system in the evaporators comprises of:
• Vapour bleeding from II- or III- effect for heating (from 35 °C to 70 °C) in the raw (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
• 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 45
to 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 utilised 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 practise 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 n 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

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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 utilisation 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
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 120
days 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 saving
achieved was Rs.11.00 million. This required an investment of Rs.6.50 million, which had an
attractive simple payback period of 8 months.

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Case study 9
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 colourremoval.
The flow of the weighed juice to the sulphiters through the juice heaters,
has to be maintained at a steady flow rate, to achieve uniform heating 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 rateand 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.

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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.
The plant team decided to conduct trials with a suitable variable speed mechanism for the
weighed juice pumps. A variable speed system will help achieve the RPM variation of the pump
and exactly match the varying capacity requirements.
The installation of a variable speed system, will not only ensure a consistent flow, resulting
inimproved quality of the product, but also, offer substantial energy savings.
Among the different variable speed systems, the installation of a variable frequency drive (VFD)
can result in maximum energy savings. The VFD can be put in a closed loop with the discharge
pressure.
This will enable constant flow of juice to the juice heater and sulphiter, irrespective of the level
in the juice tank. The discharge pressure set point can be adjusted periodically,depending on
the crushing rate or number of tips manually. In the new sugar mills, the number of tips and
time interval between the tips is measured. This can be used by the VFD, for automatically
varying the juice flow through the system, according to the rate of crushing.
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 Cost benefit analysis
Rs.0.236 million. The investment made wa
Rs 0.25 million, with an attractive payback
period of 12 months. • Investment - Rs. 0.25 millions
Replication Potential • Simple payback - 12 months

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.

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Case study 10
Installation of Thermo-compressor for use of Low Pressure

Steam
Background
The sugar industry has many steam users - both iolively
medium pressure (MP) steam and exhaust steam. Some of
these live steam users can be totally replaced with exhaust
steam, while in some other users, the live steam consumption
can be partially replaced with exhaust steam.
One such live steam user in a sugar mill is the adjoining

distillery. A typical distillery requires steam at about 0.7 - 0.9
ksc for the distillation column and about 1.0 - 1.2 ksc for the
ENA column. The exhaust steam pressure of 0.4 ksc available
from the sugar mill, will not be able to cater to this requirement.
Hence, live steam is drawn from the 8.0 ksc header and
dropped to 1.5 ksc, through a pressure-reducing valve, for use
in the distillery.
Any conservation measure, which can replace/ minimise the

live MP steam consumption, can result in maximising the
cogeneration in a sugar mill. One such method of minimizing the MP steam consumption is
by the installation of a thermo- compressor.
The thermo-compressor, by passing a very small quantity of MP steam can iacompresslr the
waste exhaust steam (typically about 0.4 ksc) available in the sugar mill. The resultant LP
steam (typically about 1.5 ksc) can be utilised for any process steam requirement, such as
the distillation column and ENA column in a distillery.
This modification can result in minimising the usage of MP steam consumption, effectively
utilise the heat value of exhaust steam and maximise the cogeneration potential.
Previous status
In a typical 4000 TCD sugar mill
in Maharashtra, the turbine
exhaust steam at 0.40 ksc, was
continuously vented out. The
quantity of the steam vented,
amounted to about 6300 kg/
h.There were no process users
in the sugar mill or the distillery,
which could utilise this exhaust
steam of 0.40 ksc.

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The distillery required 10 TPH of steam at 1.5 ksc. A separate boiler was meeting the steam
requirements of the distillery. The sugar mill boiler met any additional requirement of steam.
In both the cases, steam was generated at 8 ksc and reduced to 1.5 ksc through a pressure-
reducing valve.
Benefits of thermo compressor

• Increased co-generation
The expansion of steam through a pressure-reducing valve is not a good system, as no power
is generated with pressure reduction. The turbine exhausts steam, instead of being venting
out, could be converted to medium /high-pressure steam through thermo-compression and
used to meet the steam requirements of the distillery.

A thermo-compressor system was installed, for reusing the turbine exhaust steam, in the
distillery. The resultant MP steam saved in the distillery, was passed through the power generating
turbines, for generation of additional power.

In the thermo-compressor body, high or medium pressure motive steam accelerates through
thenozzle. As it enters the suction chamber at supersonic speeds, it entrains and mixes with
low-pressure exhaust steam, entering from the suction inlet.
The resultant steam mixture then enters the convergent-divergent diffuser. In this section, the
velocity reduces and its kinetic energy is converted to pressure energy. The steam discharged
by the thermo-compressor is then recycled to a localised process.
The resultant discharge steam is available at a pressure, suiting the particular process
application.The outlet steam pressure and quantity can be designed, by varying the velocity
and quantity of the motive steam and fine-tuning the configuration of the thermo-compressor.

A thermo-compressor system along with the associated mechanical hardware including traps,
strainers, safety valves etc., and flow control instrumentation on the motive steam, was installed.
The thermo-compressor operating parameters are
• Motive steam : 3700 kg/h at 20 ksc
• Suction steam : 6300 kg/h at 0.4 ksc
• Discharge steam : 10000 kg/h at 1.5 ksc
There were no problems faced during the implementation of this project. Moreover, the thermo-
compressor operation is maintenance free. The system was installed in 6 months time.

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Benefits
The resultant 1.5 ksc steam obtained by thermo-compression of exhaust steam, was directly
used in the distillery. This reduced the passing of high/ medium-pressure steam through the
pressure-reducing valve.
Financial analysis
The annual energy saving achieved was Rs.6.00 million. This required an investment of Rs.2.00
million, which had a very attractive simple payback period of 4 months.

there are about 50 plants in India with distillery integrated with the sugar mill. The possibility
of installing a thermo compressor exists in majority of the plants. The investment potential for
this project is therefore Rs 100 million.

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Case Study 11
Installation of Hydraulic Drives for Mill Prime Movers
Background
The mill prime movers in sugar mills are typically steam turbines. The
use of steam turbines as prime movers gained popularity over the
earlier steam engines, on account of its simple design and operational
flexibility, even though it has a very high specific steam consumption.
These steam turbines are single stage impulse type turbines. They
are characterised by very low efficiencies of 35 to 40%. The efficiency
of the steam turbines remains at optimum levels, only when the input
steam parameters and speed are kept at the rated level. Even with
moderate steady steam parameters and speed, the steam turbine
driven mills require about 25 - 30% more running power over that
actually required.
With the normally prevalent steam pressure fluctuations in the sugar

mills, its consequent effect on efficiency of the steam turbines and the
increasing trend towards commercial cogeneration systems, the trend
of late, is to replace these steam turbines with either DC drives or hydraulic drives.
The benefits of installing DC drives, have already been discussed in the other case study
described. This case study highlights the benefits of installing hydraulic drives in place of
steam turbines for themill prime movers.
Benefits of hydraulic drives for mill prime movers

• Increased drive efficiency
• Stable operation
• Reduced maintenance
One of the sugar mills had the following mill drive configuration:
• For 6 mill system- 600 BHP rating steam turbine x 3 nos. (2 mills driven by a single steam
turbine)
• For 4 mill system - 600 BHP rating steam turbine x 2 Nos. (2 mills driven by a single steam
turbine) This configuration was designed to cater to the initial installed capacity of 2500
TCD.
The following operational parameters were observed:
• The specific steam consumption of these steam turbines were 24 kg/kW, as compared to
the specific steam consumption of 13 kg/kW in the power turbines.
• Speed range and speed accuracy were very poor
• Adaptability to complex system is difficult

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• Monitoring of power consumption is not possible
• The overall efficiency is only of the order of 27 to 30%
• Maintenance and lubrication requirements are very high
• Space requirements are large
The plant teams had plans to increase the cane crushing capacity to 4000 TCD. The inherent
disadvantages of the steam turbines can be overcome, especially after the proposed increase
in cane crushing rate, by the installation of hydraulic drives.

The steam turbines used as mill drives were partially replaced by hydraulic drives, during the
capacity upgradation activity.

The hydraulic drives are a combination of two components - the pump normally driven by an
electric motor and the hydraulic motor, which runs by the displacement of oil. The speed of
the motor depends on the rate at which the displacement of oil takes place. The hydraulic drive
works on the principle of high torque delivery at low speeds. The torquedelivered is directly
proportional to the system pressure and the speed is directly proportional to the oil flow.
The advantages of hydraulic drives are as follows:
• High transmission efficiency - the overall efficiency of converting steam power into shaft
power for a hydraulic system is about 58%. This results in substantial power savings
• Very low inertia enabling the system operation on load
• Upgradable modular design
• Easy adaptability on existing mills
• Simple to operate
• Instantaneous and unlimited reversal of rotation, enabling quick response to load changes
• Compact unit, resulting in space savings
• Reliable and rugged design
• Minimal foundation work
• Alignment problems eliminated, thereby minimising maintenance
Due to the above-mentioned advantages, hydraulic drives are increasingly replacing the
conventional steam turbine mill drives.

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The mill configuration was altered, to cater to the capacity upgradation of 4000 TCD, as per
the following:
The second mill drive of the 6-mill system was removed and added as the fifth mill drive of
the 4-mill system, thus, making two 5-mill systems.
The last four mill steam turbine drives (of the old 6-mill system) were replaced with hydraulic
drives of 300 kW each.
The new fifth mill drive (of the modified 4-mill system) was provided with an hydraulic drive
of 600 kW rating.
There were initial technical problems related to the oil-pumping unit, which was rectified by the
supplier. Apart from this, there were no particular problems faced during the implementation
of this project.
The entire implementation was taken up during the off-season and was completed in 6 months
time.
Benefits achieved
The net installed power consumption reduced from 0.895 kW/TCD (for average crushing of
2500 TCD) to 0.509 kW/TCD (for average crushing of 4800 TCD). In addition, very stable
operating conditions (constant crushing) are being achieved, at almost negligible maintenance
costs.
Financial analysis
This project was implemented as a technology upgradation measure. The installation of hydraulic
drives helps in achieving mechanical, electrical and process benefits. Hence, the saving achieved
could not be exactly quantified. The entire modification required an investment of Rs. 25.00
million.


582
Case study 12
Install nozzle governing system for multi jet condensers
Background
Sugar Syrups are normally boiled at 0.15 bar absolute pressure generating water vapours at
52 degree C saturation temperature. Each Sugar factory releases 30 - 200 Ton Vapours
through 5 - 30 boiling vessels called Vacuum Pans. Latent Heat of these vapours is absorbed
by cold water sprayed in the individual Condenser attached to each vessel. Air and non-
condensable gases are removed by inbuilt Water Jet Ejectors of the Condenser. Temperature
of water increases due to absorption of Latent Heat of the Vapour. Either Cooling Tower or
Spray Pond cools this heated water by transferring this heat to ambient air by heat and mass
transfer.
The Condenser consists of multiple Spray and Jet Nozzles. Spray & Jet Nozzles are primarily
needed for condensation and for non-condensable gas/air ejection through tail pipe for the
creation of vacuum in the Pan. The cold water flowing in from Spray-Pond /Cooling Tower is
supplied to the Condenser by Injection Pumps under pressure for the said purpose.
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.
Single Valve Control

A common control valve regulates pressure to both Jet & Spray Nozzles. Control valve starts
regulating water pressure when both vapour and non-condensable gases load are
simultaneously within limits of the Condenser. Any increase in either vapour or air load beyond
Condenser capacity at reduced pressure will lead to 100% opening of valve. Thus vacuum is
maintained with set values.
Double Valve Control

Two separate control valve regulate the pressure of Jet & Spray Nozzles separately. At lower
vapour load the Spray Nozzles control valve starts regulating the water pressure. Similarly at
lower non-condensable gases load it’s control valves saves water and controls vacuum by
lowering jet box pressure. Any increase in vapour or air load beyond Condenser capacity at
reduced pressure will lead to 100% opening of that valve. Thus vacuum is maintained within
the set values.
Drawbacks in Conventional Systems

The efficiency of Condenser is reduced due to loss of pressure Head and lowering in Spraying
Pressure owing to throttling of valve and the basic purpose of the equipment to create the
desired vacuum fails.

583
The vapour and air load variation in Condenser is 0 to 125% of designed capacity separately.
Initially, air load is more, in the middle vapour load more and by the end there is no air/ vapour
load. So Condenser’s requirement varies from time to time.
Proposed nozzle governing system

Spray & Jet Nozzles should always work at high differential pressure to achieve mist formation
(for condensing) and impact (air extraction). In the proposed automation system, water supply
is controlled by opening or closing of number of Spray & Jet Nozzles. So a Nozzle always
works at high pressure and efficiency. Here all the Nozzles are transferring entire pressure
energy into the Condenser resulting in good efficiency even at 15% capacity. Here there is no
loss of energy in the throttling. where almost 75% energy loss takes place after the valve at
50% flow rate (92% Energy loss at 25% flow rate). So nozzle governing system is far superior
then controlling system.
Advantage in this system

The nozzle governing system for Multi-jet Condenser will ensure optimum utilisation of hydraulic
energy of water provided to it by the Pumps. It also ensures best Condenser efficiency even
at 25% load.

In a 6750 TCD plant, a nozzle governing system was introduced for controlling the water flow
to the condenser. A 6750 TCD [Tons (Cane) Crushing per Day) Plant was consuming 1150
kWh of Power at Cooling & Condensing System, which has now been brought down to 450
kWh, after the installation.

There was a substantial reduction in power consumption of the injection water pumps. The
power consumption of injection with pumps reduced from 1150 units/ton to 450 units/ton.
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.

584

585
Case Study 13
Installation of Fully Automated Continuous Vacuum Pans for

Curing
Background
The vacuum pan is vital equipment, used in the
manufacture of sugar. The concentrated syrup coming
out of the evaporator at around 60-65 Brix is further
concentrated in these pans. This is a critical process
for the production of good quality sugar and involves
removal of water and deposition of sugar molecules
on the nuclei.
Massecuite boiling is conventionally carried out by

batch process in the Indian sugar industry.
These pans are characterised by the following:
• The hydrostatic head requirement is high
• Higher hydrostatic heads necessitate higher massecuite boiling temperatures, which aid
colour formation
• Massecuite looses its fluidity, especially towards the end of the batch cycle
• Higher boiling point elevation results in lower heat flux, for a given steam condition
• Consumes very high steam, by design - due to the non-uniform loading cycle, unloading
cycle and pan washing cycle times
Of late, the continuous vacuum pans have been developed and installed in many sugar plants
with substantial benefits. This case study highlights the benefits of installing a continuous
vacuum pan for curing.
Previous status
One of the sugar mills, had the following pan configuration for the massecuite curing:.
v Batch vacuum pans of 40 Tons holding capacity (11 nos.)

• 5/ 6 nos. for A – massecuite
• 4 nos. for B - massecuite
• 2/ 3 nos. for C - massecuite
v Batch vacuum pans of 80 Tons holding capacity (3 nos.)

• 2 nos. for A - massecuite
• 1 no for B massecuite
v Continuous vacuum pan of 135 tons holding capacity
• 1 no. for C - massecuite

586
The above configuration was designed for 6000 TCD capacity. 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
To overcome these inherent shortcomings and to cater to their capacity upgradation plans to
8000 TCD, continuous vacuum pans were installed for all three types of massecuite curing.

Consequent to the capacity upgradation to 8000 TCD, continuous vacuum pans were installed
for A- massecuite, B- massecuite and C- massecuite curing.

A continuous operation of a vacuum pan means, a complete integrated system comprising of
the sub-systems, covering total control of the inputs and outputs. The operation of the pan
in a continuous manner, makes it easy for automation and installing control systems.
The latest continuous vacuum pans are being installed with predictive control systems, which
ensure a steady and more consistent operation of the pan. Besides these automation facilities,
the continuous vacuum pans have many advantages:
• There is no heat injury to the sugar crystal, due to reduced hydrostatic head and lower
boiling point elevation
• The use of smaller diameter tubes provides greater heating area per unit of calendria. This
aspect gives more flexibility on thermal conditions of the steam that can be used.
• This also allows maximum evaporation rates, commensurate with maximum possible
crystallisation rates
• Facilitates the use of low pressure steam, on account of increased transmission coefficient,
brought about by higher circulation rate of massecuite
• Reduction in steam consumption by 10-20%, as compared to the batch pans
• On account of reduction in steam consumption, the condensing and cooling water power
consumption also gets reduced
• There is no draining, rinsing as in batch process, which cause thermal losses and dilution

587
• The coefficient of variation of crystal size is equivalent to or better than in batch pans, on
account of plug flow conditions and multi-compartment design
• 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.

During the expansion stage (8000 TCD), the batch pans were replaced in phases and the new
configuration is as follows:
v Continuous vacuum pans of 40 tons holding capacity (5 nos.)

• 1 no. for A - massecuite
• 2 nos. for B - massecuite
• 2 nos. for C - massecuite
v Continuous vacuum pans of 80 tons holding capacity (2 nos.)

v Continuous vacuum pan of 135 tons holding capacity (4 nos.)

• 1 no. for B - massecuite
• 1 no. for C - massecuite
The experience of having operated a continuous vacuum pan for the C- massecuite, enabled
the operators to gain first hand working knowledge and trouble-shooting skills. Hence, there
were no particular problems faced, during the phased replacement of the remaining batch
vacuum pans, with continuous vacuum pans.
The replacement of all the batch vacuum pans with continuous vacuum pans was completed
in two sugar seasons.
Benefits achieved
The following benefits were achieved by the installation of continuous vacuum pans:
v The continuous pans facilitate the use of low-pressure steam.

588
• The vapour bleeding from the II - effect of evaporator, for heating in the A - pans and
B- pans
v The vapour bleeding from the I - effect of evaporator, for heating in the C- pans
• The continuous pans enable stabilised operation of the evaporators
v Reduction (10 - 20%) in steam consumption as mentioned below:
Identity Steam consumption (kg/ ton of massecuite)
With batch With continuous

vacuum pan vacuum pan
A - massecuite Not available Not available
B - massecuite 242 229
C - massecuite 354 313
• Improved grain size quality
• Reduced sugar loss
• Heat balance optimisation
Financial analysis
The annual equivalent energy saving achieved was Rs.19.26 million (for 120 days sugar
season and bagasse cost of Rs.250/MT). This required an investment of Rs.100.00 million,

The installation of continuous vacuum pans through a proven project has been taken up only
in 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.

589

590
Sugar Consultants K.K.Pudur, Sai Baba Colony

COIMBATORE - 641038,
Boilers INDIA
AVANT – GARDE ENGINEERS AND
CONSULTANTS (P) LTD. SHRI M.G.JOSHI
No. 58, Fourth Avenue, 3, Vasant Bagh Society,
Ashok Nagar, Bimbewadi,
Chennai – 600083, PUNE- 411037
INDIA INDIA
Tel : 91 44 4894457, 4894460, 4894474, Tel: 91 20 4214945
Fax : 91 44 4894432
E Mail :avantgar@giasmd01.vsnl.net.in, Shri Mydur Anand
Web Site : www.ag-india.com 27/106, 11-B, 11th Main,
Malleshwar,
M/S J . P. MUKERJEE & ASSOCIATES PVT. BANGLORE - 560 003
LTD. INDIA
JYOTI HOUSE, Tel : 91 11 3311223, 3346873
172, DHANUKAR COLONY, Fax : 91 11 3349573
KOTHRUD , ‘
PUNE - 411029,
INDIA SHRI P.K.JHINGAN
TEL: 91 212 347303, M/S SUPRABHAT CONSULTANTS
FAX : 91 212 347307 43-B,Pocket A,
SFS Flats, Mayur Vihar Phase 3
M/S K.S.PROJECTS & PROCESS NEW DELHI - 110049,
ENGINEERS (P) LTD. INDIA
A-1/18, SECTOR - B TEL: 91 11 2610094,2610072,
ALIGANJ EXTENSION, Fax: 91 11 2614559
LUCKNOW - 226024. E Mail: superbhat@nyeq.com
INDIA
TEL : 91 522 375042, 377166. SHRI VIKRAM SINGH
FAX : 91 522 377166 C-2/2305,VASANT KUNJ
NEW DELHI.
P.J.INTERNATIONAL GROUP CONSULTANTS INDIA
A-101,YAMUNA APARTMENTS, Tel: 91 11 6898884
ALAKNANDA,
NEW DELHI-110019 Alfred Bartholomai
INDIA Hansen Consulting
TEL: 91 11 6461081, Atlanta, Georgia USA
FAX:91 11 6474514
Consultants to the food industry
M/S SUCRO CONSULT INTERNATIONAL www.hansenconsulting.com
SACCHARUM ,
E- 1, Greater Kailash Enclave 1, Equipment Manufacturers
New Delhi - 110048, ATV PROJECTS INDIA LIMITED
INDIA D-8, MIDC, STREET
Tel : 91 11 641616 NO.16, MAROL, ANDHERI (EAST),
MUMBAI-400 093.
NATIONAL FEDERATION OF INDIA
COOP.SUGAR MILLS TEL : 91 22 8351761,
VAIKUNTH, IIIRD FLOOR, FAX : 91 22 8365786, 8387592
82-83, NEHRU PLACE,
NEW DELHI-110 019 FCB-K.C.P.LTD.
INDIA RAMAKRISHNA BUILDING,
2, DR.P.V.CHERIAN CRESCENT,
Shri A.P.Chinnaswamy CHENNAI-600 105.
Ponn Ram Sugar House, INDIA
Krishnamal Cross Street No 1, PO : TEL : 91 44 8241633,

591
FAX : 91 44 8230306 Jaipur 302013, Rajashtan,

EMAIL : fcbkcp@vsnl.com INDIA Tel:91-141-331542,260183
260184(O)517574,700909(R),
KRUPP INDUSTRIES INDIA LTD. FAX:91-141-331543
PIMPRI, E Mail: jayantrajvanshi@hotmail.com
PUNE-411 018, INDIA Contact Person: Mr.Jayant Rajvanshi
TEL : 91 212 774461, SPECIALIST IN: Boiler Water Treatment
FAX : 91 212 771150 Chemicals, Cooling Water Treatment
EMAIL : krupp@giaspn01.vsnl.net.in Chemicals, Effluent Treatment Chemicals ,
Sugar Specialty Chemicals, Industrial Safety
NATIONAL HEAVY ENGINEERING Equipments
CO-OPERATIVE LTD.
16, MAHATMA GANDHI ROAD, AISHWARYAA CHEMICALS
PUNE-411 001, INDIA 101/12, Om Apartments,
TEL : 91 2114 22261, Medavakkam Tank Road,
FAX : (0212) 644920 Kilpauck, Chennai 600010,
E Mail : nhecl.talegaon@gems.vsnl.net.in INDIA TEL: 91 44 6422851,6414419,
FAX: 91 44 6431605
PRAJ INDUSTRIES LIMITED E mail: raja.aishwaryaa@gems.vsnl.net.in
PRAJ HOUSE, BAVDHAN, SPECIALISTS IN:Process Chemicals
PUNE- 411 021, INDIA
TEL: 91 2139 51511, 52214, CENTRAL AGENCIES
FAX: 91 2139 51718, 51515 All kind of Sugar Process Chemicals
E MAIL : info@praj.net 4672 / 21, DARYA GANJ,
WEB : www.praj.net NEW DELHI - 110002 - INDIA
TEL : 91 11 3273662,3266023,
FAX : 91 11 3278554
ALCOHOL / DISTILLERY PLANT : EMAIL : catech@ndb.vsnl.net.in
Turnkey plant and equipment supplier
for molasses and starch based alcohol plants INDUSTRY AID PRODUCTS
B-196, OKHLA INDL.AREA, 160, Dr. D N ROAD, FORT,
PHASE-I, NEW DELHI-110 020. INDIA MUMBAI 400001 - INDIA
TEL : 91 11 6811878, 6811721, 6815047, TEL : 91 22 207747,
FAX : 91 11 6812280 FAX : 91 22 2074249
E Mail: triveni@del2.vsnl.net.in E Mail: kiran_vaidya@hotmail.com
TEXMACO LTD. CHEMICAL SYSTEMS

Sugar Division, Birla Bldg., D 57-58, Amar Colony,
9/1,R.N.Mukerjee Marg, Lajpat Nagar-IV,
CALCUTTA - 700 001, New Delhi – 110024, INDIA
INDIA Tel : 91 11 6476344, 6438807
TEL: 91 33 205712, 205553 Fax : 91 11 6476352
E Mail Indoam@del2.vsnl.net.in
UTTAM INDUSTRIAL ENGG. LTD. SPECIALISTS IN: CHEMICALS FOR
7C, J-BLOCK SHOPPING CENTRE, BETTER SUGAR PRODUCTION
SAKET, NEW DELHI-110 017.
INDIA TEL : 91 11 6563860, 6856721, 6858578, ION EXCHANGE (INDIA) LTD.
FAX : 91 11 6856721 Tiecicon House, Dr. E Moses Road,
Mahalaxmi Mumbai – 400011
WALCHANDNAGAR INDUSTRIES LTD. Tel :91 22 4939520/23/25,
16, M.G. ROAD, PUNE-411 001. Fax : 91 22 4938737
INDIA TEL : 91 212 631801, SPECIALISTS IN: Process Chemicals
FAX : 91 212 631747
MULTITRADE CORPORATION
Chemical suppliers for sugar industry 401, GORADIA HOUSE,
AQUA CHEMICALS 100/104, KAZI SAYAD STREET,
B-237 A, Road No :6-D, MUMBAI 400003 - INDIA
V.K.Industrial Area, TEL : 91 22 3439360,

592
FAX : 91 22 3429140 International callers:Phone: +61 7 3277 9630,

Fax: +61 7 3277 9640 E Mail:
CHEMICAL CENTRE (INDIA) armtim@arm.com.au
7/26 ANSARI ROAD SPECIALIST IN : Maintenance free sugar mill
DARYA GANJ rollers
NEW DELHI -110002 - INDIA
TEL : 91 11 3267775 3253336, GOEL TRADELINES
FAX : 98-11 -3268834 14 RANI JHANSI ROAD,
NEW DELHI 110055
KULKARNI ORGANICS PVT. LTD INDIA
172, SHANIWAR PETH, TEL: 91 11 3551444,3679444,3613075,
TRIMBAKESHWAR CO-OP. HOUSING FAX: 91 11 3613075
SOCIETY, E MAIL : goel@sugar-ind.com
PUNE - 411 030 - INDIA SPECIALIST IN : WEDGE WIRE SCREENS,
TEL : 91 212 450934 / 532090 ROTARY JUICE SCREENS
P.K.B. TRADERS FLENDER LIMITED

75, NAGDEVI CROSS LANE, 41, Nelson Manickam Road,
2ND FLOOR, R B. NO. 13043, Aminjikarai
MUMBAI - 400003 - INDIA Chennai – 600029,
TEL : 91-22-3400581, 344T228, 3 (R) 5163635 , INDIA
FAX : 91-22-3401630 Tel : 91 44 4810476/78/79/80
Fax : 91 44 4810473
King – Win Hydro Chem Ltd. SPECIALISTS IN Hydraulic Drives
C-26-B, Malviya Industrial Area,
JAIPUR 302017, INDIA Hagglunds Hydraulic Drives (India) Pvt. Ltd.
Tel : 91 141 521205, 522924 , 18/4 & 19/4, Hadpasar
Fax : 91 141 522694 Industrial Estate, Hadapsar ,
E Mail :kingwins@jp1.vsnl.net.in PUNE -411013, INDIA
TEL: 91 212 613841, 613842
SURYA CORPORATION FAX: 91 212 613844
27, Chetty Street,
PONDICHERRY 605001, INDIA Jeffress Engineering Pty Ltd
TEL: 91 413 220309, 345221 351 Melton Road, Northgate
FAX: 91 413 339733,345221 Queensland Australia 4013
E MAIL: aurosale@md2.vsnl.net.in Phone +61 7 3266 1677,
Fax:+61 7 3260 5487
Sugar Machinery Email: sales@jeffress.com.au
AVANT – GARDE ENGINEERS AND Cutter Grinders, Disintegrators
CONSULTANTS (P) LTD.
No. 58, Fourth Avenue, KAMAL ENGINERRING CORPORATION
Ashok Nagar, Chennai – 600083, 56, Industrial Estate,
Tel : 91 44 4894457, 4894460, 4894474, Yamuna Nagar –135001
Fax : 91 44 4894432 Tel : 91 1732 50300/1/2/3,
E Mail :avantgar@giasmd01.vsnl.net.in, Fax : 91 1732 50304
Web Site : www.ag-india.com SPECIALISTS IN: Weighing Scales, Sugar
SPECIALIST IN :’CONTINUOUS Graders etc.
BAGASSE FEEDING SYSTEM FOR BOILERS”.,
NATIONAL HEAVY ENGINEERING
Abrasion Resistant Materials Pty Ltd CO-OPERATIVE LTD.
PO Box 546, Archerfield, 16, MAHATMA GANDHI ROAD,
Queensland, 4108, PUNE-411 001,
AUSTRALIA INDIA TEL : 91 2114 22261,
39 Randolph Street, Rocklea, FAX : 91 212 644920, 91 2114 22762
Queensland, 4106, E Mail: nhecl.talegaon@gems.vsnl.net.in
AUSTRALIA SPECIALIST IN : CENTRIFUGAL MACHINES
Phone: 07 3277 9630,
Fax: 07 3277 9640

593
NEON INNOVATIVE PVT. LTD. SNEHA ENGINEERS

31. Latif House, S.T.Road, F – 46, M.I.D.C.
Carnac Bunder, Industrial Area,
MUMBAI 400009 . Waluj, Aurangabad –431136,
INDIA MAHARASHTRA
TEL : 91 22 3426851, INDIA
FAX : 91 22 3429011 Tel : 0240 – 332585, 331695,
E Mail: neon_Ipe@hotmail.com Fax : 332796 SPECIALISTS IN:
SPECIALISTS IN: CANE MILLING Evaporators & Vacuum Pans
Low Pressure Extraction Systems
SHRIJEE ENGINEERING WORKS
Maddocks and Associates Pty Ltd, 1-9, Everest, 156 Tardeo Road,
GDT Lining Systems SPECIALIST IN : MUMBAI - 400034, INDIA
LOW COST MOLASSES STORAGE Tel:91 22 4952248,4954699,4954715,
Fax: 91 22 4952249
PRAJ INDUSTRIES LIMITED E Mail: shrijee@bom3.vsnl.net.in
PRAJ HOUSE, BAVDHAN SPECIALISTS IN: Process House
PUNE- 411 021, INDIA
TEL: 91 2139 51511, 52214, Equipments, Sugar Driers
FAX: 91 2139 51718, 51515 526, Narayan Peth,PUNE 411030 INDIA
E MAIL : info@praj.net Tel: 91 20 453360,454790,
WEB : www.praj.net Fax: 91 20 453970
ALCOHAL / DISTILLERY PLANT : SPECIALISTS IN: TRF
Turnkey plant and equipment supplier Cane Mill Feeding System.
for molasses and starch based alcohol plants UTTAM INDUSTRIAL ENGG.LTD.
7C, J-BLOCK SHOPPING CENTRE,
Single Tray Juice Clarifiers SAKET, NEW DELHI-110 017.
Filtrate Clarification Systems INDIA TEL : 91 11 6563860, 6856721, 6858578,
Rotary Juice Screen FAX : 91 11 6856721 SPECIALISTS IN: CANE
MILLING
Suviron Equipments Pvt.Ltd. GOEL ENGINEERS (INDIA)

Swaroop Kala, 23/11, Renavikarnagar, Savedi, INDIA’S FIRST MANUFACTURERS
Ahmednagar 414 003 (India) OF CENTRIFUGAL LINERS
Telephone 91 241-423582 / 778711 Fax : 91 F-11/A OKHLA IND.
241-778711 AREA, PHASE 1,
E-mail : contact@suviron.com Web : NEW DELHI 110020 INDIA
www.suviron.com TEL: 91 11 2 6815109, 2 6812004,
Person : Shri Subodh V. Joshi FAX: 91 11 2 6811176
E MAIL : sales@goelka.com
SPRAY ENGINEERING DEVICES web: www.goelka.com
Cooling & Condensing systems for SPECIALIST IN : Screens for
Sugar & Processing Plants BATCH CENTRIFUGALS &
25, Industrial Area, Phase- II FILTERS, BACKING WIRES
Chandigarh INDIA – 160002
Tel : 91 172 652415 Suviron Equipments Pvt.Ltd.
Fax : 91 172 653247 Swaroop Kala, 23/11, Renavikarnagar, Savedi,
Ahmednagar 414 003 (India)
S.S. ENGINEERS Telephone 91 241-2423582 / 2 Fax : 91 241-
J – 179, M.I.D.C. Bhosari, 2778711
Pune – 411026, E-mail : contact@suviron.com Web :
INDIA www.suviron.com
Tel :91 212 327567, Person : Shri Subodh V. Joshi
Fax : 91 212 328572 Rotary Juice Screens,Single Tray Juice
E Mail: sse@wmi.co.in Clarifiers
SPECIALISTS IN: Five/Six Roller MILLS Filtrate Clarification Systems Rotary Juice
Screens

594
ATUL ELECTROFORMERS PVT. LTD SHIVA HITECH NON CONVENTIONAL

11,KUBERA ESTATE , 408/14 , SYSTEMS PVT. LTD.
CTS 10, Gultekadi Road, 107, Vijaya Towers,
PUNE 411037,INDIA Nagarjunanagar, Ameerpet,
TEL : 91 20 2466398, 2464589 , 2468982, Hyderabad 500073 INDIA
Fax : 91 20 2462835 Tel : 91 40 3744675, 3740224, 3740432
E Mail:atulefpl@vsnl.com Fax : 91 40 3745833
SPECIALIST IN : Nickel Screens SPECIALISTS IN Magneto Hydro Dynamic
Systems
FINE PERFORATORS
14 RANI JHANSI ROAD, VISHWA Systems Pvt Ltd
NEW DELHI 110055 INDIA W-155, M.I.D.C., Ambad,
TEL: 91 11 23551444, 23679444, Nashik 422010, INDIA
FAX: 91 11 23613075 Tel: 91 253 385243, 380802, 380673.
E MAIL : finehole@bol.net.in Fax: 91 253 385243
SPECIALIST IN : Batch Centrifugal & Filter E Mail: vishwa@bom6.vsnl.net.in
Screens SPECIALISTS IN: Process Control Equipment
& Control Systems.Manufacturer of Sulphur
SHRADDHA ENGINEERING COMPANY. Burner, PRD Station, Transient Heater /
11,Rajgrah Apt. Krushinager, PH Control Systems, Molasses conditioner /
College Road, Nashik-422005.India Juice Flow Stablisation Systems, Superheated
“Jyoti” Sitarramnager,Near Wash water Systems, Lime Classifier
Jaikranti College, Latur-4413531
Telefax : 91 253 355009 , 91 238 240759. FORBES MARSHALL
E Mail :shraddhaengg@rediffmail.com, Kasarwadi, , Pune – 411034, INDIA
kbhujbal@yahoo.co.in, bhujbal@hotmail.com. Tel :91 212 794495, Fax : 91 212797413
Person :Satish S. Sonar, Kishor M.Bhujbal. SPECIALISTS IN: INSTRUMENTATION &
Product Details : Designer and manufacturer FLOW TECHNOLOGY
of Continuous Sulphur Burner, Pressure
Reducing and Desuperheather ,Juice BELLISS INDIA LIMITED
and Syrup Sulphitation Unit, Mollasses 18, Community Centre,
conditioner, Superheated Wash Water System, East Of Kailash,
Boiler Automation, Auto Mill Imbibition Control NEW DELHI 110065, INDIA
System. TEL: 91 11 6431836,
FAX: 91 11 6468089
CHEMICAL SYSTEMS E Mail : belliss@del2.vsnl.net.in
D 57-58, Amar Colony, SPECIALIST IN Steam Turbine
Lajpat Nagar-IV,
New Delhi – 110024, INDIA DLF Industries Ltd.
Tel : 91 11 6476344, 6438807 Model Town, Sector 11,
Fax : 91 11 6476352 FARIDABAD 121 006, INDIA
E Mail :Indoam@del2.vsnl.net.in SPECIALIST IN Steam Turbine
Satwik Electric Controls Pvt. Ltd TRIVENI ENGINEERING & INDUSTRIES LTD.
SUGAR PROCESS ENGINEERS 12-A, Peenya Industrial Area,
E / 12-13, M.I.D.C Peenya, Bangalore 560058,
Industrial Area, INDIA
NASHIK – 422 007, INDIA Tel :91 80 8394721, 8394771, 8395278
Tel : 91 253 351072 / 77, Fax : 91 253 351079 Fax : 91 80 8395211
E Mail : E Mail: mkt.tbg@gnblr.ems.vsnl.net.in
control@satwik.xeeisk.xeemail.ems.vsnl.in SPECIALIST IN Steam Turbine
SPRAY ENGINEERING DEVICES Associations in India

25, Industrial Area, Phase- II THE SUGAR TECHNOLOGISTS’
Chandigarh 160002 INDIA ASSOCIATION OF INDIA
Tel : 91 172 652415 C Block, 2nd Floor, Ansal Plaza,
Fax : 91 172 653247 August Kranti Marg,
SPECIALIST IN Cooling & Condensing New DelhiI-110 049,India.
systems for Sugar & Processing Plants TEL : 91 11 6263694-95

595
FAX : 91 11 6263694 staidel@vsnl.com NATIONAL FEDERATION OF

WebSite: www.staionline.org COOP.SUGAR MILLS LTD.
C Block, 2nd Floor, Ansal Plaza,
THE DECCAN SUGAR TECHNOLOGISTS August Kranti Marg,
ASSOCIATION New DelhiI-110 049,India
17/1, Opp.Shivajinagar Tel: 6263425, 6263426
S.T.Bus Stand, Fax: 91 11 6463425
Pune-411 005 E Mail: nfcsf@ndb.vsnl.net.in
Tel : 91 20 58575
NATIONAL COOP. DEVELOPMENT CORPN.
The South Indian Sugarcane And Sugar 4, Sirifort Instn. Area,
Technologists Association Hauz Khas,
21, Door No.5, Iiird Main Road, New Delhi-110 016.
Gandhi Nagar, India Tel : 6567475
Chennai-600 020,
India SUGAR TECHNOLOGY MISSION
Tel : 91 44 4415934 Department of Science &
Fax : 91 44 4402324, Technology, Govt. of India
E Mail:Sissta@Md4.Vsnl.Net.In D-5, Apartment, Qutab Hotel,
New Mehrauli Road,
INDIAN SUGAR MILLS ASSOCIATION New Delhi -110016, India
SUGAR HOUSE, 39, Tel:91 11 6960599, 6960617
NEHRU PLACE, Fax: 91 11 6863866
NEW DELHI-110 019,
INDIA TEL : 91 11 6472554, 641671, 6462096 TAMILNADU COOPERATIVE
Other organizations in India SUGAR FEDERATION LTD.
474, Anna Salai, Nandanam,
INDIA CHENNAI 600035,
INDIAN SUGAR AND GENERAL INDIA TEL:91 44 4330222
INDUSTRY EXPORT IMPORT CORP. LTD.
C Block, 2nd Floor, WINROCK INTERNATIONAL INDIA.
Ansal Plaza, August Kranti Marg, 7 Poorvi Marg, Vasant Vihar,
New DelhiI-110 049,India NEW DELHI-110057,
Tel: 91 11 6263421 - 24, INDIA TEL:91 11 6142965,
E Mail: isiec@yahoo.com FAX:91 11 6146004
E Mail:winrockindia@winrock.ernet
Contact for Alternative Baggasse Cogeneration

Energy Conservation in Power Plant Sector
596
Power plant
Per Capita Consumption 350 kWh (277 kg of oil equivalent)
Energy Intensity 6 – 8% of power generation
Energy saving potential Rs.3000 Million (US $ 60 Million)
energy saving projects Rs. 5000 Million (US $ 1000 Million)

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POWER PLANT SECTOR
INTRODUCTION
1.0 Energy Scenario

The power sector has always been high on India’s priority as it is a growing sector, offering
tremendous potential for improvements and new investments.
As per the recent projections by CEA, The total generating capacity which is today at about
1,07,000 MW is expected to reach 2,15,000 MW by 2012. The share of various sources in
meeting this requirement is shown in Table-1.
Table 1: Power Sector Growth Projection in MW
Coal Gas Nuclear Hydro Others Total
Installed Capacity
as on Feb 2003 63800 11560 2720 26760 2800 107644
Additional Capacity
to be increased
(2003-2012) 50690 19860 8380 27050 2170 108150
Total Capacity
by 2012 114490 31420 11100 53810 4970 215800
Source: CEA
Economic growth in India crucially depends on the long-term availability of energy in increasing
quantities from sources that are dependable, safe and environmentally friendly.
India, like many other developing countries, is a net importer of energy, 20 per cent of primary
energy needs being met through imports mainly in the form of crude oil and natural gas.

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Currently, thermal power plants accounts for major share of about 70%. Coal is the mainstay
fuel in India for power generation. With total coal reserve around 220 billion tones, of which
84.4 billion tonnes are proven, coal will continue to be an assured energy source for the next
century and beyond.
Though coal based plants account for major share in power generation, recently there is an
increasing trend in going for gas-based power plants also, particularly in the private sector.
1.1 Power Generation Capacity

The power generating capacity in India has increased over 80-fold, from 1,362 MW in 1947 to
1,07,644 MW in 2003.
The share of various sources of power generated is pictorially shown in figure 1.
(Source: Ministry of Power)
The industrial sector is the highest consumer of electricity (34 percent) followed by agriculture
(30 percent) and domestic (18 percent) sector.
1.2 Per-Capita Energy Consumption

Per capita energy consumption in India is about 277 Kg of oil equivalent, which is 3.5 per cent
of that in the USA, 6.8 per cent of Japan, 37 percent of Asia and 18.7 per cent of the world
average. Per-capita consumption of electricity for various countries is shown in figure 2.
Figure 2: Per-capita consumption in Kwh
(Source: Ministry of Power)

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But, energy intensity, which is energy consumption per unit of GDP, is one of the highest in
comparison to other developed and developing countries. For example, it is 3.7 times that of
Japan, 1.55 times of the USA and 1.5 times of the World average. This signifies that there
is tremendous scope for energy conservation in the country.
1.3 Thermal Power Plants in India

In India, size of thermal power plants started with ratings of 60/70 MW during 1965, which
touched 500MW rating in 1979. At present National Thermal Power Corporation (NTPC) is
planning to install units in the range of 660MW rating, operating with supercritical parameters
at Sipet in Chattishgarh State by the year 2005.
There are about 85 major thermal power plants installed in India. The eastern belt being coal
abundant, major plants are located in that region.
Figure 3: Thermal Power Plants
(Info: http://www.osc.edu/research/pcrm/emissions/thermalemissions)
Apart from private and public utilities and IPP’s, most of the industries have there own captive
generation.

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1.3.1 Captive Power Plants

Industrial Sector is the largest consumer of energy. Besides consuming power from Utilities,
a number of industries which are primary producers of infrastructure material such as Aluminium,
Cement, Fertilizers, Iron & Steel, Paper and Sugar etc. have their own captive power plants.
The installation of captive generation plants has been either to supplement the electricity
purchased from the Utilities or for emergency use in case of power outages or for producing
energy from by-product of the industrial process (e.g., Sugar Plants).
Table 3 shows sector wise captive power plant installed in the country.
Table 3: The break up of Captive Power Plants
Installed Percentage of
Sl.No. Name of Industry Capacity TotalInstalled
(MW) Capacity
1 Chemicals, Mineral Oil &
Petroleum 1993 13.86
2 Textile 1884 14.54
3 Aluminium 1742 12.32
4 Iron & Steel 1686 15.78
5 Cement 1466 10.16
6 Fertilizers 1155 9.02
7 Sugar 7862.66
8 Paper 5994.06
9 Heavy & Light Engineering 4532.50
10 Non-Ferrous Metal 4243.94
11 Automobiles 2311.13
12 Food 115 0.53
13 Mining & Quarrying 38 0.68
14 Other Industries 1360 8.82
Total 13932 100.00
Source: CEA
India has a total capacity of 2500 MW thermal based Independent power plants (IPP’s)

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CHAPTER II
PROCESS, TECHNOLOGY AND TRENDS
2.1 Technology Trends

Thermal power generation started with ratings of 60/70 MW rating units in the year 1965,
simultaneously raised to 110/120 MW units by the year 1966. The next size of 200/210 MW
plants, which are widely installed all over India from the year 1972 onwards grew into 500 MW
units by the year 1979.
As the unit ratings grew, the boiler parameters supplying steam to such turbines have also
increased. Following table 4 shows the trends in super heater outlet pressures and temperatures
for various unit sizes.
Table 4: Turbine Sizes and Pressure Parameters
Unit Size Steam Flow Super Heater Super heater

(T/H) Outlet Pressure / Re Heater Outlet
(KG/CM2) Temperature (oC)
30 MW 150 63 490
60/70 MW 260 96 540
110/120 MW 375 139 540
200/210 MW 690 137/156 540
250 MW 805 156 540
500 MW 1670 179 540
Source: BHEL
The over all efficiencies of power plants with sub critical parameters fall in the range of 35-
39 percent which can be improved to 45 percent using supercritical parameters with conventional
steam turbines. Using combined cycle mode, the maximum efficiency that can be attained is
about 50 percent.
Table 5 shows the heat rate for various capacities of turbines achieved in power plants.

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Table 5: Turbine Sizes and Heat Rate
Unit capacity Turbine inlet Turbine Heat Rate

parameter (Kcal/Kwh)
60/100 MW 90 ata 535oC 2315
110/120 MW 130 ata 535oC 2180
200/210 MW 130 ata 535oC 2025
210/250 MW 150 ata 535oC 1975
500 MW 170 ata 535oC 1950

Source : BHEL
Power plants are adopting several latest technologies to improve the efficiency and operating
practices. Some of the power plants are installed with multi fuel capabilities by design for the
following benefits.
• Flexibility to use depending on availability and price
• To address environmental issues like Nox and Sox reduction
2.2 Clean Coal Technologies

Environmental performance of thermal power plants is accorded tremendous importance to
meet global emission standards and need for balancing development and social obligations.
Clean coal technologies for power generation that posses the potential to contain pollutants
either at the combustion or pre-combustion stage will be the technologies that would eventually
replace the conventional PC firing.
India’s experience in clean coal technology started with the development of AFBC (Atmospheric
Fluidized Bed Combustion) for high ash coals. CFBC (Circulating Fluidized Bed Combustion)
was later introduced to cater to higher capacity power plants and to realize higher efficiency.

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It has been a challenge for the Indian power plants to adopt several measures to bring down
the ash disposal and to meet the stringent environmental regulations, some of which are
shown below
• Importing high grade coal
• Lower emission technologies
• Improving efficiency of equipment
Power plants are also exploring various possibilities to utilize the fly ash as by-product for
some processes like
• Utilising in cement preparation as substitute for clinker
• Manufacturing of Flyash bricks
2.2.1 AFBC Boilers

Atmospheric fluidized bed Combustion (AFBC), promises to provide a viable alternative to
conventional coal fired boilers for utility and industrial application.
The advantages of AFBC boilers are
• Suitable to burn variety of fuels
• Combustion efficiency is higher
• It can completely burn fine particle (Fuel size range:6-12 mm)
• Losses due to unburnt are avoided
• Simple auxiliaries i.e., Lower operating cost
2.2.2 CFBC Boilers

Circulating Fluidized Bed Combustion (CFBC) boiler is normally designed for high reliability
and availability with low maintenance.
Some of the advantages of CFBC boilers are
• Thermal efficiency is higher than AFBC
• Technology is suitable to burn a wide range of fuels (high ash coal, high sulphur coal,
lignite, pet, coke, anthracite clum, wood paste, etc.)
• CFBC boiler availability is more than 95%.
• Lesser Sox, Nox emissions
• Auxiliary power consumption of these boilers is relatively lower (do not require high pressure
blowers)

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2.2.3 Super Critical Boilers

Super critical boilers operate at main steam pressures exceeding 225 ata i.e., critical pressure
at which there is spontaneous changeover from liquid phase to vapour phase.
Supercritical units normally operate around pressure of 240-250 ata. The main steam temperature
& reheat temperature for these units are normally in the range of 535-565oC. Boilers with
steam pressures and temperatures beyond 250 ata/565oC are termed as ultra supercritical
boilers.
Some of the excellent features of supercritical boilers are
• Enhanced boiler efficiency
• Operational flexibility to respond quickly to load changes
• Reduced emissions
2.4 Renovation & Modernization
Old power plants are modernized to keep up the operation of the equipment and its efficiencies.
The advantages of Renovation & modernization are
• Enhancement of operational efficiency
• Improvement in Plant Load Factor (PLF)
• Meeting stringent environmental pollution control standards
• Extend plant life
• Capacity augmentation
Some of the renovation and retrofitting techniques that are followed by the power plants are
1. Steam turbine retrofitting (blades replacement and improvement of the labyrinths’ operation
and turbine control system, etc)
2. Improvement of the fuel preparation and firing system
3. Implementation of techniques for further reduction of the Nox emissions and for the flue gas
de-sulphurization

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4. Improvement of particles collecting systems
5. Optimization of the existing fuel drying system or implementation of new effective drying
techniques
6. Replacement, rearrangement or size change of heat exchange surfaces
7. Supplementary heat exchange surfaces for further heat recovery from flue gas
8. Improvement of the air preheating system
CHAPTER III
ENERGY SAVING PROJECTS
3.1 Energy Saving & Investment Potential in Power plants

The consumption of electricity by power plant auxiliaries depends on factors such as unit size,
level of technology, plant load factor, fuel quality etc.
The auxiliary consumption in general varies between 3 to 6% for larger plants and close to 10
% for smaller captive power plants.
CII studies indicate that the energy saving potential in small size power plants (CPP’s & IPP’s)
varies between 6% - 10% of auxiliary consumption. It is estimated that the saving potential is
150 MW of power amounting to Rs.300 crores annually.
CII study also indicates that the investment potential for energy efficiency in small size
power plants is Rs.500 crores. This does not include saving potential in utility plants.
3.2 List of Projects

All energy saving projects are classified in to three categories namely Short term, Medium term
and Long term based on the investment and returns available in each project.
These projects apply to IPP’s & CPP’s and can be easily implemented. Some of these
projects are equally applicable in utility power plants.
3.2.1 Short Term Projects
A) Boilers
1. Install online O2 analyser and improve combustion efficiency of the boilers
2. Arrest air infiltration in boiler flue gas path, particularly economiser and air preheater section
3. Install water heating system for preheating gas through waste heat recovery from Boiler
exhaust
4. Install waste heat recovery system for boiler blow down
5. Install LP steam air heater for FD fan air inlet to boiler
6. Optimise the operating breakdown voltage of ESP’s

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B) Steam & Condensate Systems

1. Avoid steam leakages
4. In case coal has higher percentage of fines, ensure wetting is done.
5. Install flash vessels for heat recovery from hot condensate vapours
6. Replace electric heaters with LP steam heaters for RFO tracing lines
C) Electrical Areas
1. Install delta to star converters for lightly loaded motors
2. Use translucent sheets to make use of day lighting
6. Group the lighting circuits for better control
7. Operate at maximum power factor
8. Switching ‘OFF’ transformers based on loading
9. Optimise TG sets operating frequency, depending on user needs
10. Optimise TG sets operating voltage
D) Miscellaneous
1. Replace Aluminium blades with FRP blades in cooling tower fans
5. Segregate the service air &
instrument air and optimise optimise operating pressure
6. Reduce system pressure of the compressed air system close to operating pressure of
the users
7. Install variable frequency drive for hot well makeup water pump
8. Install Variable Frequency Drive (VFD) for cooling tower make up pump with water level
control feed back
9. Install Variable Frequency Drive for DM water transfer pump

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10. Close Suction Dampers at Stand-By Equipment and Reduce RPM of Dust Extraction
Blowers in the Coal Handling Plant
11. Install the next lower size impeller for the chilled water pumps
12. Avoid idle flow of cooling water in stand by DG sets and compressors
13. Install chlorine dosing and HCL dosing for circulating water
3.2.2 Medium Term Projects
A) Boilers
5. Segregate Intermediate Pressure & High Pressure Boiler Feed Water Pump
6. Install Variable Frequency Drive (VFD) for CCW pump and operate in closed loop control,
based on the discharge header pressure.
7. Reduce Heat rate of gas turbines by optimizing NOx water injection and arresting of
leakages through bypass dampers
8. Install Turbine inlet air cooling to increase power output of gas turbines
9. Install Low excess air burners
10. Reduce one stage of feed water pump or install variable frequency drive with feed back
control to exactly match with the system pressure
11. Install lower head fan for power plant boiler ID fan
B) Steam & Condensate Systems

2. Install condensate recovery systems in air heaters
3. Utilise waste condensate for de-superheating the process steam
4. Install Variable Fluid Coupling or variable frequency drive for condensate extraction pump
5. Utilise flash steam from boiler blow down for deaerator heating

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C) Electrical & Miscellaneous Areas

5. Install Sodium vapour lamps instead of MV lamps for Yard, Street and General Lighting
7. Install neutral compensator in lighting circuit
8. Optimise voltage in lighting circuit by installing servo voltage stabilisers
9. Minimise overall distribution losses, by proper cable sizing and addition of capacitor banks
10. Replace V-belts with synthetic flat belts/Cog ‘V’ belts
11. Replace heater - purge type air dryer with heat of compression (HOC) dryer for
compressed air requirement above 500 cfm
3.2.3 Long Term Projects

1. Install VFD for Boiler ID/FD fans
2. Install VFD for Boiler feed water pump
3. Install Circulating Fluidised bed boilers for Efficient combustion
4. Install steam driven equipment to prevent HP steam flow through pressure reducing valves
5. Convert chain grate/spreader stoker boilers to AFBC technology
6. Install high efficiency turbines
7. Install vapour absorption system to utilise LP steam for air-conditioning
8. Install Distributed control system (DCS) for Power Plant Operation and monitoring

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3.2 Case Studies
Case Study: 1
Convert Spreader Stoker Boilers to Fluidised Bed Boilers
Background
In the older power plants, the boilers are the conventional stoker boilers.
These boilers were characterised by:
• Higher unburnts in ash
• Lower thermal efficiency
The latest trend has been to install the fluidised bed boilers or conversion of the existing chain
/ spreader stocker boilers, which have the following advantages:
• Coal having high ash content/ low calorific value can be used
• Biomass fuels can also be used
• Lesser unburnts in ash
• Higher thermal efficiency
Hence, the older plants are also in a phased manner, converting their old stoker-fired boilers
to fluidised bed boilers. This case study describes one such project implemented.
Previous Status
A power plant had four numbers of spreader stoker boilers, operating to meet steam
requirements of the plant. These spreader stoker boilers, were designed for high calorific value
coal (4780 kCal/kg) with low ash content.
Due to non-availability of this type of coal, these boilers had to be fired with coal of low calorific
value and high ash content. This resulted in the capacity down-gradation and loss in efficiency.
The steam generation was only 14 TPH, as against the design rating of 30 TPH. The boiler
efficiency achieved was only 65%.

The plant team modified two of the spreader stoker boilers into fluidised bed combustion
boilers.

610

In addition to the benefits of fluidised bed combustion mentioned earlier, they also enable the
use of biomass fuels, such as saw dust, generated in the chipper house.
The steam generation capacity increased to 27 TPH and the thermal efficiency improved to
78%, with this modification. The improved thermal efficiency has resulted in an annual coal
saving of 5639 MT. Additionally, the use of saw dust (calorific value of about 3000 kCal/kg) has
resulted in an annual coal savings of 3600 MT.
Finalcial Analysis
The annual benefits achieved were Rs.10.50 million. This required an investment of Rs.27.0
million (for the conversion of two spreader stoker boilers to fluidised bed combustion boilers),

The plant took up implementation of the project after a detailed planning with the EPC contractor.
The modification was taken up during the annual shut down (30 days). The shut down had to
be extended to avoid 30 days to complete the project. The commissioning of the new boiler
took about 4 days and there were no problem during implementation.

611

612
Case Study: 2
Install VFD for Boiler ID fans and PA fans
Background
In a major captive power plant, three irculating fluidised bed combustor (CFBC) were in
operation. Each boiler has two ID fans and three PA fans.
• All these fans had higher capacity & head by design and controlled either by IGV’s or
Dampers to meet the operating requirements.
• The IGV opening of the ID fans varied between 50-60%, resulting in tremendous energy
loss. The measured pressure loss across the damper & IGV was of the order of 40-45%
of the total pressure rise of the fan.

• The operation of a fan with damper control or IGV control is an energy inefficient practise,
as a part of the energy supplied to the fan is lost across the damper or IGV.
• Also, the operation of a fan operating with IGV or damper control will result in operation of
the fan in an energy inefficient zone on the fan performance curve. Instead the speed of the
fan can be varied to meet the operating condition of the boiler by installing variable frequency
drives.
• The estimated operating efficiency of the fans was in the range of 60% - 65% as against
design efficiency of 80%. It was confirmed that the fans were operating in an energy
inefficient zone.

Variable frequency drives were installed for 6 nos of ID fans and 9 nos of PA fans to control
the speed of the fan with respect to operation of the boiler.

613
The VFD’s were installed during the stoppage of the plant for maintenance. The plant personnel
were well trained in operation and maintenance of VSD’s (prior to the installation of VFD) and
therefore no problems were faced with implementation. The inlet guide vanes were kept fully
opened after the VFD was installed.

• The advantage of installing a variable frequency drive for the boiler ID fans are as follows:
Energy saving
Precise control of parameters
Financial Analysis
The annual energy savings achieved was Rs 6.0 million and the investment was Rs 10.0
million for installing 15 nos of variable frequency drives, which got paid back in 20 Months.

Similar projects can be taken up for FD & Secondary air fans also. The project has high
replication potential in majority of the captive power plant and IPPs. For ID, FD, secondary air
and primary air fans

614

615
Case Study: 3
Install steam drives to prevent HP steam flow through pressure reducing valves
Background
• In a major captive power plant, the auxiliary steam requirement was at a pressure of 24 kg/
cm2 and 4100C.
• The quantity of process steam requirement was about 11.5 kg/cm2. To meet the process
requirement the steam from extraction was passed through PRDS.
• When steam pressure is reduced by passing through a pressure reducing valve, the enthalpy
of the steam remains constant. But due to pressure loss, the opportunity for converting the
low grade energy (thermal energy) to high grade energy (mechanical energy) is lost.
• The quantity of steam passed through the pressure reducing valve was varied depending
upon the process requirement.
• Instead of dropping the high pressure to low pressure by throttling, the same energy can
be used for power production.

• The potential available was tapped by installing 2 back pressure steam turbines which were
used for driving the drip pumps (2 Nos.). The exhaust steam from the back pressure turbine
was utilised for auxiliary steam requirements.
In a captive power plant the modification of the plant on a continuous basis is essential. A
stoppage for replacing the motor with a turbine for drip pump was not possible. Therefore 2
new drip pumps with back pressure turbines (300 kW) each were installed and the system
was hooked up during a maintenance shut down. Though the investment was high the stoppage
of plant could be avoided.

616
Benefits
The implementation of the project resulted in improving the co-generation potential.
Finalcial Analysis
The annual energy savings achieved was Rs 27.5 million and the investment was Rs 12.5
million for installing back pressure turbines, Generator and steam piping, which had a pay
back of 6 Months.


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Case Study: 4
INSTALL VAPOUR ABSORPTION HEAT PUMP IN PLACE OF VAPOUR

COMPRESSION SYSTEM
Background
In a captive power plant (of 21 MW capacity) of a large integrated paper plant, certain areas,
viz., the boiler & TG control room, static excitation room, ESP/Ash handling plant control room
and coal handling plant control room required a temperature of 26 ± 2 °C to be maintained.
The total air-conditioning load was 60 TR. Since, this power plant was in the project stage, the
plant team had the option of choosing between a vapour compression system and a vapour
absorption system, for maintaining these conditions. A techno-economic study favoured the
installation of a vapour absorption system.

The vapour absorption system scores over vapour compression system when
:
• Back pressure steam from a turbine is available
• Any waste source of heat is available on a continuous basis e.g. DG exhaust
• Cost of a electricity is high
In this case study, the turbine had the capacity to accept additional 300 kg/hr of low cost low
pressure steam. This gives an excellent spin-off benefit by generating additional power in the
turbine.

The plant team installed a 60 TR vapour absorption system for meeting the air conditioning
requirements of the various control rooms. This project was taken up at the design stage itself.
Comparison of Vapour Absorption Vs Vapour Compression

The comparative analysis of a vapour compression system and a vapour absorption system,
for achieving the same amount of air-conditioning, are as follows:

619
Parameter Units Vapour Vapour

compression absorption
system system
Rating TR 60 60
Power consumption kW 60 60
Steam consumption at
4 ksc kg/h - 300
Annual operating cost * Rs.lakhs 16.80 6.60
Annual savings Rs.lakhs - 10.20
Investment required Rs.lakhs 12.00 19.00
* Operating cost based on steam cost @ Rs.250/MT

and electricity cost @ Rs.3.50/kWh
In addition to the above, other benefits achieved were as follows:
• The room conditions were met as desired
• No maintenance shut down required, since there are no moving parts
Benefits & Financial Analysis


The installation of vapour absorption refrigeration system is in its nascent stage in the Indian
industry. The potential for installation of vapour absorption system in combination with a co-
generation system is tremendous in Indian industry and therefore needs to be pursued.

620

621
CHAPTER IV
Service Agencies in the sector
4.1 List Of Suppliers
1. Bharat Heavy Electricals Ltd (BHEL)

Building BHEL Building
Street Siri Fort Road
City 110 049 New Delhi
Country India
Telephone (+91) 11 - 649 30 31
Facsimile (+91) 11 - 649 30 21
E-Mail lodpms@bhelindustry.com
Internet www.bhelis.com
Description Power Generation and New & Renewable Energy Technologies
2. Thermax Babcock & Wilcox Ltd (TBW)

Building Sagar Complex
Street Mumbai Pune Road
Place Kasarwadi, Nasik Phata
City 411 034 Pune
Country India
Telephone (+91) 20 - 712 57 45
Facsimile (+91) 20 - 712 55 33
E-Mail tbw-web@tbwindia.com
Internet www.tbwindia.com
Description Heat Recovery Steam Generators, Circulating Fluid Bed Boilers,

Grate & Gas Fired Boilers
3. Thermax Ltd
Building Thermax House
Street 4, Mumbai Pune Road
Place Shivaji nagar
City 411 005 Pune

622
Country India
Telephone (+91) 20 - 551 21 22
Facsimile (+91) 20 - 551 22 42
E-Mail abunglow@thermaxindia.com
Internet www.thermaxindia.com
Description Boilers & Heaters, Captive Power, Cooling, Water & Waste
Solutions, Air Pollution Control and Chemicals
4. Larsen & Toubro Ltd – EPC Centre

Building Ashish Complex
Steet NH8, Chhani
City 391 740, Vadodara-Gujarat
Country India
Telephone (+91) 265 – 2775317 /2774941-5
Facsimile (+91) 265 - 27773898/5286
E-Mail yps@enc.ltindia.com,
Internet www.lntenc.com
Description Power Projects Development, Renovation & Modernisation,

Hydro Projects
5. Foster Wheeler India Pvt Ltd

Building Prakash Presidium
Street 110, Mahatma Gandhi Road
Place Nungambakkam
City 600 034 Chennai
Country India
Telephone (+91) 44 - 28227341
Facsimile (+91) 44 - 28227340
E-Mail fwenergy@fwc.com
Internet www.fwc.com
Description PC Fired & FBC Boilers, HRSG, Gasifiers

623
6. TurboTech Precision Engineering Pvt Ltd

Street No 28/29, 2nd Main Road
Place Industrial Town, Rajajinagar
City 560 044 Bangalore
Country India
Telephone (+91) 80 - 320 07 89
Facsimile (+91) 80 - 330 72 27
E-Mail turbo1@vsnl.com
Internet www.turbotech-india.com
Description Manufacturers of Small, Efficient Steam and Gas

Turbines
7. Neptunus Power Plant Services Pvt Ltd (NPPS)

Building 511, Arenja Corner
Street Plot 71, Sector 17
Place Vashi
City 400 705 Navi Mumbai
Country India
Telephone (+91) 22 - 789 32 58
Facsimile (+91) 22 - 790 60 81
E-Mail neptunus@vsnl.com
Internet www.neptunus-power.com
Description Captive Power Plants, Power Generation, Co-

Generation etc
8. Aravinthraajan Energy Systems

Building Madhurams Flat
Street 17/1 Senthil Andavar Street
Place Vadapalani
Country India
Telephone (+91) 44 - 484 46 27
Facsimile (+91) 44 - 484 46 27

624
E-Mail aessoft@satyam.net.in
Internet www.geocities.com/powerfulsolution/
Description Power Plant System Design and Optimisation

Software
9. Turbo Engineers (TE)

Street 2/C/1, Picnic Garden 3rd Lane
City 700 039 Kolkata
Country India
Telephone (+91) 33 - 343 49 48
Facsimile (+91) 33 - 343 44 11
E-Mail turbo@cal2.vsnl.net.in
Internet www.maxpages.com/turboengineers/
Description Thermal & Hydro Power Generation
10. DUKJIN E & C

Building 277, Nonhyun-Dong
Street Kangnam-GU
City Seoul
Country Korea
Telephone 82-02-3443-0692 to 5
Facsimile 82-02-3443-0696
E-Mail dukjinec@dukjinec.com
Internet www.dukjinec.com
Description Water Treatment & Ultra Filtration system
4.2 List of consultant in the sector
1. TCE Consulting Engineers Limited

Building Sherif Center
Street 73/1 St, Marks Road
Country India
Telephone (+91) 80 – 2274721

625
Facsimile (+91) 80 - 2274873
E-Mail kini@bangalore.tce.co.in
Internet www.tce.co.in
Description Consultancy Services in Power Generation, Transmission

& Distribution
2. Avant-Garde Engineers and Consultants Pvt Ltd (AGEC)

Street 68a, Porur-Kundrathur High Road
Place Porur
Country India
Telephone (+91) 44 - 482 87 17
Facsimile (+91) 44 - 482 85 31
E-Mail avantgarde@vsnl.com
Internet www.avantgarde-india.com
Description Concept to Commissioning of Renewable Energy Projects
3. FICHTNER Consulting Engineers (India) Private Ltd

Street 64, Eldams Road
Country India
Telephone (+91) 44 – 2435 9158
Facsimile (+91) 44 – 2434 4579
E-Mail mail@chn.fichtner.co.in
Internet www.fichtner.co.in
Description Consultancy Services in Gas & Thermal Power Plants
4. Acon Power Consultants

Street 45 Satyanand Vihar
District Rampur
City 482 008 Jabalpur
Country India
Telephone (+91) 761 - 66 72 61

626
Facsimile (+91) 761 - 66 42 07
E-Mail acon@sancharnet.in
Internet www.acon4power.com
Description Engineering Consultancy Services, Specializing in Power

(Thermal/Hydro/Non-Conventional Energy Source)
5. Mitsui Babcock Energy (India) Private Ltd

Building Alsa Tower
Street 186-187 Poonamalle High Road
Place Kilpauk
Country India
Telephone (+91) 44 - 26612901
Facsimile (+91) 44 - 26612907
E-Mail jmcphail@mitsuibabcock.com
Internet www.mitsuibabcock.com
Description Thermal Power Plants
6. L&T - Sargent & Lundy Ltd

Building L&T-Energy Centre
Street Near Chhani Jakat Naka
District Baroda
City 390 002 Vadodara
Country India
Telephone (+91) 265 - 77 23 90
Facsimile (+91) 265 - 79 52 35
E-Mail ltsl@ltecd.ltindia.com
Internet www.lntsnl.com
Description Complete Consultancy Services in the Field of Power

Generation from Concept to Commissioning for Power
Projects

627
7. Mantech Synergies Pvt Ltd

Street 73, Sardar Patel Road
Place Guindy
Country India
Telephone (+91) 44 - 220 02 45
Facsimile (+91) 44 - 220 02 46
E-Mail mantech@vsnl.com
Internet www.mantechsynergies.com
Description Project Development Consultants for Independent Power

Projects from 100 MW to 350 MW
8. Energy Economy & Environmental Consultants

Street #506, 15th Cross
Place Indiranagar 2nd Stage
Country India
Telephone (+91) 80 - 525 61 71
Facsimile (+91) 80 - 525 91 72
E-Mail eeec@vsnl.com
Description Consulting Services for Cogeneration Plants, Distribution Loss

Reduction, Waste Minimisation

List of Suppliers
628
List of Suppliers
List of Energy Auditors
List of Energy Service Companies

629
Mr. Sudhir Naik Dr Jairam Varadaraj

Vice President - Corporate Mktg. Managing Director
Hi-Rel Electronics Limited ELGI EQUIPMENT LTD
AC DRIVES
B -117 & 118, GIDC, Elgi Industrial Complex
Mr Ranjan Kumar De
Electronics Zone, Sector-25 Trichy Road
Country Manager
Gandhi Nagar 382044 Singanallur P O
ALLEN BRADLEY INDIA LTD
Tel: 02712-21636, 22531 Coimbatore 641 005
C - 11, Industrial Area
Fax: 02712-24698 Tel: +91-422-574691 to 5
Site IV,shahiabad
Email: Fax: +91-422-573697
Ghaziabad 201 010
mktg.hrcl@hirel.sprintrpg.ems.vsnl.net.in Email: investor@elgi.jet.co.in
Tel: +91-120-471112 / 0103 / 0105 / 0164
Fax: +91-120-4770822
Mr N C Agrawal Mr. Rahul C Kirloskar
Email: msseshadri@ra.rockwell.com,
Managing Director Chairman & Managing Director
rnm@raabil.com
MEDITRON Kirloskar Pneumatic Co Limited
SIRTDO Industrial Estate Hadapsar Industrial Estate
Cegelec India Ltd.
P O BIT, Mesra Pune 411 031
A - 21/24, Sector 16
Ranchi 835 215 Tel: 91-20-670133, 670341
Noida 201 301
Tel: +91-651-275875 / 628 Fax: 91-20-670297, 670634
Tel: 011 - 852 5643
Fax: +91-651-275841 Email: kpc@kirloskars.com
Fax: 011 - 852 0405
Email: meditron@dte.vsnl.net.in,
jyoti@dte.vsnl.net.in Mr Amol Parkhe
Mr Sandeep Maity
Product manager
Business Unit Manager (VSD)
Adsorption Dryers. Kirlosker Copeland (EE)
Danfoss Industries Pvt. Ltd.
Mr. Rajnish Joshi 1202/1,Ghole Road
296, Old Mahabalipuram Road
Exe. Vice President Near Ramchandra Sabhagurha
Sholinganallur, Chennai 600 119
Delair India Pvt. Ltd. Pune-411004
Tel: 44 450 3511
20, Rajpur Road, Tel: 020-5536350
Fax: 44 450 351844 450 3521
New Delhi 110054 Fax: 020-5534988
Email: danfoss.india@danfoss.com
Tel: 011-2912800 Email: amolp@kircop.com
Fax: 011-2915127, 2521754
EMCO Lenze Pvt. Ltd.
Email: bryair@nda.vsnl.net.in Air conditioning systems
106, Sion Koliwada Road
Mr Anand Ekbote
Sion (East)
AFBC Boilers, President
Mumbai 400 022
Mr K Kuppuraju TATA LIEBERT LTD
Tel: 022 - 407 6432/ 1816
President-Technical Plot No C - 20, Road No 19
Fax: 022 - 409 0423
CetharVessels Pvt ltd Wagle Industrial Estate
4,Dindigul road, Thane (W)
Energytek Electronics Pvt. Ltd.
tiruchirappilly Mumbai 400 604
A - 31, GIDC Electronics Zone
Tel: 0431-482452/53 Tel: +91-22-5828405, 5802388
Gandhinagar 382 044
Fax: 0431-481079 Fax: +91-22-5828358, 5800829
Tel: 02712 - 25562
Email: try_cvltry@sanchar.com Email: tataliebert@vsnl.com
Fax: 02712 – 30544
air & gas compressors, Ms Sajitha M Nair
Messung Systems Pvt Ltd
Mr Andre Schmitz Marketing executive
S - 615, 6th Floor, Manipal Centre
Managing Director Presvi Controls Pvt ltd
Dickinson Road
Atlas Copco (India) Ltd no 8, 2nd street,Venkatram nagar extn
Bangalore 560042
Mahatma Gandhi Memorial Building Adayar
080 – 5320480
Netaji Subhas Road Chennai 600 020
Email: bco@messung.com
Mumbai 400 002 Tel: 91-044-24420977/ 93
Tel: +91-22-796416 / 17 Fax: 91-044-24410289
Ador Powertron Industries Ltd.
Fax: +91-22-797928
Plot 51, Ramnagar Complex
Email: r.suresh@atlascopco.com Mr J P Singh
D - 11 Block,
Managing Director
MIDC, Chinchwad
Air compressors YOKOGAWA BLUE STAR LTD
Pune 411 019
Mr M Raveendran 40/4, Lavelle Road
Tel: 020 - 772 532, 773 778
Director Bangalore 560 001
Fax: 020 - 775 817
Coimbatore Compressor Engineering Co Tel: +91-80-2271513
Pvt Ltd Fax: +91-80-2274270
Mr K N Balaji
S F No 429, Thanneerpandal Email: ybilr@giasbg01.vsnl.net.in
Chief Operating Officer
Peelamedu
Eurotherm Del India Ltd
Coimbatore 641 004
152, Developed Plots Estate
Tel: +91-422-570323
Perungudi
Fax: +91-422-571447
Chennai - 600 096
Email: compressor@eth.net
Tel: 044-4961129
Fax: 044-4961831
Email: sales@eurothermdel.com
List of Suppliers
630
Mr. B G Raghupathy Ambiator Automatic voltage regulators (AVR)

Vice Chairman Mr. A Vaidyanathan Mr B.V.Subba Rao
GEA Cooling Tower Technologies (India) Pvt Managing Director Addl. GM
Ltd HMX - SUMAYA Systems BHEL
443, Anna Salai, Teynampet A 422, Peenya Industrial estate RC Puram
Chennai-600018 !st cross, 1 st stage Hyderabad
Tel: 044-4326171 Bangalore 560058
Fax: 044-4360576 Tel: 080-3722325, 1065 AUTOMATIC VOLTAGE STABILIZER
Email: gct@vsnl.in Fax: 080-3722326 Mr Dilip Dharmasthal
Email: ambiator@hmx.biz Managing Director
Mr Ashok M Advani Alacrity Electronics Limited
Chairman & Chief Executive Ash handling systems; high alumina “Suresh Mahal”, 12 - B
BLUE STAR LTD ceramics Valmiki Street
Kasturi Buildings Mr K R Natu T Nagar
Mohan T Advani Chowk Managing Director Chennai 600 017
J Tata Road DEMECH LTD Tel: 044 - 823 6620
Mumbai 400 020 78, Bhosari Industrial Estate Fax: 044 - 825 9406
Tel: +91-22-2020868 Pune 411 026
Fax: +91-22-2874498, 2824043 Tel: +91-20-7120994, 7120020 Consul Consolidated Pvt., Ltd.,
Email: suneel@bluestarindia.com Fax: +91-20-7120774, 5654185 4/329-A, Old Mahabalipuram Road
Email: Thiruvanmiyur
Mr Anil K Srivastava Chennai 600 041
Managing Director ATOMISERS FOR HUMIDIFICATION Tel: 044 – 4926651 / 2 / 3
CARRIER AIRCON LTD SYSTEMS Fax: 044- 4925754
Chiller Business Unit Techno Plast Email: Consul@vsnl.com
114, Shahpur Jat Spin free System
Near Asian Games Village No.1 Krishna flats Automation /
New Delhi 110 049 B/H Ambika hotel,Near Mothibai High Mr P S Sridharan
Tel: +91-11-6497131 to 34 school,Amraiwadi Managing Director
Fax: +91-11-6497140 Ahmedabad – 26 MEGATECH CONTROL PVT LTD
Tel: 079 – 5850898 Alsha Complex
K N A Chandrasekar 51, 1st Main Road
Regional Manager Automatic oil fired burners Gandhi Nagar
Amtrex Hitachi Appliances Ltd Mr. R. Rawat Chennai 600 020
Tulsi Apartments Partner Tel: +91-44-4996733 / 5654
47,II Main Road, R A Puram Burnax India Fax: +91-44-4341668, 4996215
Chennai 600 028 338, Balmukund Khand, Email: megatech@md2.vsnl.net.in
Tel: 044 - 4937483 Giri Nagar, Kalkaji,
Fax: 044- 4935534 New Delhi 110019 AXIAL FLOW FANS
Email: Tel: 011-6215124, 6230498 Amalgamated Indl. Composites Pvt. Ltd.
kna.chandrasekar@amtrexhitachi.com Fax: 011-6215124 Unit No.111/112
Ashok Service Industrial Estate
Mr T Nakamoto Automatic Power Factor Controller L B S Marg, Bhandup (West)
Managing Director Mr. Vipin SuriI Mumbai 400 078
Daikin-Shriram Air Conditioning Pvt Ltd Managing Director Tel: 022-591 3591/04565, 534 6919
12th floor, Surya Kiran Building Sylvan Electronics Fax: 022-591 3611, 5346920
19KG Marg A-92/1, Naraina Indl. Area,
New Delhi 110 001 Phase-I Mr V S Rajendran
Tel: 011-375-2647 New Delhi 110028 In charge- Engg and marketing,After market
Fax: 011-375-2646 Tel: 011-5791044/2324 business
Fax: 011-5794617 Flakt India ltd
Mr. Seichi Yoshii 147, Poonamalle high road
Managing Director A Square Incorporation Village Numbal
Matsushita Air-conditioning India Pvt Ltd 11 (Old: 7) ‘Subramanyaa” Chennai 600077
A 11& 12, SIPCOT Industrial Park 1st Floor, 3rd Street Tel: 044-26272023, 2216
Irungattukottai Santhi Nagar,Aadambakkam Fax: 044-26272606
Chennai 600 001 Chennai 600 088 Email: vs.rajendran@in.abb.com
Tel: (91)-(44)-56039/5603940/5603941/ Tel: 044 – 2451853
5603942 Email: srisuras@satyam.net.in Paru Engineers Private Limited
Fax: (91)-(44)-56041 B-56, Durgabai Deshmukh Colony
Hyderabad 500 007
Tel: 040 - 764 4174
Fax: 040 - 764 4174

631
Basic Refractories Bangalore 560 001 Mr Chakor L Doshi

Tel: +91-80-2271513 Chairman
Mr V K Gopalakrishnan Fax: +91-80-2274270 WALCHANDNAGAR INDUSTRIES LTD
Director Email: ybilr@giasbg01.vsnl.net.in 3, Walchand Terraces
VRW INDUSTRIES LTD Opp Air Conditioned Market
No 15, Reddy Street Mr K C Rana Tardeo
Virugambakkam Managing Director Mumbai 400 034
Chennai 600 092 AVU ENGINEERING PVT LTD Tel: +91-22-4939498, 4934800
Tel: +91-44-4838638 / 385 A - 15, APIE Fax: +91-22-4936655
Fax: +91-44-4833153 Balanagar
Hyderabad 500 037 Mr. Arun Gandhi
Blowers Tel: +91-40-3773235 / 2343 Proprietor
Mr R P Sood Fax: +91-40-3772343 / 3235 Crescent Engineering Corporation
Managing Director Email: avuhyderabad@rediffmail.com 49, H-32, Sector - 3,
ENCON FURNANCES PVT LTD Rohini,
14/6, Mathura Road MrC S Radhakrishnan New Delhi 110085
Faridabad 121 003 Executive Director Tel: 011-7164109, 7276448
Tel: +91-129-274408, 275307 / 607 Foster Wheeler India Pvt Fax: 011-7274553, 7162490
Fax: +91-129-276448 Prakash Presidium
110 Mahatma Gandhi Road, Nungambakkam Krupp Industries India Ltd.
Mr L Chandrashekar Chennai 600 034 V Floor, Temple Tower,
Managing Partner Tel: 91-44-822-7341 672, Anna Salai, Nandanam
MYSORE ENGINEERING Fax: 91-44-822-7340 Chennai 600 035
ENTERPRISES Email: fwenergy@fwc.com Tel: (91)-(44)-4339482/4346993
No 169, Industrial Suburb Fax: 91)-(44)-4348198
II Stage Mr B Pattabhiraman
P B No 5859, Peenya Post Managing Director Burners
Bangalore 560 058 GB Engineering Enterprises Pvt Ltd Mr S M Jain
Tel: +91-80-8394423 D - 99, Developed Plots Estate Vice President
Fax: +91-80-3349746 Thuvakudi ADOR TECHNOLOGIES LTD
Email: keeebgl@vsnl.net.in Trichy 620 015 Plot No 53, 54 & 55
Tel: +91-431-501111 (8 lines) F - II Block, MIDC Area, pimpri
Boilers & Axuliaries Fax: +91-431-500311 Pune 411 018
Mr. Ashok Tanna Email: gbengg@tr.dot.net.in Tel: +91-20-7470225, 7476009
Managing Director Fax: +91-20-7470224 / 7358
Vinosha Boilers Pvt. Ltd. And Taurus Heat Mr Ranjit Puri Email: info@ador-technologies.com
Systems Chairman & Mg Director
Baarat House, Ist Floor, INDIAN SUGAR & GENERAL Mr B S Adishesh
104, Apollo Street, Fort, ENGINEERING CORPORATION (THE) Wholetime Director
Mumbai 400001 A - 4, Sector 24 IAEC INDUSTRIES MADRAS LTD
Tel: 022-2674590, 2676447 Noida 201 301 Rajamangalam
Fax: 022-2611515: Tel: +91-118-4524071 / 72 Villivakkam
Fax: +91-118-4528630, 4529215 Chennai 600 049
Mr Michael H W Band Email: rp@isgec.com Tel: +91-44-655725, 6257783
Executive Director Fax: +91-44-4451537, 4995762
Mitsui Babcock Energy (India) Pvt Ltd Mr. Cyrus Engineer Email: iaec.mds@elnet.ems.vsnl.net.in
516-520, International Trade Tower Vice President
Nehru Place Industrial Boilers Ltd. Calorifiers
New Delhi 110 019 701-C, Poonam Chambers, Mr. Dinesh Harjai
Tel: +91-11-6436790, 6446118 Dr. Annie Besant Road, Worli, Partner
Fax: +91-11-6489793 Mumbai 400018 Crupp Metals
Email: Tel: 022-4926629 Kh. No. 56/1, Mundka,
administrator.del@mitsuibabcock.com Fax: 022-4937505 Rohtak Road,
New Delhi 110041
Krupp Industries India Ltd. Mr Prakash Kulkarni Tel: 011-5189024, 5474133
V Floor, Temple Tower, Managing Director Fax: 011-5183085
672, Anna Salai, Nandanam THERMAX BABCOCK & WILCOX LTD
Chennai 600 035 Sagar Complex Capacitors
Tel: (91)-(44)-4339482/4346993 Kasarwadi Auric Engineering Pvt ltd
Fax: 91)-(44)-4348198 Pune 411 034 8-4-368/A Sanathnagar
Tel: +91-20-7125745 Hyderabad 500018
Mr J P Singh Fax: +91-20-7125533 Tel: 040-3814035
Managing Director Email: kulkarnip@tbwindia.com, Fax: 040-3811829
YOKOGAWA BLUE STAR LTD tbwmkt@giaspn01.vsnl.net.in Email: auricengg@hotmail.com
40/4, Lavelle Road

List of Suppliers
632
Tel: 020 6821502,03-06

Mr R G Deshpande Centrifugal Pumps Fax: 020-6821509
Managing Director Mr BSS Rao/rajiv Email: kmlpune@vsnl.com
BC COMPONENTS INDIA PVT LTD Sr General manager
Loni - Kalbhor, (Central Railway) Beacon Weir ltd CLEATED BELT CONVEYOR
Pune 412 201 no 28, Industrial estate Kraft Engg. & Projects Ltd
Tel: +91-20-6913451, 6913285 Ambattur 189, Arcot Road, Vadapalani
Fax: +91-20-6913609 chennai-600098 Chennai 600 026
Email: ram.deshpande@bccomponents.com Tel: 044-6250739 Tel: 044 - 484 5811
Email: bwlmarketing@vsnl.net Fax: 044 - 484 7838
Shri. S K Nevatia Mr P U K Menon
Hind Rectifiers Ltd Executive Director coalesor
Lake Road MATHER & PLATT INDIA LTD Siemag Hi tech filters
Bhandup West P B No 7 R k Industry house
Mumbai Chinchwad Walbhat Road
Tel: 22 - 564 41 22 Pune 411 019 Goregaon (E)
Fax: 22 - 564 41 14 Tel: +91-20-7476196 to 98, 7477434 (D) Mumbai 400 063
Email: hirect@vsnl.com Fax: +91-20-7462519 Tel: 022-26851885, 3231
Email: matherpn@giaspn01.vsnl.net.in Fax: 022-26851048
Momaya Capacitors Email: siemag@vsnl.com
401, Madhav Apartments CERAMIC COATING
Jawahar Road, Opp. Rly. Stn. RAVI Thermal Engineers Pvt. Ltd. cogeneration power plants based on
Ghatkopar (East) No.11, 4th Cross, Central Excise Layout waste heat
Mumbai 400 077 Vijaynagar Mr Pinaki Bhadury
Tel: 022 - 516 2899/ 1005/ 0745 Bangalore 560 047 Senior Manager
Fax: 022 - 516 0758 Tel: 080 - 330 5794 Thermax Limited Cogen Division
Shakti Capacitors Pvt Ltd Fax: 080 - 330 3964 Sai Chambers, 15 Mumbai-Pune Road
Plot No 104/105 Wakdewadi
PB No 176 CERAMIC FIBRE Pune 411003
Industrial Estate Minwool Rock Fibres Limited Tel: 020-205511010
Sangli 416 416 204, Kings Apartments Fax: 020-205511042
Tel: 91-233-310-915 Juhu Tara Road
Fax: 91-233-310-984 Juhu COMPRESSED AIR SYSTEM
Email: shkcap@pn2.vsnl.net Mumbai 400 049 MAINTENANCE
Tel: 022-6154809 Orchid Energy Systems
Mr. S. Jayaraman Fax: 022-6178921 1141 – B, Trichy Road
Sr. General Manager-Mktg. Coimbatore 641 045
Kapsales Electricals Limited Ceramic Fibre products Tel: 0422 – 318389
Khatau House, Mr.Mahesh Chavda Fax: 0422 – 312073
Plot No. 410-411, Mogul Lane, Mahim, Sales Manager
Mumbai 400016 Murugappa Morgan Thermal Ceramics Ltd Compressed air systems
Tel: 022-4461975, 4450050 Tiam House-Annexe Building’-3rd Floor Mr K.S. Natarajan
Fax: 022-4450016 No.28 Rajaji Salai, Managing Director
Chennai-600001 Trident Pneumatics Pvt Ltd.
Centrifugal & axial fans Tel: 044-5224897,5272781 5/232, K.N.G. Pudur Road
Mr J B Kamdar Fax: 044-5213709,5227093 Somayampalayam Post
Chief Executive Email: mahesh@ho.mmtcl.co.in Coimbatore 641 108
NADI AIRTECHNICS Tel: 0422 2400492
26, G N T Road CFL Fax: 0422 2401376
Erukkenchery Mr Vinay Mahendru Email: sales@tridentpneumatics.com
Chennai 600 118 A-39, Hosiery Complex
Tel: +91-44-5570264 / 771 Indo Asian fuse gear ltd
Fax: +91-44-5371149 phase II extn
Email: ebmnadi@md2.vsnl.net.in Noida-201305 Condenser
Tel: 0120-2568471, 2568093-98 Mr M Sreenivasan
Mr A P Gokhale Fax: 0120-2568473 Chief Executive
Director Email: ecolite@indoasian.com SUPER ENGINEERING COMPANY
Autowin systems povt ltd B - 1, Industrial Estate
Plot no 2, Vedant Nagari Chillers Ariamangalam
Karve nagar Harshlal Suragne Trichy 620 010
Pune-411052 Er-Marketing Tel: +91-431-441131
Tel: 020-5431052, 5423358 Kirloskar Mcquay pvt ltd Fax: +91-431-441366
Fax: 020-5467041 PB No 1239,Hadapsar industrial estate
Email: autowin@vsnl.com pune 411013 Cooling Tower

633
Mr Raviselvan Jaipur 302013 Tel: +91-11-7535566 to 68, 525632, 522983,

Managing Director Tel: 0141-2331542,5061909 528510
Gem Cooling Towers Private Limited Fax: 0141-2331543 Fax: +91-11-7516598, 528510
SF. No. 100/A Email: JayantRajvanshi@aqua-
Arasur chemicals.com Mr Girish Mohan
Coimbatore 641407 Director
Tel: 0422-887059/880129 Nalco chemicals india ltd TIMKEN SERVICES PVT LTD
Fax: 0422-888247 20/A Park Street 725, Udyog Vihar
KOLKATA 700 016 Phase V
Mr Vikram Swarup Tel: 033-2172494 Gurgaon 122 016
Managing Director Fax: 033-2171709 Tel: +91-124-347725 / 6, 342840
Paharpur Cooling Towers Ltd. Fax: +91-124-342320, 348086
Paharpur House DC DRIVES
8/1/B Diamond Harbour Road Siemens Ltd. Mr K C Dhingra
Kolkata 700027 Motors, Drives & UPS Division Managing Director
Tel: 91-33-24792050 Sector - 11, Plot 11 WESTERN INDIA MACHINERY CO PVT
Fax: 91-33-24792188 Kharghar Mode LTD
Email: pctccu@paharpur.com Navi Mumbai 410 208 Park Plaza
Tel: 022 – 757 7030/ 31/ 32 North Block, 6E, 6th Floor
Mr S Bansal Fax: 022 – 757 7106: 71, Park Street
Chief Executive Kolkata 700 016
Paltech Cooling Towers & Equipments Ltd. DC DRIVES Tel: +91-33-2468913 / 9674
A-502 & 601 Larsen & Toubro Ltd Fax: +91-33-2468914
ANSAL CHAMBER - I Control & Automation Section
BHIKAJI CAMA PLACE 10, Club House Road Mr Sumit Mazumder
NEW DELHI 110066 Anna Salai Managing Director
Tel: 011-6108114 / 6174250 Chennai 600 002 TIL LTD
Fax: 91-11-6174250 Tel: 044 – 852 2141 1, Taratolla Road
Fax: 044 – 852 0769 Garden Reach
Mr Pankaj Bhargava Kolkata 700 024
Managing Director DG sets Tel: +91-33-4693732 to 36, 4696497 to 99
Parag Fans & Cooling Systems Limited Mr Mohan M Gujrar Fax: +91-33-4692143 / 3731
Plot no. 1/2b & 1b/3a Managing Director Email: ug@tilindia.com
Industrial Area no. 1 Gurjar Power Engineers Pvt ltd
A.B. road no 18, Ist Floor,Corporation Building Mr Anand Kothaneth
Dewas 455 001 Residency Road General Manager
Tel: 07272-58135 / 58131 Bangalore-560025 BATLIBOI ENGINEERS PVT LTD
Fax: 91 - 7272 - 30273, 58850 Tel: 080-2216416, 7469 99/2 & 99/3, N R Road
Email: paragb@bom2.vsnl.net.in Fax: 022-2216416 Bangalore 560 002
Email: gurjarmohan@yahoo.com Tel: +91-80-2235061 to 63
Cooling Tower water treatment Fax: +91-80-2235085
Hercules Speciality Chemicals Ltd Powerica Limited Email: blr.batlico@axcess.net.in
5TH FLOOR, VAYUDNOOTH 115 Mittal Court
CHAMBERS B-Wing Nariman Point Diffuser
15/16, MAHATMA GANDHI ROAD Mumbai 400021 Siemag Hi tech filters
BANGALORE 560001 Tel: 022-2825949 R k Industry house
Fax: 91-22-22043782 Walbhat Road
Cooling water Systems Goregaon (E)
Mr M Amjad Shariff Mr Pradeep Mallick Mumbai 400 063
Director Managing Director Tel: 022-26851885, 3231
Shriram Epc Ltd WARTSILA INDIA LTD Fax: 022-26851048
No 9 Vanagaram Road, 76, Free Press House Email: siemag@vsnl.com
Ayanambakkam Nariman Point
Chennai 602 102 Mumbai 400 021 Dryers
Tel: 6533109/3313/1592 Tel: +91-22-2815601 / 5598, 28175995 / 5601 Mr A D Parekh
Fax: 653 2780/826 2416 Fax: +91-22-2842083 General Manager
Email: shriramepc@vsnl.net Email: pradeep.mallick@wartsila.com HDO PROCESS EQUIPMENT AND
SYSTEMS LTD
Cooling water treatment chemicals Mr D R Dhingra 5/1/2, GIDC Industrial Estate
Mr JayantRajvanshi Managing Director Vatva
Director CONTINENTAL GENERATORS PVT LTD Ahmedabad 382 445
Aqua Chemicals 3869, Behind Primary School Tel: +91-79-5830591 to 94
B-237A Road No. 6D G B Road Fax: +91-79-5833286
V.K.I.Area Delhi 110 006 Email: patfilt@ad1.vsnl.net.in

List of Suppliers
634
Electronic ballasts
ECONOMISERS Mr Shantilal patel Energy efficient coolers for cement
Megatherm Engineers & Consultants Pvt. Propreitor Industry
Ltd. Nishan Power converters MR. PRADEEP KAPOOR
10, Kodambakkam High Road Krishna Vijay saw mill compound Director
Chennai 600 034 Opp S T stand, Agra Road Fuller India ltd
Tel: 044 - 823 3528/ 3707 Bhivandi-421302 J-11, IIND FLOOR,
Fax: 044 - 825 8559 Tel: 91-2522-257201 REAR FLAT, SAKET
Fax: 91-2522-222032 NEW DELHI 110017
Mr B P Deboo Email: krishnas@vsnl.com
Managing Partner Mr Madhusudan Rasiraju
ALBAJ ENGINEERING CORPORATION Mr V Ramaraj I K N engineering India pvt ltd
340, Clover Centre Managing Partner Three star Business Centre
Moledina Road OPAL A14 A, II nd Avenue
Pune 411 001 NO 5, rajeswari street Anna Nagar
Tel: +91-20-6131511, 6133018, 6121542 Mehta nagar Chennai 600102
Fax: +91-20-6137255 chennai 600029 Tel: 044-26218994,6210960
Email: albaj@vsnl.com Tel: 044-23742036 / 1218 Fax: 044-26284567,0439
Fax: 044-23742036 / 1218 Email: madhusudikn@vsnl.com
Eddy current control systems Email: opal@md2.vsnl.net.in
Dr. M. J. Davis Energy efficient drying system
Executive Director Mr. K. G. Madhu Mukesh Shah
Eddy Current Controls (India) Limited Managing Director Director
Eddypuram, Chalakudy, Ammini Energy System Pvt. Ltd. Mecord Systems and Services (P) Ltd.
District Thrissur Industrial Estate, 314 Hill View Industrial Estate
Thrissur 680722 Pappanamcode, Ghatkopar West
Tel: 0488-842882/716/698 Trivandrum 695019 Mumbai 400086
Fax: 0488-842716 Tel: 0471-490508 Tel: (022)-5008604
Fax: 0471-490832 Fax: (022)-5007560
Efficiency enhancement coating for Email: ammini@md2.vsnl.net.in
pumps Energy Efficient Induction Motors
Mr G V Muralidhara Mr.P.S.Sasidharan Mr. Sanjeev Gupta
SBU Head(Anti Corrosion Products Managing Director Proprietor
Division) Pamba Electronic Systems Pvt Ltd. Oxford Engineering Industries
Kirloskar Brothers Limited 1/40A, Pamba House, Kureekkad P.O G-27, East Gokalpur,
408/15, Chintan Thiruvankulam Loni Road,
Mukundnagar Ernakulam-682 305 New Delhi 110094
Pune-411037 Tel: 0484-711129,712721 Tel: 011-2280434, 2299979
Tel: 020-4402137 Fax: 0484-711398 Fax: 011-2293370
Email: anticorrosion@pnq.kbl.co.in Email: pambaele@satyam.net.in
Energy efficient lighting systems
Electric motors Electronic energy meters Mr R Nandakishore
Mr Rahul N Amin Mr I C Agarwal Sr General Manager Marketing
Chairman & Mg Director Chairman & Mg Director Philips India Ltd
JYOTI LTD GENUS OVERSEAS ELECTRONICS Motorola excellence centre, 5th floor 415/2,
Industrial Area LTD Mehrauli Gurgaon Road, Sector 14,
P O Chemical Industries SPL - 3, RIICO Industrial Area Gurgaon-122001
Vadodara 390 003 Tonk Road Tel: 0124-8991980
Tel: +91-265-380633, 380627 Sitapura Fax: 0124-8991993
Fax: +91-265-380671, 381871 Jaipur 302 022 Email: R.Nandakishore@philips.com
Email: cmd.jyoti@sm3.sril.in Tel: +91-141-580003 / 4 / 9
Fax: +91-141-580319 ENERGY EFFICIENT MOTORS
Electrical Measuring Instruments Email: genus@jp1.dot.net.in Asea Brown Boveri ltd
Mr R R Dhoot Plot No 5 & 6, II Phase
Chairman Energy Efficiency & ESCO Services Peenya Industrial Area
IMP POWER LTD Mr R B Sinha P B no 5806, Peenya
Advent, 7th Floor Chief Executive Bangalore 560058
12 - A, General J Bhosale Marg Energy Audit Services Tel: 080-8370416 / 8394734 extn 2322 /
Nariman Point 1116 6691375
Mumbai 400 021 Sector No 17 Fax: 080-8399178 / 8396537
Tel: +91-22-2021890 / 886 / 697 Faridabad -121 002
Fax: +91-22-2026775 Tel: 0129 - 2282132/2284125/2224504 Mr N J Danani
Email: contactus@imp-power.com Fax: 0129 2262576 Vice Chairman & Mg Director
Email: sinhaeas@ndb.vsnl.net BHARAT BIJLEE LTD

635
Central Marketing Office (Motor) 1, Raj Narain Marg

P O Box 100 Civil Lines Energy Saving Lighting Systems.
Kalwe, Thane Belapur Road Delhi 110 054 Mr. Praveen Kumar Sood
Mumbai 400 601 Tel: +91-11-3935237 to 40, 2944469 to 72, Managing Director
Tel: +91-215-7691656 3981101 to 05 Linear Technologies India Pvt. Ltd.
Fax: +91-215-7691401 / 2: Fax: +91-11-3921500, 3981100 K-37, Green Park,
Email: marketing@havells.com Main Basement,
Crompton Greaves Limited New Delhi 110016
CG Industrial Systems Mr Lalit Seth Tel: 011-6854395, 6854946
ETD Building, 2nd Floor Chief Executive Fax: 011-6854057
Kanjur Marg (E) HPL-SOCOMEC PVT LTD
Mumbai 400 042 Atma Ram Mansion, 2nd Floor Mr. Ajit R. Shah
Tel: 022-5782451 Extn 8956/ 5795688 1/21, Asaf Ali Road Managing Director
Fax: 022-5789169 New Delhi 110 002 Eurolight Electricals Limited
Tel: +91-11-3236811 / 4811 20,Sadashiv Peth, Rahi Chambers,
Energy efficient Pumps Fax: +91-11-3232639 L B S Road,
Mr G Rajendran Email: hpl@hplindia.com Pune 411030
Managing Director Tel: 0212-531287, 534128
C.R.I. Pumps (PVT) Limited Energy Recovery Ventilator (ERV), Fax: 0212-532787
Athipalayam Road, Mr. Rajnish Joshi Email: yantra @ bom3vsnl.net.in
Chinnavedampatti Exe. Vice President
Coimbatore 641 006 Arctic India Engineering Pvt. Ltd. Energy Services Consultancy
Tel: (422) 867051 /2/6395 20, Rajpur Road, Mr P S Sankaranayaran
New Delhi 110054 Director
Mr N K Ranganath Tel: 011-2912800 Avant Garde Engineers & Consultants (p)
Chief Executive Fax: 011-2915127, 2521754 Ltd.
Grundfos Pumps India Pvt Ltd Email: bryair@nda.vsnl.net.in 68A Porur Kundarathur High road
Ground floor Porur
Chamiers apartment Energy saver for air conditioners Chennai 600 116
119/121, Chamiers road Dr V K Koshy Tel: 044-4828717,18,19,22
Chennai 600028 Chairman & Mg Director Fax: 91-44-4828531
Tel: 044-4323487 / 4357065 BHARAT ELECTRONICS LTD Email: avantgrade@vsnl.com
Fax: 044-4323489 Shankaranarayan Building, 2nd Floor
25, M G Road ESCO
Mr N C Tiwari Bangalore 560 001 Mr B S Punia
Assistant General Manager, Product Tel: +91-80-5595729 Jr Vice President
Development & Mangement Fax: +91-80-5584911 DCM Shriram Consolidated Ltd
Kirloskar Brothers Limited Email: imd@bel-india.com 5th floor,Kanchenjunga Building
Ujjain Road 18,Barakhamba Road
Dewas-455001 Energy saver for Lighting New Delhi-110001
Tel: 07272-27315 Mr R Sekar Tel: 011-3316801
Fax: 07272-27347 Chairman & Managing Director Fax: 011-3318261
Email: ntiwari@dws.kbl.co.in ES Electronics (India) Pvt Ltd Email: baldeeppunia@dscl.com
438,4th Main Road
Energy management & Control systems Nagendra Block,B.S.K.I Stage, Mr Nalin Kanshal
Mr Lalit Seth Bangalore 560050 Business Director
Chief Executive Tel: 080-6727836 / 8761 Elpro energy Dimensions Pvt ltd
HPL-SOCOMEC PVT LTD 6,7,8 IV N Block
Atma Ram Mansion, 2nd Floor CLIPSAL Lighting India (P) Ltd Dr RajKumar Road, Rajaji Nagar entrance
1/21, Asaf Ali Road Bajaj Niwas Bangalore-560010
New Delhi 110 002 OpP. C.K.P. Club, Tel: 080-3122676,3123238,3132035,3132036
Tel: +91-11-3236811 / 4811 712 , Linking Road, Khar (W) Fax: 080-3487396
Fax: +91-11-3232639 Mumbai Email: support@ecoenergycentre.com
Email: hpl@hplindia.com Tel: 022-6046483
CMS ENERGY Management systems energy savers for AC Induction motors EVAPORATIVE CONDENSERS
W 324, Rabale MIDC Santronix india pvt ltd Baltimore Aircoil Company Inc.
Mumbai 400701 unit no 12 122, Hema Industrial Estate
Tel: 91-022-27696720,86 Electronic sadan III Sarvodaya Nagar
Fax: 91-022-27694585 MIDC, Bhosari Jogeshwari (E)
Pune 411026 Mumbai 400 060
Energy meters Tel: 020-7122758 Tel: 824 5714
Mr Qimat Rai Gupta Fax: 020-7129518 Fax: 824 5713
Chairman & Mg Director Email: satronix@bom3.vsnl.net.in Email: swapan@bom5.vsnl.net.in
HAVELL‘S INDIA LTD

List of Suppliers
636
Systems & Components (India) Private SULZER INDIA LTD Mr. Arun Gandhi
Limited Sulzer House Proprietor
110, Gautam Udyog Bhavan Baner Road, Aundh Crescent Engineering Corporation
L.B.S Marg, Bhandup (West) Pune 411 007 49, H-32, Sector - 3,
Mumbai 400 078 Tel: +91-20-5888991 / 98 Rohini,
Tel: 022-564 0166-67 Fax: +91-20-5886393 New Delhi 110085
Fax: 022-564 5896 Email: Tel: 011-7164109, 7276448
Email: sycomp@bom3.vsnl.net.in comml.pune@sulzerind.sprintrpg.ems.vsnl.net.in Fax: 011-7274553, 7162490
Evaporative Cooling Pad (ECP) and Aerotherm Systems Pvt Ltd Mr Vilas H Patil
Control Panel heat Extractor Plot no 1517 Phase III Managing Director
Mr. Rajnish Joshi GIDC Vatwa DYNAMIC FURNACES PVT LTD
Exe. Vice President Aheemedabad 382445 65, Universal Industrial Estate
Arctic India Engineering Pvt. Ltd. Tel: 079-5890158 I B Patel Road
20, Rajpur Road, Fax: 079-5834987 Goregaon (E)
New Delhi 110054 Email: vadherad1@sancharnet.in Mumbai 400 063
Tel: 011-2912800 Tel: +91-22-8733516, 8746138
Fax: 011-2915127, 2521754 Mr K C Patel Fax: +91-22-8733021
Email: bryair@nda.vsnl.net.in General Manager Email: tarsod@bom3.vsnl.net.in
Gujarat Perfect Engineering Ltd
Fans 301, Shailja Complex II, Akota Road Mr R P Sood
Mr Saroj Poddar Vadodara 390 020 Managing Director
Chairman Tel: +91-265-334861, 645786 ENCON FURNANCES PVT LTD
ALSTOM LTD Fax: +91-265-646880 14/6, Mathura Road
14th Floor, Pragati Devika Tower Email: gperfect@icenet.net.in Faridabad 121 003
6, Nehru Place Tel: +91-129-274408, 275307 / 607
New Delhi 110 019 FRP BLADES Fax: +91-129-276448
Tel: +91-11-6449906, 6449907, 6449902 / 3 Amalgamated Indl. Composites Pvt. Ltd.
Fax: +91-11-6449447 Unit No.111/112 Mr C P Maheshwari
Ashok Service Industrial Estate Managing Director
Mr A M Naik L B S Marg, Bhandup (West) HC GIDDINGS PVT LTD
Mg Director & CEO Mumbai 400 078 3, Chittaranjan Avenue
LARSEN & TOUBRO LTD Tel: 022-591 3591/04565, 534 6919 Kolkata 700 013
L & T House Fax: 022-591 3611, 5346920 Tel: +91-33-272820, 261740
Ballard Estate Fax: +91-33-2372820, 2361740
Mumbai 400 001 Encon (India)
Tel: +91-22-2618181 2 - B/17, Shivkripa Mr M Gopal
Fax: +91-22-2620223, 2610396, 2622285 N C Kelkar Road Managing Director
Email: amn@lth.ltindia.com Dadar (West) HIGHTEMP FURNACES LTD
Mumbai 400 028 I - C, Phase II
filters for Air Compressors Tel: 022 - 437 2949, 4306578 P B No 5809
Mr. Sanjay Joshi Fax: 022 - 431 0992, 4321929 Peenya Industrial Area
Managing Director Bangalore 560 058
Domnick Hunter India Pvt Limited Furnace Tel: +91-80-8395917 / 4076 / 1446
B-214, ANSAL CHAMBER-I Mr Saroj Poddar Fax: +91-80-8397798 / 2661
3, BHIKAIJI CAMA PLACE Chairman Email: hightemp@vsnl.com
NEW DELHI 110066 ALSTOM LTD
Tel: 11 61 92172 14th Floor, Pragati Devika Tower Mr M K Sen
Fax: 011-6185279 6, Nehru Place Managing Director
New Delhi 110 019 INCORPORATED ENGINEERS LTD
Flue Gas Analysers Tel: +91-11-6449906, 6449907, 6449902 / 3 D - 400, Gayatri
Mr T V Krishnamurthy Fax: +91-11-6449447 MIDC, Uran Phata
Chief Executive Nerul
Marvel Engineering company Mr Mithu S Malaney Navi Mumbai 400 706
28,Deivasigamani road Chairman & Mg Director Tel: +91-22-7619352, 7619366
Roypettah VULCAN ENGINEERS LTD Fax: +91-22-7619368
Chennai-600014 427, Unique Industrial Estate Email: idvl@bol.net.in
Tel: 044-8110582,2297 Off Veer Savarkar Marg
Fax: 044-8117559 Prabhadevi Mr N Gopinath
Email: marvelco@vsnl.net Mumbai 400 025 Managing Director
Tel: +91-22-4304529 / 3671 FLUIDTHERM TECHNOLOGY PVT LTD
Fluid Bed Dryer Fax: +91-22-4225814 SP - 132, III Main Road
Mr Subodh S Nadkarni Email: Ambattur Industrial Estate
President & CEO vulcan.engnr@vel.sprintrpg.ems.vsnl.net.in Chennai 600 058

637
Tel: +91-44-6357390, 6357391 Harman House Fax: +91-0866-545860

Fax: +91-44-6257632 482, 80 FT Road
Email: fluidtherm@vsnl.com Ganganagar Mr Ajit Singh
Bangalore 560 032 Chief Executive Officer
generators and boilers Tel: +91-80-3530036 / 37 AIRFRIGE INDUSTRIES
Mr K G Ramachandran Fax: +91-80-3431548 10/65, Kirti Nagar Industrial Area
Chairman & Mg Director Email: indo@harmanit.net.in New Delhi 110 015
BHARAT HEAVY ELECTRICALS LTD Tel: +91-11-5931909 / 72, 5162118 / 19
BHEL House harmonic filters Fax: +91-11-5436781
Siri Fort Power Linkers Email: afi@del3.vsnl.net.in
New Delhi 110 049 122,Nahar & seth estate
Tel: +91-11-6001010 chakala Mr B P Deboo
Fax: +91-11-6493021, 6492534 Mumbai 400099 Managing Partner
Tel: 022-28325565, 28371902 ALBAJ ENGINEERING CORPORATION
Mr Praveen Sachdev Fax: 022-28386025 340, Clover Centre
Mg Director & CEO Email: powersys@vsnl.com Moledina Road
GREAVES LTD Pune 411 001
1, Dr V B Gandhi Marg Mr. R. K. Iyer Tel: +91-20-6131511, 6133018, 6121542
P O Box 91 Vice President Fax: +91-20-6137255
Mumbai 400 001 Saha Sprague Limited Email: albaj@vsnl.com
Tel: +91-22-2671524 / 4913 No.805, North Rear Wing, 8th Floor, Manipal
Fax: +91-22-2677850, 2652853 Centre Mr Deepak Singh
47, Dickenson Road, Executive Director
Harmoic analyser Bangalore 560042 BUILDWORTH PVT LTD
Neptune India ltd Tel: 080-5595463, 5595266 G S Road
Neptune house Fax: 080-5595463 Dispur
C 270 SFS Sheikh sarai Guwahati 781 005
Phase I Harmonic measurement and analysis Tel: +91-361-560354
New delhi 110017 Power Linkers Fax: +91-361-561411
Tel: 011-6013367-70 122,Nahar & seth estate Email: bwpl@gwl.vsnl.net.in
Fax: 011-6013371 chakala
Email: neptune@del2.vsnl.net.in Mumbai 400099 Mr Sucha Singh
Tel: 022-28325565, 28371902 Managing Director
Mr Dilip Dharmasthal Fax: 022-28386025 COIL COMPANY PVT LTD
Managing Director Email: powersys@vsnl.com A - 21/24, Naraina Industrial Area
Alacrity Electronics Limited New Delhi 110 028
“Suresh Mahal”, 12 - B Harmonic utility Equipments Tel: +91-11-5701967 / 1968 / 9127
Valmiki Street Mr Parag J Pandya Fax: +91-11-5709126
T Nagar CEO Email: coilco@nda.vsnl.net.in
Chennai 600 017 Amtech Electronics India ltd
Tel: 044 - 823 6620 E - 6 GIDC Electronics Zone Er Ashok Kumar Gupta
Fax: 044 - 825 9406 Gandhi Nagar Chairman
Gandhi Nagar 382 028 CRANE-BEL INTERNATIONAL
Avante Global services Tel: 079 - 3225324/3227294/3227304 Dev - Satya Bhavan
225, Prakash Mohalla Fax: 079 - 3224611 C - 23, Lohia Nagar
East of Kailash, Email: info@amtechelectronics.com Ghaziabad 201 001
New Delhi 110065 Tel: +91-120-4722994, 4716883, 4713281/82
Tel: 011-26233259,26443097 Heat exchanger Fax: +91-120-4712709, 4722995
Email: avante@eth.net Mr M Sreenivasan Email: international@crane-bel.com
Chief Executive
Mr. P Anil Kumar SUPER ENGINEERING COMPANY Mr. Dinesh Harjai
Managing Director B - 1, Industrial Estate Partner
TOWLER ENTERPRISE SOLUTIONS Ariamangalam Crupp Metals
PVT.LTD Trichy 620 010 Kh. No. 56/1, Mundka,
HARMAN HOUSE Tel: +91-431-441131 Rohtak Road,
482, 80 FT ROAD, GANGANAGAR Fax: +91-431-441366 New Delhi 110041
BANGALORE 160032 Tel: 011-5189024, 5474133
Tel: 080-3530033-36,3432289 Mr Mohammed Meeran Fax: 011-5183085
Fax: 080-3431548 Proprietor
AASIA RADIATORS Mr. A. Bhasker Reddy
Mr Lalit Kumar Pahwa P S C Bose Road Managing Partner
Managing Director Jawahar Autonagar Enfab
HARMAN INNOVATIVE Vijayawada 520 007 C-2, Shanthi Nivas,
TECHNOLOGIES LTD Tel: +91-0866-543881 Mettuguda,

List of Suppliers
638
Secunderabad 500017 Email: idvl@bol.net.in Email: unitop@unitopengrs.com

Tel: 040-823073, 830010 Mr Ranjit Puri Mr Chakor L Doshi
Fax: 040-823073, 830010 Chairman & Mg Director Chairman
Email: enfabs @ hd1.vsnl.net.in INDIAN SUGAR & GENERAL WALCHANDNAGAR INDUSTRIES LTD
ENGINEERING CORPORATION (THE) 3, Walchand Terraces
Mr B Pattabhiraman A - 4, Sector 24 Opp Air Conditioned Market
Managing Director Noida 201 301 Tardeo
GB Engineering Enterprises Pvt Ltd Tel: +91-118-4524071 / 72 Mumbai 400 034
D - 99, Developed Plots Estate Fax: +91-118-4528630, 4529215, 4542072 Tel: +91-22-4939498, 4934800
Thuvakudi Email: rp@isgec.com Fax: +91-22-4936655
Trichy 620 015
Tel: +91-431-501111 (8 lines) Mr P V Rao Mr Pashupati Nath Kapoor
Fax: +91-431-500311 Managing Partner Partner
Email: gbengg@tr.dot.net.in INDIRA INDUSTRIAL WORKS KASHI INDUSTRIES
1 - 528, Lankalapalem P O 16/80, B 1
Mr K C Patel Visakhapatnam 531 021 Civil Lines
General Manager Tel: +91-891-29461 / 53 Kanpur 208 001
GUJARAT PERFECT ENGINEERING Fax: +91-891-29461 Tel: +91-512-311395, 319074
LTD Email: Fax: +91-512-319074
301, Shailja Complex II
Akota Road Mr S V Mehta Mr Roy Eapen
Vadodara 390 020 Chairman & Director Proprietor
Tel: +91-265-334861, 645786 INDUSTRIAL MACHINERY HEAT TRANSFER DEVELOPMENT
Fax: +91-265-646880 MANUFACTURERS PVT LTD 84 - C, Jeevan Complex
Email: gperfect@icenet.net.in 3607 - 3609, GIDC Estate 5th Cross, 100 Feet Road
Phase IV Gandhipuram
Mr C P Maheshwari Vatva Coimbatore 641 012
Managing Director Ahmedabad 382 445 Tel: +91-422-858271 / 2
HC GIDDINGS PVT LTD Tel: +91-79-5831152 / 1449 Fax: +91-422-447341
3, Chittaranjan Avenue Fax: +91-79-5832216
Kolkata 700 013 Email: Mr J Peter Arokiam
Tel: +91-33-272820, 261740 sysadmin@immpl.xeeahm.xeemail.com Managing Director
Fax: +91-33-2372820, 2361740 MANIKAM RADIATORS PVT LTD
Mr L Chandrashekar 11/275 - B, Subramaniapalayam
Mr A D Parekh Managing Partner K N G Pundur Road
General Manager MYSORE ENGINEERING G N Mills Post
HDO PROCESS EQUIPMENT AND ENTERPRISES Coimbatore 641 029
SYSTEMS LTD No 169, Industrial Suburb Tel: +91-422-843311 / 12
5/1/2, GIDC Industrial Estate II Stage Fax: +91-422-843311
Vatva P B No 5859, Peenya Post Email: mrad@md4.vsnl.net.in
Ahmedabad 382 445 Bangalore 560 058
Tel: +91-79-5830591 to 94 Tel: +91-80-8394423 Heat recovery boilers
Fax: +91-79-5833286 Fax: +91-80-3349746 Mr K G Ramachandran
Email: patfilt@ad1.vsnl.net.in Email: keeebgl@vsnl.net.in Chairman & Mg Director
BHARAT HEAVY ELECTRICALS LTD
Mr B S Adishesh Mr V David Selvaraj BHEL House
Wholetime Director Vice President (Operations) Siri Fort
IAEC INDUSTRIES MADRAS LTD PARANI STEELS PVT LTD New Delhi 110 049
Rajamangalam AL - 84, 4th Street Tel: +91-11-6001010
Villivakkam 11th Main Road Fax: +91-11-6493021, 6492534
Chennai 600 049 Anna Nagar
Tel: +91-44-655725, 6257783 Chennai 600 040 Heat Recovery Wheel (HRW)
Fax: +91-44-4451537, 4995762 Tel: +91-44-6286285 / 2246 / 2247 Mr. Rajnish Joshi
Email: iaec.mds@elnet.ems.vsnl.net.in Fax: +91-44-6211265 Exe. Vice President
Arctic India Engineering Pvt. Ltd.
Mr M K Sen Mr Ramesh Wadhwani 20, Rajpur Road,
Managing Director Managing Director New Delhi 110054
INCORPORATED ENGINEERS LTD UNITOP ENGINEERS PVT LTD Tel: 011-2912800
D - 400, Gayatri 78/1, GIDC Industrial Estate Fax: 011-2915127, 2521754
MIDC, Uran Phata P O Box No 761 Email: bryair@nda.vsnl.net.in
Nerul Makarpura
Navi Mumbai 400 706 Vadodara 390 010
Tel: +91-22-7619352, 7619366 Tel: +91-265-642161 / 62
Fax: +91-22-7619368 Fax: +91-265-644698

639
El -Tra Equipment Company (India) Pvt. Ltd. INDUSTRIAL MACHINERY

Heat Treatment furnances 11th Mile, Old Madras Road, MANUFACTURERS PVT LTD
Mr R N Bakshi Avalahalli, P.O. Virgonagar, 3607 - 3609, GIDC Estate
Managing Director Bangalore 560049 Phase IV
UNITHERM ENGINEERS LTD Tel: 080-8510652, 8472229 Vatva
101, Laxmi Market, 1st Floor Fax: 080-8510652 Ahmedabad 382 445
Vartak Nagar Junction, Pokhran Road No 1 Email: eltrablr@hotmail.com Tel: +91-79-5831152 / 1449
Mumbai 400 606 Fax: +91-79-5832216
Tel: +91-22-5406131, 5371654, 5371655 High Efficiency Pumps Email:
Fax: +91-22-5406569 Sulzer Pumps India Ltd sysadmin@immpl.xeeahm.xeemail.com
Email: unitherm@vsnl.com No.9, MIDC, Thane Belapur Road
Dingha, HVAC
Mr. S. R. Babbar Navi Mumbai 400 708 Mr. Sandeep Saxena
Partner Tel: +91 22 790 4321 Manager
Wellmake Engineering Company Fax: +91 22 790 4306 Capital Enterprise
A-28,Mangolpuri Indl. Area, Email: sulpump@vsni.com 36 Industrial Estate
Phase-II, Mr Andre Schmitz MLN Regional Engineering College
New Delhi 110034 Allahabad 211002
Tel: 011-7018199, 7025409 HOC Driers Tel: 545362
Fax: 011-7019330 Managing Director Fax: 461775
ATLAS COPCO (INDIA) LTD Email: mall@vsnl.com
High alumina refractories Mahatma Gandhi Memorial Building
Mr V K Gopalakrishnan Netaji Subhas Road incinerators
Director Mumbai 400 002 Mr S M Jain
VRW INDUSTRIES LTD Tel: +91-22-796416 / 17 Vice President
No 15, Reddy Street Fax: +91-22-797928 ADOR TECHNOLOGIES LTD
Virugambakkam Email: r.suresh@atlascopco.com Plot No 53, 54 & 55
Chennai 600 092 F - II Block, MIDC Area, pimpri
Tel: +91-44-4838638 / 385 Mellcon Engineering Pvt Limited Pune 411 018
Fax: +91-44-4833153 B-297, Okhla Industrial Area Tel: +91-20-7470225, 7476009
Phase-1 Fax: +91-20-7470224 / 7358
High Efficiency Electric Motors New Delhi 110 020 Email: info@ador-technologies.com
Mr. Liakat Ali Tel: 011 – 6811727 / 6816103
Proprietor Fax: 011 – 6816573 / 6819151 Mr U V Rao
Premier Electric Company Director
Plot No.7, MVS Engineering Limited ALLIED CONSULTING ENGINEERS
12/2 Mathura Road, MVS House, E-24 PVT LTD
Faridabad 121002 East of Kailash Allied House
Tel: 0129-270858, 274311 New Delhi 110 065 Road No 1, chembur
Fax: 0129-270858 Tel: 011 - 6431908, 6436869 Mumbai 400 071
Fax: 011 - 6464994 Tel: +91-22-5284028
High Efficiency Electric Transformers Email: E-mail: mvs@terrysoft.com Fax: +91-22-5283805
Mr. Liakat Ali Email: ace@bom3.vsnl.net.in
Proprietor Puriflair India
Premier Electric Company 22, GIDC Estate Mr M K Sen
Plot No.7, P.B 790, Makarpura Managing Director
12/2 Mathura Road, Vadora 390 010 INCORPORATED ENGINEERS LTD
Faridabad 121002 Tel: 0265 – 642487 / 645248 D - 400, Gayatri
Tel: 0129-270858, 274311 Fax: 0265 – 644070 MIDC, Uran Phata
Fax: 0129-270858 Nerul
HT capacitors, Furnace duty capacitors Navi Mumbai 400 706
Mr. T. V. Joseph Mr. M.D. Killedar Tel: +91-22-7619352, 7619366
General Manager Manager (Works) Fax: +91-22-7619368
Transformers and Electricals Kerela Goa Capacitors Pvt. Ltd. Email: idvl@bol.net.in
Ltd.(TELK) 14, Corlim Industrial Estate,
Angamaly P.O. 683573, Corlim, Ilhas, Induction heaters
Angamaly 683573 Panaji 403110 Inventum engineering company
Tel: 04856-452251 Tel: 0832-286176/240 P O box 9435
Fax: 04856-452873 Fax: 0832-286203 Andheri (E)
Mumbai 400093
High efficiency power distribution & Humidifiers Tel: 022-26730499/ 590
special Transformers. Mr S V Mehta Fax: 022-26730887
Mr. Nitin Nayak Chairman & Director Email: inventun@vsnl.net.in
Director

List of Suppliers
640
Tel: +91-61-502508, 503898 Gandhi Nagar

Fax: +91-61-503898 Chennai 600 020
Industrial Ceramics Email: sanghi@cal2.vsnl.net.in Tel: +91-44-4996733 / 5654
Mr N Anjiah Fax: +91-44-4341668, 4996215
Managing Partner Aero therm systems pvt ltd Email: megatech@md2.vsnl.net.in
Annapurna Annapurna Technical ceramics Plot no 1517 Phase III
21-118 GIDC Vatwa Mr A N Sen
Kakani Nagar Aheemedabad 382445 Managing Director
Vaisag 534007 Tel: 079-5890158 AN INSTRUMENTS PVT LTD
Tel: code-507659: Fax: 079-5834987 59 - B, Chowringhee Road
Email: atceramics@hotmail.com Email: vadherad1@sancharnet.in 5th Floor
Kolkata 700 020
Industrial fans& blowers Instrumentation control systems Tel: +91-33-2402222, 2472509
Mr Arindom Mukherjee Mr P S Kumar Fax: +91-33-2806684
Chairman & Mg Director Managing Director Email: ani@cal.vsnl.net.in
ANDREW YULE & CO LTD ABB INSTRUMENTATION LTD
Yule House, 8, Dr Rajendra Prasad Sarani 14, Delhi Mathura Road Insulation
Kolkata 700 001 P O Amarnagar Lloyds Insulation
Tel: +91-33-2422796 / 8210 Faridabad 121 003 386, Veer Savarkar Marg
Fax: +91-33-2434721 Tel: +91-0129-5275592 / 3 / 7, 5276350 / 54 / Mumbai 400 025
Email: yulecp@cal2.vsnl.net.in 62 / 67 Tel: 022-4340876
Fax: +91-0129-5275019 / 466 Fax: 022-4376858
Industrial furnaces Email: bktl@giasdl01.vsnl.net.in
Mr U V Rao intermediate controller for compressed
Director Mr M L Anand air
Allied Consulting Engineers Pvt Ltd Chairman Mr Kiran C pande
Allied House ANAND CONTROL SYSTEMS PVT LTD Manager-Compressed air management
Road No 1, chembur D - 67/68, Sector VI solutions
Mumbai 400 071 Noida 201 301 Godrej & boyce manufacturing company ltd
Tel: +91-22-5284028 Tel: +91-118-4537395, 4554627 Pirojshanagar, Vikhroli
Fax: +91-22-5283805 Fax: +91-118-4533782 Mumbai-400079
Email: ace@bom3.vsnl.net.in Email: anandpwr@nda.vsnl.net.in Tel: 022-55962251-56
Fax: 022-55961525
Mr Anup Dasgupta Fisher Rosemount (India) Limited Email: hnd@godrej.com
Director D Wing, 2nd Floor
FIRE GASES & KILN (INDIA) PVT LTD Modern Mills Compound Inverter welding
156, Jodhpur Park Mahalaxmi Tejas Enterprises
Kolkata 700 068 Mumbai 400 011 C/5/72
Tel: +91-33-4730164 / 1289, 4728391 / 2 Tel: 91 22) 462 0462 Sahyadri Nagar
Fax: +91-33-4731540 Fax: (91 22) 462 0500 Charakop, Kandivili West
Mumbai 200067
Mr S L Mathur Libratherm Instruments Tel: 022-28678692
Managing Director 402, Diamond Industrial Estate Fax:
STEIN HEURTEY INDIA PROJECTS Ketki pada Road Email: sillweld@yahoo.co.in
PVT LTD Dahisar East
8/1, Middleton Row Mumbai 400068 Jet Tower-Induced draught without fan
Kolkata 700 071 Tel: 022-28960659 and Fills
Tel: +91-33-2260194, 2457484 / 89 Fax: 022-28963823 Mr Bhagwan Harani
Fax: +91-33-2443636, 2476655 Email: libratherm@vsnl.com Technical Director
Email: shipp@cal.vsnl.net.in Armec group
Mr. Prem Dua Armec house
Mr N M Sudharshan Director Tiny Industrial estate,Kondhwa (B)
Chief Operating Officer Puneet Industrial Controls Pvt. Ltd. Pune-411048
ELECTROTECHNIK 45 Community Centre, Tel: 020-6930218
“B” Wing, 9th Floor East of Kailash, Fax: 020-6930537
Parsn Complex New Delhi 110065 Email: armecbom@vsnl.com
Chennai 600 006 Tel: 011-6423328, 6419479
Tel: +91-44-8259437 Fax: 011-6423328 Kiln furniture systems
Fax: +91-44-8269617 Mr N G Manoharan
Mr P S Sridharan Managing Director
Mr R K Agrawal Managing Director Abref Private ltd
Chief Executive Officer MEGATECH CONTROL PVT LTD NO 32, Meeran Sahib street
EASTERN EQUIPMENT & ENGINEERS Alsha Complex Anna Salai
S - 14, Civil Township 51, 1st Main Road Chennai-600002
Rourkela 769 004

641
Tel: 044-28250074 Fax: 91-4344-276358/59

Fax: 044-28233486 Email: M F induction melting/holding furnace
Email: abref@snl.com Mr Mukesh B Bhandari
Electronics India Chairman & Mg Director
kilns No. 438, 4th Main Road ELECTROTHERM (INDIA) LTD
Mr M K Sen Nagendra Block Survey No 72
Managing Director BSK First Stage Village - Palodia
INCORPORATED ENGINEERS LTD Bangalore 560 050 Via Thaltej
D - 400, Gayatri Tel: 080 – 662 1836 Ahmedabad 382 115
MIDC, Uran Phata Fax: 080 – 662 1831 Tel: +91-2717-39953 to 57, 39613 to 15
Nerul Email: Fax: +91-2717-39616, 91-79-6740923
Navi Mumbai 400 706 Email: electrotherm@vsnl.com
Tel: +91-22-7619352, 7619366 Jindal Electric & Machinery Corp
Fax: +91-22-7619368 C-57, Focal Point, Maximum Demand Controller
Email: idvl@bol.net.in Ludhiana 141010 CMS ENERGY Management systems
Tel: 670250 / 670250 / 676968 W 324, Rabale MIDC
Mr Mithu S Malaney Fax: 0161 – 670252 Mumbai 400701
Chairman & Mg Director Email: Tel: 91-022-27696720,86
VULCAN ENGINEERS LTD Fax: 91-022-27694585
427, Unique Industrial Estate low energy consuming Portable
Off Veer Savarkar Marg Generators Medium frequency induction melting
Prabhadevi Mr. Wasim Javed and heating systems
Mumbai 400 025 Birla Yamaha Limited Mr D G Sastry
Tel: +91-22-4304529 / 3671 A-7, Ring Road, Managing Director
Fax: +91-22-4225814 N. D. S. E. Part - 1, PILLAR INDUCTION INDIA PVT LTD
Email: New Delhi 110049 A/13, 2nd Avenue
vulcan.engnr@vel.sprintrpg.ems.vsnl.net.in Tel: 011-4690352 to 54, 4691852 Anna Nagar
Fax: 011-4626188 Chennai 600 102
Mr Anup Dasgupta Email: Tel: +91-44-6261703 to 5
Director Fax: +91-44-6260189
FIRE GASES & KILN (INDIA) PVT LTD Low loss Power & Distribution Email: pillar@md2.vsnl.net.in
156, Jodhpur Park Transformers
Kolkata 700 068 Mr. Adrian J D’Souza Most energy efficient tube light systems-
Tel: +91-33-4730164 / 1289, 4728391 / 2 Director T5 Lamps
Fax: +91-33-4731540 Southern Power Equipment Company Mr . Suresh Dhingra
Email: 42, Yumkur Road, Executive Vice President
Yeshwanthpur, Asian Electronics
Bangalore 560022 Surya plasa
LED based medium intensity aviation Tel: 080-3372996, 3372741 First follr, K 185/1 Sarai Julena, new friends
obstruction light Fax: 080-3372997 colony
Binay opto electronics Private ltd Email: New Delhi-110025
44,Armenian street Tel: 011-26317232,26929073,26929075
Calcutta 700001 LT Power capacitors Fax: 011-26837406
Tel: 033-2429082,2103807 Mr. M.D. Killedar Email: aeldel@vsnl.com
Fax: 033-2421493 Manager (Works)
Email: info@binayled.com Goa Capacitors Pvt. Ltd. Motors
14, Corlim Industrial Estate, Mr Saroj Poddar
LED indicator modules Corlim, Ilhas, Chairman
Binay opto electronics Private ltd Panaji 403110 ALSTOM LTD
44,Armenian street Tel: 0832-286176/240 14th Floor, Pragati Devika Tower
Calcutta 700001 Fax: 0832-286203 6, Nehru Place
Tel: 033-2429082,2103807 Email: New Delhi 110 019
Fax: 033-2421493 Tel: +91-11-6449906, 6449907, 6449902 / 3
Email: info@binayled.com LUX METER AND HARMONIC Fax: +91-11-6449447
ANALYSER Email:
LIGHTING ENERGY SAVER / LIGHTING Mr Dilip Dharmasthal
TRANSFORMER Managing Director Mr S M Trehan
Mr S Raghavan Alacrity Electronics Limited Managing Director
Manager - Sales & Marketign “Suresh Mahal”, 12 - B
Beblec (India) Pvt. Ltd., Valmiki Street
126, Sipcot Indl.Complex T Nagar
Hosur 635 126 Chennai 600 017
Tel: 91-4344-276358/278658/276958/276959 Tel: 044 - 823 6620
Fax: 044 - 825 9406

List of Suppliers
642
CROMPTON GREAVES LTD Email: eaplindia@vsnl.com

1, Dr V B Gandhi Marg oil/gas burners,
Mumbai 400 001 Mr. Dinesh Harjai Mr Balagopal Karat
Tel: +91-22-2657937 (Direct) Partner Executive Director
Fax: +91-22-2653740 (Direct), 2028025, Crupp Metals SPA ENGINEERING COMPANY LTD
2625814 Kh. No. 56/1, Mundka, 114, 3rd Floor, M G Road
Email: kkn@cgl.co.in Rohtak Road, Bangalore 560 001
New Delhi 110041 Tel: +91-80-5267981
Mr M V Srisha Tel: 011-5189024, 5474133 Fax: +91-80-5260818
General Manager - FA Fax: 011-5183085
Fanuc India Limited Pneumatic Tools
NO. 41, Electronic City Ovens Dr Jairam Varadaraj
KEONICS Mr N Gopinath Managing Director
Bangalore 561 229 Managing Director ELGI EQUIPMENT LTD
Tel: 080-8520057 / -0109 FLUIDTHERM TECHNOLOGY PVT LTD Elgi Industrial Complex, Trichy Road
Fax: 80-852-0051 SP - 132, III Main Road Singanallur P O
Ambattur Industrial Estate Coimbatore 641 005
Mr. R Vijayraghavan Chennai 600 058 Tel: +91-422-574691 to 5
Managing Director Tel: +91-44-6357390, 6357391 Fax: +91-422-573697
INTEGRATED ELECTRIC CO (P) LTD. Fax: +91-44-6257632 Email: investor@elgi.jet.co.in
66 A, GROUND FLOOR, Email: fluidtherm@vsnl.com
ALSA REGENCY Portable Engines & Water Pumping Sets
165,ELDAMS ROAD, ALWARPET, Mr M Gopal Mr Sanjeev Govil
Chennai 600018 Managing Director General Manager-marketing
Tel: 080-8362465 / 2047 / 2785 / 2793 / 2465 HIGHTEMP FURNACES LTD Honda Siel Power products ltd
I - C, Phase II, P B No 5809 5th Floor, Kirthi Mahal Building
Multi effect evaporator Peenya Industrial Area 19, Rajendra Palace
Praj Industries Bangalore 560 058 New Delhi-110008
Praj house Tel: +91-80-8395917 / 4076 / 1446 Tel: 011-25739103-05
Bavdhan Fax: +91-80-8397798 / 2661 Fax: 011-2572218, 25753652
Pune 411021 Email: hightemp@vsnl.com Email: ho.mktg@hspp.com
Tel: 020-2951511/2214 Portable Gensets,
Fax: 020-2951718/2951515 Mr Mithu S Malaney Mr Sanjeev Govil
Email: cthe@praj.net Chairman & Mg Director General Manager-marketing
VULCAN ENGINEERS LTD Honda Siel Power products ltd
NEUTRAL COMPENSATOR 427, Unique Industrial Estate 5th Floor, Kirthi Mahal Building
Static Transformers (P) Ltd Off Veer Savarkar Marg 19, Rajendra Palace
G-4, A/D, Industrial Estate Prabhadevi, Mumbai 400 025 New Delhi-110008
Polo Ground Tel: +91-22-4304529 / 3671 Tel: 011-25739103-05
Indore 452 015 Fax: +91-22-4225814 Fax: 011-2572218, 25753652
Tel: 0731 - 420 793, 420 859 Email: Email: ho.mktg@hspp.com
Fax: 0731 - 431 968, 420793 vulcan.engnr@vel.sprintrpg.ems.vsnl.net.in
Email: static@sancharnet.in Power & control cables
Plate & spiral heat exchangers,dryers & Mr Y Kamesh
Oil coolers evaporators Managing Director
Mr Mohammed Meeran Mr Satish Tandon GEM CABLES & CONDUCTORS LTD
Proprietor Managing Director No 1, Badam Sohana Apartments
AASIA RADIATORS ALFA LAVAL (INDIA) LTD Raj Bhavan Road
P S C Bose Road Mumbai Pune Road Somajiguda
Jawahar Autonagar Dapodi Hyderabad 500 082
Vijayawada 520 007 Pune 411 012 Tel: +91-40-3310486, 3395970
Tel: +91-0866-543881 Tel: +91-0212-27127721 Fax: +91-40-3313486
Fax: +91-0866-545860 Fax: +91-02121-2797711 Email: gemcable@hd1.vsnl.net.in
Email: satish.tandon@alfalaval.com
OIL FIRED THERMOPAC/AQUATHERM Power & Distribution Transformers
SYSTEM PLC Mr R R Dhoot
Thermax Limited Mr Madhav P. Kamat Chairman
Thermal Engg. Division Managing Director IMP POWER LTD
Chinchwad Electronic Automation Pvt. Ltd. Advent, 7th Floor
Pune 411 019 No. 20, K.H.B Industrial Area, 12 - A, General J Bhosale Marg
Tel: 020 - 775 941 to 49 Yelanhanka Nariman Point
Fax: 020 - 775 907 Banglore-560064 Mumbai 400 021
Tel: 080-8567561-562,8567161 Tel: +91-22-2021890 / 886 / 697
Fax: 080-8567129 Fax: +91-22-2026775

643
Email: contactus@imp-power.com Email: corporate@bellscontrols.com

Mr. S. Dasgupta Power control equipments, Mr Amod Gujral
Sr. Mktg. Manager Mr A Sarkar Managing Director
Marson’s Limited Vice President Encardio-Rite Electronics Pvt Ltd
18, Palace Court, SCHNEIDER ELECTRIC INDIA LTD A - 7, Industrial Estate, Talkatora Road
1, Kyd Streeet, 58, MIDC Area, Satpur Lucknow 226 011
Calcutta 700016 Nashik 422 007 Tel: +91-522-416460, 418855
Tel: 033-297346, 2264482 Tel: +91-253-350394 / 95 / 96 Fax: +91-522-418968
Fax: 033-2263236 Fax: +91-253-350771 Email: sales@encardio.com
Email: asarkar@pobox.com
power & energy monitor Mr P V Kannan
Mrs Hema Hattangady Power factor compensation Managing Director
Managing Director Neptune India ltd MICROMAX SYSTEMS LTD
Enercon Systems Pvt Ltd. Neptune house 104, Salai Road
23, KHB Light Industries Area C 270 SFS Sheikh sarai, Phase I Sethu Rukmani Complex
P B No.6418, Yelahanka New Delhi 110017 Trichy 620 003
BangaloreHL Tel: 011-6013367-70 Tel: +91-431-760704
Tel: 080 – 8460666 / 8460555 Fax: 011-6013371 Fax: +91-431-762422
Fax: 080 – 8460667 Email: neptune@del2.vsnl.net.in Email: micromax@pv.dot.net.in
Email: marketing@enercon.co.in
Power Factor controller Mr K N Balaji
Power and control cables CMS ENERGY Management systems Chief Operating Officer
Mr Hiten A Khatau W 324, Rabale MIDC Eurotherm Del India Ltd
Chairman & Mg director Mumbai 400701 152, Developed Plots Estate
CABLE CORPORATION OF INDIA LTD Tel: 91-022-27696720,86 Perungudi
Laxmi Building, 4th Floor Fax: 91-022-27694585 Chennai - 600 096
6, Shoorji Vallabhdas Marg Tel: 044-4961129
Ballard Estate Mr. R. K. Iyer Fax: 044-4961831
Mumbai 400 001 Vice President Email: sales@eurothermdel.com
Tel: +91-22-2666764 Saha Sprague Limited
Fax: +91-22-2632694 No.805, North Rear Wing, 8th Floor, Manipal Mr N C Agrawal
Centre, 47, Dickenson Road, Managing Director
Power capacitors Bangalore 560042 MEDITRON
Mr. M.D. Killedar Tel: 080-5595463, 5595266 SIRTDO Industrial Estate
Manager (Works) Fax: 080-5595463 P O BIT, Mesra
Goa Capacitors Pvt. Ltd. Ranchi 835 215
14, Corlim Industrial Estate, Power plant & industrial cooling towers Tel: +91-651-275875 / 628
Corlim, Ilhas, Mr. N. Venkatanarayanan Fax: +91-651-275841
Panaji 403110 Managing Director Email: meditron@dte.vsnl.net.in,
Tel: 0832-286176/240 Enviro Clean Systems Ltd. jyoti@dte.vsnl.net.in
Fax: 0832-286203 Hema Nagar, P.O.Box No.10,
P.O. Uppal, Program logic control (PLC)
Mr. Shantilal H. Karani Hyderabad 500039 Mr Laxman R Katrat
Owner Tel: 040-7170876/879/881 Mg Director & CEO
Malde Capacitors Manufacturing Company Fax: 040-7172717/4726 KATLAX ENTERPRISES PVT LTD
401,Madhav Apt, Jawahar Rd, 507, Golden Triangle
Opp. Rly.St, Ghatkopar (E), Power plant equipment Stadium Road
Mumbai 400077 Mr Pradeep Mallick Ahmedabad 380 014
Tel: 022-5168283/84 Managing Director Tel: +91-79-6461991 / 646, 6854693,
Fax: 022-5160758 WARTSILA INDIA LTD 6851521
76, Free Press House, Nariman Point Fax: +91-79-6464719 (W), 6853978
Power Consultants Mumbai 400 021
Mr D B Arora Tel: +91-22-2815601 / 5598, 28175995 / 5601 Programmable controllers
Managing Director Fax: +91-22-2842083 Mr Ranjan Kumar De
Acon Power consultants Email: pradeep.mallick@wartsila.com Country Manager
45, Satyanand Vihar ALLEN BRADLEY INDIA LTD
Rampur Process control instruments C - 11, Industrial Area
Jabalpur-482008 Mr Sudhir Jalan Site IV,shahiabad
Tel: 91-0761-2667261, 9826246688 Chairman & Mg Director Ghaziabad 201 010
Fax: 91-0761-2664207 BELLS CONTROLS LTD Tel: +91-120-471112 / 0103 / 0105 / 0164
Email: acon@sancharnetin Bells House, 21, Camac Street Fax: +91-120-4770822
Kolkata 700 016 Email: msseshadri@ra.rockwell.com,
Tel: +91-33-2475211 / 15 rnm@raabil.com
Fax: +91-33-2471620

List of Suppliers
644
Reactive power compensation Mr I C Sinha

Pumps equipment and systems Managing Director
Mr D K Hohenstein Mr. S. M. Subba Rao BURN STANDARD CO LTD
Chief Executive Officer Adviser 10 - C, Hungerford Street
KSB PUMPS LTD Meher Capacitors (P) Ltd. Kolkata 700 017
Mumbai Pune Road 52/1, Basappa Road, Tel: +91-33-2471772 / 067 / 762
P O Pimpri Shantinagar, Fax: +91-33-2471788
Pune 411 018 Bangalore 560027 Email: bsclh@giasc101.vsnl.net.in
Tel: +91-20-7472006, 7473684 Tel: 080-2236879, 2241272
Fax: +91-20-7476120 Fax: 080-2225325 Mr Kantilal Gugalia
Email: hohensteindk@ksb.co.in Chief Executive
Reactors KATNI TILE WORKS
Mr K C Dhingra Mr Ranjit Puri P B No 62
Managing Director Chairman & Mg Director Katni 483 501
WESTERN INDIA MACHINERY CO PVT INDIAN SUGAR & GENERAL Tel: +91-7622-52682, 53212, 50894
LTD ENGINEERING CORPORATION (THE) Fax: +91-7622-52733
Park Plaza A - 4, Sector 24
North Block, 6E, 6th Floor Noida 201 301 Mr M L Chand
71, Park Street Tel: +91-118-4524071 / 72 Executive Director
Kolkata 700 016 Fax: +91-118-4528630, 4529215, 4542072 OCL INDIA LTD
Tel: +91-33-2468913 / 9674 Email: rp@isgec.com Rajgangpur,
Fax: +91-33-2468914 Dist. Sundergarh 770 017
Reciprocating & centrifugal pumps Tel: +91-6624-220121 (4 lines)
radiant heater Mr Hemant Didwania Fax: +91-6624-220933 / 133 / 733
Mr. Ashok Tanna Director Email: ocl_refractories@oclindia.com
Managing Director INDIAN COMPRESSORS LTD
Vinosha Boilers Pvt. Ltd. And Taurus Heat 33, Okhla Industrial Estate Mr Arun Bhalotia
Systems New Delhi 110 020 Managing Director
Baarat House, Ist Floor, Tel: +91-11-6839440 / 9, 635030 TATANAGAR REFRACTORIES &
104, Apollo Street, Fort, Fax: +91-11-6840020 MINERALS CO LTD
Mumbai 400001 Chamber Bhawan
Tel: 022-2674590, 2676447 Recuperators Bistupur
Fax: 022-2611515 Mr R K Agrawal Jamshedpur 831 001
Chief Executive Officer Tel: +91-657-427187, 435039, 428044
RADIANT TUBE RECUPERATIVE EASTERN EQUIPMENT & ENGINEERS Fax: +91-657-428044
HEATER S - 14, Civil Township
Mr U V Rao Rourkela 769 004 Mr K S Swaminathan
Director Tel: +91-61-502508, 503898 Mg Director & Vice Chairman
ALLIED CONSULTING ENGINEERS Fax: +91-61-503898 TATA REFRACTORIES LTD
PVT LTD Email: sanghi@cal2.vsnl.net.in P O Belapur
Allied House Jharsuguda 768 218
Road No 1, chembur Refractoreis Tel: +91-6645-50260
Mumbai 400 071 Mr.R.Rajagopalan Fax: +91-6645-50243
Tel: +91-22-5284028 Dy.General Manager
Fax: +91-22-5283805 Carborundum Universal Limited-Super Daka Monolitics Pvt. Ltd.
Email: ace@bom3.vsnl.net.in Refractories 32-B, Samachar Marg
Plot Nos.102&103,Sipcot Industrial Complex Opp. Allahabad Bank
Thermax Limited Phase II Mumbai 400 023
Thermal Engg. Division Ranipet-632403 Tel: 044 - 265 4837
Chinchwad Tel: 04172-244197,244951,244582
Pune 411 019 Fax: 04172-244982 Refrigeration Dryers.
Tel: 020 - 775 941 to 49 Email: rgopal@ho.cumi.co.in Mr. Rajnish Joshi
Fax: 020 - 775 907 Exe. Vice President
Mr N anjiah Delair India Pvt. Ltd.
Reactive compensator Managing Partner 20, Rajpur Road,
Emco Electronics Annapurna Annapurna Technical ceramics New Delhi 110054
106, Industrial area 21-118 Tel: 011-2912800
Sion (East) Kakani Nagar Fax: 011-2915127, 2521754
Mumbai 400022 Vaisag 534007 Email: bryair@nda.vsnl.net.in
Tel: 022-24096731/782 Email: atceramics@hotmail.com
Fax: 022-24096039

645
Rotary kilns Separator and other oil & gas Mr. K. W. Kekane
Mr Madhukar Sinha processing equipments Director Sales
Managing Director Mr A D Parekh Minilec Marketing Services Pvt. Ltd.
Associated Plates & Vessels Pvt Ltd 1/A - General Manager S.No. 1073/1-2-3, At. Post. Pirancoot,
14, 15 & C - 17, Industrial Area HDO PROCESS EQUIPMENT AND Tal. Mulshi,
Bokaro Steel City, Bokaro 827 104 SYSTEMS LTD Pune 412111
Tel: +91-6542-51034, 51434 5/1/2, GIDC Industrial Estate Tel: 02139-22162, 22354 to 57
Fax: +91-6542-51334 Vatva Fax: 02139-22134, 22180
Email: apvpl@dte.vsnl.net.in, Ahmedabad 382 445
msinha32@hotmail.com Tel: +91-79-5830591 to 94 Mr Ranjan Kumar De
Fax: +91-79-5833286 Country Manager
Rotometers Email: patfilt@ad1.vsnl.net.in ALLEN BRADLEY INDIA LTD
AQUAMEAS (Danfoss) C - 11, Industrial Area
Commerce avenue, 3rd floor, Servo voltage stabiliser Site IV,shahiabad
Mahaganesh SOC., Paud Road Green Dot electric corporation Ghaziabad 201 010
Pune 411 038 G 9, Hem Kunt Tower Tel: +91-120-471112 / 0103 / 0105 / 0164
Tel: +020 544 9767, 544 9757 98, Nehru Place, Fax: +91-120-4770822
Fax: +020 542 0401 New delhi 100019 Email: msseshadri@ra.rockwell.com,
Email: aquameas@vsnl.net Tel: 011-26416395 rnm@raabil.com
Fax: 011-26222088
EUREKA INDUSTRIAL EQUIPMENTS Email: greendotindia@hotmail.com Crompton Greaves Limited
PVT. LTD. Electronics Technology Div.
Royal Chambers, Paud Road, Slip Power Recovery Systems 71 / 72, MIDC, Satpur
Pune 411038 Mr A M Naik Nashik 422 007
Tel: 91 20 5443079 / 4004535/ 4004554 Mg Director & CEO Tel: 0253 - 351 069
Fax: 91 20 5441323 LARSEN & TOUBRO LTD Fax: 0253 - 351 492
L & T House Email:
Fitzer Instruments (India) Pvt. Ltd. Ballard Estate
Near Ambivli Station (W) Mumbai 400 001 Mr. Sudhir Naik
P.O. Mohone Tel: +91-22-2618181 Vice President - Corporate Mktg.
Thane 421 102 Fax: +91-22-2620223, 2610396, 2622285 Hi-Rel Electronics Limited
Tel: 0251 – 2271321 Email: amn@lth.ltindia.com B -117 & 118, GIDC,
Fax: 0251 – 2271336 Electronics Zone, Sector-25
Email: fitzer@bom7.vsnl.net.in Mr J Schubert Gandhi Nagar 382044
Managing Director Tel: 02712-21636, 22531
SCADA System for Energy management SIEMENS LTD Fax: 02712-24698
Mr. Shashank Kalkar 130, Padurang Budhkar Marg
Director Marketing Worli Project & Supply
RMS Automation Systems Pvt. Ltd. Mumbai 400 018 A - 605, Sunswept
W-218, M.I.D.C., Tel: +91-22-4931350 / 60 okhandawala Complex
Ambad, Fax: +91-22-4950552 Swami Samarth Nagar, 4, Bungalow,
Nasik 422010 Email: Andheri (West)
Tel: 0253-383261, 384604 Mumbai 400 050
Fax: 0253-383261, 384604 Smart demand controller Tel: 022 - 626 6584
Mrs Hema Hattangady
Screw compressors Managing Director Vrushali Services
Mr Jasmohan Singh Enercon Systems Pvt Ltd. 5, Swapna Nagar, Hanuman Nagar,Near
Managing Director 23, KHB Light Industries Area DNC High School
FRICK INDIA LTD P B No.6418, Yelahanka Nandivli Road, Dombivli (East)
21.5 KM, Main Mathura Road BangaloreHL -Mumbai- 421 201
Faridabad 121 003 Tel: 080 – 8460666 / 8460555 Tel: 0251 – 472 426
Tel: +91-129-5275691 (4 lines), 5270546 Fax: 080 – 8460667 Fax: 0251 – 431 151
Fax: +91-129-5275695 Email: marketing@enercon.co.in
Email: jasmohan@frick.co.in Software for promoting energy
Soft starter conservation
Sections & blocks for thermal insulation Excellent Industrial Instruments Mr. Rahul S. Walawalkar
Mr Shreyas C Sheth 1/63, Type E Product Manager - Eco Lumen & Manager
Managing Director Sidco Nagar Tata Infotech Ltd.
AMOL DICALITE LTD Villivakkam Manish Commercial Centre,
301, Akshay Chennai 600049 216-A, Dr. Annie Besant Rd., Worli,
53, Shrimali Society,’Navrangpura Tel: 044-6172977 Mumbai 400025
Ahmedabad 380 009 Fax: 044-6172531 Tel: 91 22 8291261
Tel: +91-79-6443331, 6560458 Fax: 91 22 8290214
Fax: +91-79-6569103

List of Suppliers
646
Software to measure the efficiency of star -delta-star converter SYNTHETIC FLAT BELTS
motors Mr M Vijayasarathy Elgi Ultra Industries Ltd.
Mr Narayana Sharma Managing Director ‘Elgi House’, Trichy Road
Director VIJAY ENERGY PRODUCTS PVT LTD Ramanathapuram
V B India S P - 75, Ambattur Industrial Estate Coimbatore 641 045
# 1032, 14th main, 7th cross Chennai 600 058 Tel: 0422 – 304141
BTM lay out Tel: +91-44-6254326, 6256883 Fax: 0422 - 311 740
1st stage, 1st cross Fax: +91-44-8282906, 6255185
Bangalore 560029 Email: vijayenergy@eth.net Habasit Iakoka Pvt. Ltd.
Tel: +91 (80) 6781315 C - 207, Kailas Esplanade
Fax: 91-080-6687798 Ambetronics Opp. Shreyas Cinema
Email: vbindia@vsnl.com 4B Pushotam L B S Marg, Ghatkopar
Girgaon Mumbai 400 086
Soot Blower with Industrial Boilers Near Dream Land Cinema Tel: 022 - 500 2464
Mr. R. Rajshekhar Mumbai 400004 Fax: 022 - 500 2466
Managing Director Tel: 022-28371143
R R Techno Mechanicals (P) Ltd. NTB group
94, Thiru Vi Ka Industrial Estate, Excellent Industrial Instruments NTB House, A-302
Guindy, 1/63, Type E, Sidco Nagar Road No.32, Wagle Estate,
Chennai 600032 Villivakkam Thane 400 604
Tel: 044-2346693 Chennai 600049 Tel: (091)-22-5822118,5821582
Fax: 044-4918183, 2333204 Tel: 044-6172977 Fax: 58100565823778
Email: Fax: 044-6172531
NTB International ltd
Sound proof gensets Steam jet ejectors A 302, Road no 32
Mr R N Khanna Forbes Marshall Wagle estate
Managing Director PB No 29, Mumbai-Pune road Thane 400604
CONTROLS & SWITCHGEAR CO LTD Kasarwadi Tel: 022-25821582, 25822118
222, Okhla Industtrial Estate Pune 411034 Fax: 022-25810056
New Delhi 110 020 Tel: 91-0212-21279445 Email: ntbgroup@vsnl.com
Tel: +91-11-6918834 to 37, 6836170 / 020 Fax: 91-0212-797413
Fax: +91-11-6848241 / 7342 / 8245 Systems engineering for captive power
Email: cs222@giasdl01.vsnl.net.in MAZDA CONTROLS LTD generation
MAZDA HOUSE Mr D R Dhingra
Speciality Refrigerants/Propellants ANCHWATI 2ND LANE, AMBAWADI Managing Director
K.Ganesh AHMEDABAD 380006 CONTINENTAL GENERATORS PVT LTD
Marketing Manager(South Asia)Regional Tel: 79 6431151 3869, Behind Primary School, G B Road
Segment Manager Fax: 79 6565605 Delhi 110 006
Dupont Flurochemicals E.I.DuPont India Ltd Tel: +91-11-7535566 to 68, 525632, 522983,
Arihant Nitco Park,^th Floor STEAM TRAP MONITOR 528510
90,Dr.Radha Krishnan Road Spirax Marshall Limited Fax: +91-11-7516598, 528510
Mylapore P B No.29, Mumbai-Pune Road
chennai 600004 Kasarwadi,Pune 411 034 TEMPERATURE INDICATOR
Tel: 044-8472800,8473752(D) Tel: 020 - 794 495 CONTROLLER (TIC)
Fax: 044-8473800 Fax: 020 - 797 593/ 413 Ensave Systems Private Limited
Email: k.ganesh@ind.dupont.com 3, Anand Shopping Center
Steel tubes for boilers Second Floor, Bhattha, Paldi
split air conditioner Tube Products of India Ahmedabad 380 007
Mr Brij Raj Punj Post Box No. 4, Avadi Tel: . 079 – 662 1116
Chairman Chennai 600 054 Fax: 079 – 663 7907
LLOYD ELECTRIC & ENGINEERING Tel: 91 44 6384040
LTD Fax: 91 44 6384051 Thermal power equipment including
M - 13A, Punj House Email: SatianathP@murugappa.co.in steam turbines
Connaught Place Mr K G Ramachandran
New Delhi 110 001 Superheater & Economiser Chairman & Mg Director
Tel: +91-11-3329091 to 98 Mr Ranjit Puri BHARAT HEAVY ELECTRICALS LTD
Fax: +91-11-3326107 Chairman & Mg Director BHEL House
Email: lloyd@giasdl01.vsnl.net.in INDIAN SUGAR & GENERAL Siri Fort
ENGINEERING CORPORATION (THE) New Delhi 110 049
A - 4, Sector 24 Tel: +91-11-6001010
Noida 201 301 Fax: +91-11-6493021, 6492534
Tel: +91-118-4524071 / 72
Fax: +91-118-4528630, 4529215, 4542072
Email: rp@isgec.com

647
Thermic filud heaters TRANSVECTOR NOZZLES Variable Drives,

Aero therm systems pvt ltd General Imsubs Pvt. Ltd. Mr. Liakat Ali
Plot no 1517 Phase III 3711/A, GIDC Proprietor
GIDC Vatwa Phase IV, Vatva Premier Electric Company
Aheemedabad 382445 Ahmedabad 382 445 Plot No.7,
Tel: 079-5890158 Tel: 079 - 584 0845/ 2503 12/2 Mathura Road,
Fax: 079-5834987 Fax: 079 - 584 1846 Faridabad 121002
Email: vadherad1@sancharnet.in Email: info@giplindia.com Tel: 0129-270858, 274311
Fax: 0129-270858
Thyristorised Power factor Controller S J United
Mr. Shashank Kalkar 300/ 1-B, 16th Cross Variable fluid couplings
Director Marketing Upper Palace Orchards Mr Praveen Sachdev
RMS Automation Systems Pvt. Ltd. Bangalore 560 080 Mg Director & CEO
W-218, M.I.D.C., Ambad, GREAVES LTD
Nasik 422010 Trivector monitor 1, Dr V B Gandhi Marg
Tel: 0253-383261, 384604 Mrs Hema Hattangady P O Box 91
Fax: 0253-383261, 384604 Managing Director Mumbai 400 001
Enercon Systems Pvt Ltd. Tel: +91-22-2671524 / 4913
Transformer 23, KHB Light Industries Area Fax: +91-22-2677850, 2652853
Mr Saroj Poddar P B No.6418, Yelahanka Email:
Chairman BangaloreHL
ALSTOM LTD Tel: 080 – 8460666 / 8460555 Variable Frequency Drive
14th Floor, Pragati Devika Tower Fax: 080 – 8460667 Mr Ramnath S Mani
6, Nehru Place Email: marketing@enercon.co.in Managing Director
New Delhi 110 019 CONTROL TECHNIQUES INDIA
Tel: +91-11-6449906, 6449907, 6449902 universal power & energy meter LIMITED
Fax: +91-11-6449447 Mrs Hema Hattangady 117/B, Developed Plot
Managing Director Industrial Estate
Mr G V Rao Enercon Systems Pvt Ltd. Perungudi
CMD 23, KHB Light Industries Area Chennai 600 096
Rowsons Marketing Pvt Ltd P B No.6418, Yelahanka Tel: 044-4961123 / 1130 / 1083
4, 7 th Street Gopalapuram BangaloreHL
Madras 600 086 Tel: 080 – 8460666 / 8460555 Mr. Balagopal
Tel: 044 - 28110196/28112958 Fax: 080 – 8460667 Managing Director
Fax: 044 - 2815741/28114021 Email: marketing@enercon.co.in Dynaspede Integrated Systems (P) Limited
Email: rowgvc@giasmd01.vsnl.net.in 136-A Sipcot Industrial Complex
Vaccum Pumps Hosur 635126
Mr N J Danani Kakati Karshak Industries Pvt. Ltd Tel: 91-4344 - 276915, 276813
Vice Chairman & Mg Director Nacharam Industrial Area Fax: 91-4344 - 276841
BHARAT BIJLEE LTD Hyderabad 500 076
Central Marketing Office (Motor) Tel: 91-40-7153104/05 Dr M T Sant
P O Box 100, Kalwe, Thane Belapur Road Fax: 91-040-7171980 President
Mumbai 400 601 Email: cvrao@hd1.vsnl.net.in TB Wood’s (India) Pvt Ltd
Tel: +91-215-7691656 27A, II Cross, Electronics City
Fax: +91-215-7691401 / 2 Nash vaccum pumps Hosur Road
67 UPS, Kaggadaspura Extension Banglore 561229
Mr Rahul N Amin Guru Layout Tel: 080 8520123
Chairman & Mg Director Bangalore Fax: 080 8520124
JYOTI LTD Tel: (+91) 80 - 521 49 38 Email: tbwindia@tbwoods.com
Industrial Area, P O Chemical Industries Fax: (+91) 80 - 528 43 37
Vadodara 390 003 Email: nashwater@mantraonline.com
Tel: +91-265-380633, 380627
Fax: +91-265-380671, 381871 PPI PUMPS PVT LTD
Email: cmd.jyoti@sm3.sril.in 4/2 PHASE 1 G I D C VATWA
AHMEDABAD 382445
Mr Sylvester P Moorthy Tel: 079-5832273/4 / 5835698
General Manager Fax: 079-5830578
MEASUREMENT SYSTEMS PVT LTD
66, 4th Main Road
Industrial Town
Rajajinagar
Bangalore 560 044
Tel: +91-80-3300347 / 494 / 522
Fax: +91-80-3303141

List of Suppliers
648
Tel: code-4895247-252 Balanagar

Mr Ranjan Kumar De Fax: 4895225-227 Hyderabad 500 037
Country Manager Email: dghosh@ra.rockwell.com Tel: +91-40-3773235 / 2343
ALLEN BRADLEY INDIA LTD Fax: +91-40-3772343 / 3235
C - 11, Industrial Area Mr J Schubert Email: avuhyderabad@rediffmail.com
Site IV,shahiabad Managing Director
Ghaziabad 201 010 SIEMENS LTD Cristopia Energy systems
Tel: +91-120-471112 / 0103 / 0105 / 0164 130, Padurang Budhkar Marg 303, Kothari Manor
Fax: +91-120-4770822 Worli NO 10, Diamon colony
Email: msseshadri@ra.rockwell.com, Mumbai 400 018 New Palasia
rnm@raabil.com Tel: +91-22-4931350 / 60 Indore 452001
Fax: +91-22-4950552 Tel: 91-0731-2433644, 2536624
Email: Fax: 91-0731-2533766
Email:
Asea Brown Boveri ltd Waste Heat Recovery Ensys Technologies (I) Pvt. Ltd.
Plot No 5 & 6, II Phase Mr U V Rao B/69-A, Seventh Avenue
Peenya Industrial Area Director Ashok Nagar
P B no 5806, Peenya ALLIED CONSULTING ENGINEERS Chennai 600 083
Bangalore 560058 PVT LTD Tel: 044 - 3711259/ 297
Tel: 080-8370416 / 8394734 extn 2322 / Allied House Fax: 044 – 4897752
6691375 Road No 1, chembur
Fax: 080-8399178 / 8396537 Mumbai 400 071
Tel: +91-22-5284028 Mr C E Fernandes
Fax: +91-22-5283805 Chairman & Mg Director
Mr S M Trehan Email: ace@bom3.vsnl.net.in GEI HAMON INDUSTRIES LTD
Managing Director 26 - A, Industrial Area
CROMPTON GREAVES LTD Mr Robert A Childs Govindpura
1, Dr V B Gandhi Marg Managing Director Bhopal 462 023
Mumbai 400 001 DEUTSCHE BABCOCK POWER Tel: +91-755-586692, 586922, 587147
Tel: +91-22-2657937 (Direct) SYSTEMS LTD Fax: +91-755-587678, 586619
Fax: +91-22-2653740 (Direct), 2028025, 18 / 2A, Sennerkuppam Email: geil@bom6.vsnl.net.in
2625814 By - Pass Road
Email: kkn@cgl.co.in Poonamallee
Chennai 600 056 Mr B S Adishesh
Tel: +91-44-4985949 / 1250 Wholetime Director
Mr. Sudhir Naik Fax: +91-44-4992221 IAEC INDUSTRIES MADRAS LTD
Vice President - Corporate Mktg. Email: dbbmds@giasmd01.vsnl.net.in Rajamangalam
Hi-Rel Electronics Limited Villivakkam
B -117 & 118, GIDC, Kuppuraju K Chennai 600 049
Electronics Zone, Sector-25 President-Technical Tel: +91-44-655725, 6257783
Gandhi Nagar 382044 CetharVessels Pvt ltd Fax: +91-44-4451537, 4995762
Tel: 02712-21636, 22531 4,Dindigul road, Email: iaec.mds@elnet.ems.vsnl.net.in
Fax: 02712-24698 tiruchirappilly
Email: Tel: 0431-482452/53 Megatherm Engineers & Consultants Pvt.
mktg.hrcl@hirel.sprintrpg.ems.vsnl.net.in Fax: 0431-481079 Ltd.
Email: try_cvltry@sanchar.com 10, Kodambakkam High Road
Mr. K. W. Kekane Chennai 600 034
Director Sales Waste Heat Recovery Recuperators Tel: 044 - 823 3528/ 3707
Minilec Marketing Services Pvt. Ltd. Mr R P Sood Fax: 044 - 825 8559
S.No. 1073/1-2-3, At. Post. Pirancoot, Managing Director
Tal. Mulshi, ENCON FURNANCES PVT LTD Mr. M. M. Narang
Pune 412111 14/6, Mathura Road Proprietor
Tel: 02139-22162, 22354 to 57 Faridabad 121 003 Membrane India
Fax: 02139-22134, 22180 Tel: +91-129-274408, 275307 / 607 347, Udyog Vihar, Ph.-II,
Fax: +91-129-276448: Gurgaon 122016
Mr Debashish Ghosh Tel: 0124-341159
Manager -commercial marketing products Waste Heat Recovery system Fax: 0124-342717
Rockwell Automation Mr K C Rana
C II, Site IV, Managing Director
Sahibabad Industrial Area AVU ENGINEERING PVT LTD
Ghaziabad dist-201010 A - 15, APIE

649
WHR boilers
Mr P V Raju
Managing Director
Thermal Systems (Hyd) Pvt. Ltd.
Plot No.1, Apuroopa Township
IDA, Jeedimetla
Hyderabad 500 055
Tel: 040 - 309 8272/ 8273
Fax: 040 - 309 7433
Email: thermal@hd2.dot.net.in

Energy Auditors
List of Suppliers
650
1 Confederation of Indian Industry ALL TYPES

35/1, Abhiramapuram 3rd Street
Alwarpet
Chennai - 600018
2 National Productivity Council ALL TYPES

5/6, Institutional Area
Utpadaka Bhawan, Lodi Road
New Delhi-110003
3 The Energy & Resources Institute All types

Darbari Seth Block
Habibat Place, Lodi Road
New Delhi-110003
4 National Council for Cement and Cement

Building materials p-121,
South Extension Part II Ring Road, New Delhi-110019
5 Cement Corporation of India Cement Plants

59, Nehru Place, New Delhi-110019
6 National Sugar Institute Sugar

Ministry of Food & Civil Supplies
Department of Food
Kanpur
7 Engineers India Ltd. Chemical & Process

Engineers India Bhawan
1, Bhikaji Cama Place
R.K.Puram, New Delhi-110066
8 M/s, North India Technical Consultancy Thermal Audits in Paper &

Organisation Ltd. S.C.O 131-132
(1st Floor) Sector 17-C, Chandigarh-160017
9 Dy. National Project Director Process Industries All types

PHD chamber of Commerce & industry
Ramakrishna Dalmia Wing, PHD House, Thaper Floor,
Opp. Asian Games
Village New Delhi-110020

651
10 M/s. SGS India limited Electrical & Thermal

210,Netaji Subhash Road
New Delhi-110020
11 Balmer Lawrie & Company Ltd. All types

21,Netaji Subhash Road
Calcutta-700001
12 Project & Development India Ltd. Fertilizer

P.O.Sindri, Distt. Dhandban
Bihar-828122
13 FACT Engineering & Design (p) Organisation Fertilizer

P.O.Sindri, Distt. Dhanban
Bihar-828122
14 Industrial and Business Management Textile,jute,Tea,Engineering

Consultants Limited & Chemical
27, Weston Street, Room-226
Calcutta-700012
15 M/s. National Small Industries Corpn. Ltd Thermal & Electrical Audit
Industrial Estate Bamunimaidan
Guwahati-21
16 M/s. Maharashtra Industrial & Tech. All types

Consultancy Organisation Ltd.(MITCON)
Kubera Chambers, 1ST Floor
Dr. Rajendra Prasad Path, Shivaji Nagar
Pune-411005
17 Ahmedabad Textile Industry’s Assn. Textile

P.O.Polytechnic, Ahmedabad-380015
18 The Bombay Textile Research Association Textile

Lal Bahadur Shastri Marg, Ghatkopar (west)
Bombay-400086
19 M/s. Associated Energy Consultants, Thermal & Electrical Energy Audit

3rd Floor, 44 Cawasji Patel, Fort
Bombay-400023
20 Dalal Consultants Thermal & Electrical Energy

404, H.K.House, Ashram Road Audit
Ahmedabad-380009

List of Suppliers
Energy Auditors
652
21 M/s. Mecon Services Thermal & Electrical

118.New Rmdaspeth
Nagpur-440010
22 M/s. Kirloskar Consultants Ltd. All types

917/19-A, A Shivaji Nagar
Fergusson College Road
Pune-411004
23 M/s. Electrical Research and Thermal & Electrical
Development Association
P.B.No 760 Mkarapura Ind. Estate
Opp. Makarpur Village
Vadodar-390010
24 M/s NSIC Technical Services Centre Thermal & Electrical

(Formerly Prototype Development &
Training Centre), Aji Industrial Area
Bhavnagar Road
Rjkot-360003
25 Fichtner Consulting Engineers India All types

Pvt.Ltd. “Ganesh Chambers”
143,Eldams Road
Channai-600018
26 M.K.Raju Consultants Pvt.Ltd. All types

Energy Management Division
16, Srinagar Colony, Temple Avenue
Channai-600015
27 Industrial & Technical Consultancy All types

Organisation of Tamil Nadu Ltd.
50-A, Graemes Road
Chennai-600008
28 M/s. Andhra Pradesh Productivity Council Thermal & Electrical Audit

3-6-69/4/3, Basheer Bagh
Hyderabad-500029
29 M/s Andhra Pradesh Industrial and All types

Technical Consultancy Organisation Ltd.
Parisharma Bhavanam, 8th Floor, Eastern Wing, 5-9-58/B, Basheerbagh
Hyderabad-500029

653
30 M/s.Central Power Research Institute All types

Energy Research Centre, P.B.No.3506
Srikrishna Nagar, Sreekariyam
Thiruvananthapuram-695017(Kerala)
31 The school of Energy Bharathidasan Electrical & Thermal

University, Khajamalai Campus
Tiruchirappalli-620023
Tamil Nadu
32 M/s. Separation Engineers Pvt.Ltd. Electrical & Thermal

5,Masilamani Colony, Sir P.S.Sivasamy Salai
Palur Kannaippa St., Mylapore
Channai-600004 (India)
33 M/s. Crompton Greaves Ltd. Electrical & Thermal

3A, Kodambakkam High Road
Nungambakkam Channai-600034
34 M/s.Energy Economy & Environmental Cosultants Thermal & Electrical

264,6th Cross, 1st Stage Indiranagar
Bangalore-560038
35 M/s. S.SM.Shakthi Consultants Thermal & Electrical

17/1, Nehru Nagar, 1st Main Road Adyar
Chennai-600020

List of Suppliers
Energy Service Companies
654
List of Indian Energy Service Companies (ESCOs)
DCM Shriram Consolidated Ltd. Thermax Energy Performance Services Limited

5th flr. Kanchenjunga Bldg.,18 Barakhamba Sai Chambers,15,Mumbai Pune Road
Road Wakadewadi
Pune - 411 003
New Delhi - 110 001
Telephone : (020) 551-1010
Telephone : (011) 331-6801 Fax : (020) 551-1144
Fax : (011) 331-8072 Contact Person : Mr. Shishir Joshipura, Chief
Email : dscpower@nde.vsnl.net.in Executive Officer
Contact Person : Dr. G.C. Datta Roy, Chief
Executive Officer Sudnya Industrial Services Pvt. Ltd.
5 Raj Apartments,28 Pushpak Park,Aundh
INTESCO Asia Ltd. Pune - 411 007
Oakland,114 Ulsoor Road Cross Telephone : (020) 5888-5601
Fax : (020) 5898-6290
Bangalore - 560 042
Email : sudnya@ip.eth.net
Telephone : (080) 558-3726
Contact Person : Mr. Shishir Athale, Director
Fax : (080) 559-6036
Email : rvasu@intescoasia.com
Shri Shakti Alternative Energy Limited
Contact Person : Mr. R. Vasu, President & CEO
Venus Plaza Begumpet
Hyderabad - 500 016
Saha Sprague Limited Telephone : (040) 790-7979
266,Dr. Annie Besant Road,1st flr. Fax : (040) 790-8989
Opp. Passport Office,Worli Contact Person : Mr. D.V. Satya Kumar, Managing
Mumbai - 400 025 Director
Telephone :(022) 421-0234
Fax : (022) 430-1969 Basera Environmental & Energy Management
Email : msaha@sahasprague.com Group
Kewra Dam Road
Contact Person : Mr. Manoj Saha, Director
Bhopal
Telephone : (075) 523-4731
Saket Projects Ltd. Fax : (075) 586-8382
Saket House,Pancheel,Usmanpura Email : basera@bomb6.vsnl.net.in
Ahmedabad - 380 013 Contact Person : Mr. Rahul Saxena, CEO
Telephone : (079) 755-1817
Fax : (079) 755-0452 Agni Energy Services Pvt. Ltd.
Email : saketprojects@vsnl.com 1-A/1 kautilya 6-3-652 Somajiguda
Contact Person : Mr. Kamal Khokhani, Director Hyderabad - 500 082
Telephone : (040) 606-2172
See Tech solutions Pvt.Ltd. Fax : (040) 339-4529
H-001,Sanchayani Prestige,Swavalambi Nagar Email : agniesco@hd2.vsnl.net.in
Nagpur - 440 022 Contact Person : Mr. G.S. Varma, President
Telephone : (071) 226-4433
Fax : (071) 226-5816 Asian Electronics Limited
Email : seemil@nagpur.dot.net.in D-11 Road No.28 Wagle Industrial Area
Contact Person : Mr. Millind Chittawar, Chief Thane - 400 064
Consultant Telephone : (022) 583-5504
Fax : (022) 582-7636
Email : aeltha@vsnl.com
Contact Person : Mr. Suresh Shah, Chairman &
Managing Director

655
Financial Mechanism

Financial Mechanism
656
ENERGY CONSERVATION AND COMMERCIALISATION

PROGRAMME (USAID FUNDED)
The Energy Conservation and Commercialisation Programme ( ECO) project is a joint project
between USAID and the Government of India. The project aims to promote widespread
commercialisation of end-use energy efficiency technologies and services in India, thereby
reducing greenhouse gas emissions per unit of electricity generated.
The project grant agreement for the project between the Government of India and USAID was
signed on January 28, 2000.(USAID Project No: 386-0542)
Project Assistance Completion Date: September 30, 2004
Objective To promote commercialisation of energy efficiency technologies and

services
Sectors Energy efficiency projects, non-sugar cogeneration, demand side

management with utilities and energy service companies (ESCO’s)
Beneficiary Public / private companies
Eligibility Project should be innovative, demonstrative and replicable. Should

achieve significant energy saving and be impact making. Assistance
for a specific project and would cover civil works, plant and machinery,
miscellaneous fixed assets, preoperative expenses etc.
Terms
Amount 50% eligible project cost or Rs 50 million whichever is lower
Repayment 6-8 years (including moratorium)
Type Rupee loan and Conditional Loans
Rate of interest 8% - 9%
Contact
Mr.Anil Malhotra,
Chief Manager
ICICI Bank Ltd
ICICI Tower, 2nd Floor, North Tower,
Bandra-Kurla Complex,
Mumbai - 400 051
Tel: 022 26536813
e-mail: anil.malhotra@icicibank.com

657
State Bank of India - Project Uptech to Finance Energy

Efficiency
SBI has launched an Uptech Project to promote Energy Efficiency measures in small and
medium enterprises. The project will be implemented in the following Circles where there is
good scope for energy saving in respect of SME sector. (i) Ahmedabad (ii) Bangalore (iii)
Chennai (iv) Hyderabad (v) New Delhi (vi) Mumbai (viii) Patna. The project will be of 3 years
duration, which may be extended if required. The Circle will identify 10 units enjoying finance
under sole banking arrangement which satisfy following criteria and are interested in adopting
EE measures.
i) Investments in plant and machinery are less than Rs 10 crore as at the date of last Balance
Sheet.
ii) Credit Rating ranging SB-1 to SB-4.
These 10 units will be assisted in the following manner to implement EE projects.
i) The consultant will be selected jointly by the unit and CCO of the Circle from the list of
consultants available with petroleum Conservation Research association (PCRA), Indian
Renewable Energy Development Agency (IREDA), ICICI, state-level energy development
agencies. The services of Institutes like National Productivity Council (NPC), Tata Energy
Research Institute (TERI) can be used.
ii) The consultants will conduct energy audit and prepare detailed project report (DPR).
iii) The DPR will be appraised by Consultancy Services Cell for techno-economic aspects.
iv) The bank will finance the project as per financial package detailed below.
Financial Package
Energy efficiency project have following cost components
i. Energy audit charges
ii. Consultancy fees for detailed project report (DPR)
iii. Consultancy charges for implementation of project
iv. Cost of plant and machinery including the cost of retrofitting /renovating / modification of
existing items, miscellaneous assets for establishing a monitoring system.
v. Charges for monitoring the energy efficiency on long-term basis.
The EE projects result in additional cash flow due to savings of energy and this is the crucial
parameter for the success of the project rather than additional assets generated. Hence the
norms for adequacy of security available in EE project needs to be liberal. The appraisal of
security aspects of financial package of the project should be done after taking this into
consideration.
The project has three distinct stages of implementation. The finance will be sanctioned in two
stages.
Stage I: Energy Audit and Preparation of Detailed Project Report

Financial Mechanism
658
In the first stage the unit is studied to explore the scope of energy saving and improving
energy efficiency and a detailed plan is drawn up outlining various steps to be undertaken,
investments required and likely benefits. The cost involved is the Consultant’s charges for
these studies namely Energy Audit and Detailed Project Report (DPR). SBI proposes to
extend grant under scheme for financing energy efficiency projects as detailed below:
Purpose
To finance cost of energy audit and detailed project report.
Financing pattern
a. Grant from TDISCF# 50% of the cost subject to a maximum of Rs. 50,000/-
b. Borrower’s contribution Balance amount
#
Technology Data and Information Services Centre Fund
Scheme of Grant for Energy Efficiency Projects

In case of energy efficiency projects the units will need incentives to encourage to take initial
steps of i) energy audit which will lead to in-depth study of units operations and processes
for saving the energy and ii) detailed project report (DPR) giving Action Plan. The Bank
proposes to provide a grant of 50 percent of cost of energy audit and DPR subject to
maximum of RS. 50,000/-, to each unit selected under the Project Uptech.
Sanctioning Authority : CCC of the circle
Documentation : Letter of agreement from borrower
The Consultancy Cell will scrutinise the DPR and if the venture is found acceptable, the
project will be financed as per details given below:
Stage II: Acquisition/ Modification/ Rrenovation of Plant and Machinery,

and Establishment of Monitoring System
Purpose
To finance cost of plant and machinery including cost of renovating /modification of existing
items, miscellaneous assets, for establishing monitoring system, fees of consultant or contractor
for implementation and monitoring of the project.
Financing Pattern MTL

Quantum 90 percent of cost subject to maximum of
Rs.100 lakh and minimum of Rs.2 lakh
Interest SBIMTLR
Tenure 5-7 years including maximum moratorium period of 1 year
Security i) Primary -Assets proposed to be acquired
ii) Collateral – Extension of charge on the assets provided as security

for the existing advance including extension of guarantee cover
where available

659
Sanctioning Authority As per scheme for delegation of financial powers
Documentation As applicable for SSI and C&I units depending upon the market
segment
If the MTL exceeds Rs. 100 lakh the balance portion of the project
cost of stage 2 will be financed under Banks usual scheme on the
normal terms and conditions.
Other Support Activities

In order to strengthen the process within the Bank as well as build awareness among potential
SME clients, the Bank has proposed a slew of activities under Project Uptech for promotion
of energy efficiency financing. These are:
i) Conduct of seminars / workshops on ‘Energy Efficiency’ projects for borrowers of the Bank.
ii) Conduct of training programme for Bank staff in appraising and financing of ‘Energy
Efficiency’ project.
iii) Support to Research Institutes, consultants, equipment manufacturers, engineering colleges,

technical institutes for development of Energy Efficient technologies, equipment, processes
and practices.
iv) Development of panel of engineers, auditors, consultants for EE projects on all-India basis,
based on Bank’s experience with consultants selected by CCOs of LHOs Circle.
Registration fees – It is proposed to charge a nominal registration fee of Rs.10,000 per unit
as a token of their commitment to project.
Parameters for Success of the Project
The project is expected to achieve the following basic benchmark within a period of 3 years.
1) Each Circle should have financed at least 10 EE projects. Thus 60 such projects would
have been funded.
2) The EE projects are immensely useful to SME sector to survive in the liberalised economy
open to global competition. The benefits will be visible in a short period. The additional
advances to the 60 projects will be around 20 crore in a span of 2 years.
Once the benefits of such projects in from of saving in energy costs are established, more
such projects are expected to come resulting in a spurt in advances to SME sector.
Contact for further information:

Mr ES Balasubramanian
Dy General Manager
State Bank of India, Development Banking Department
9th Floor Corporate CentreState Bank Bhawan
Madam Cama Road Mumbai 400 021
Tel: 022-22817462, 22022426 (ext: 3503)
E-mail: dgmdb@sbimail.com; balan1944@yahoo.com

Financial Mechanism
660
Mr Sonalal Datta
AGM (CS), Credit Appraisal Cell
State Bank of India,
Consultancy Services Cell
Local Head Office, 7th Floor
11, Sansad Marg New Delhi 110 001
Tel: 011-23368481, 233629422336 2908 (ext 453)
Email:agmtcc@lhodel.sbimail.com; sonalal@hotmail.com

661
Petroleum Conservation Research Association (PCRA)

(a) Energy Audit Subsidy
PCRA is an organization under the Ministry of Petroleum & Natural Gas. It offers subsidies
up to 50% of the cost of conducting an audit at an industrial premises limited to a
maximum of Rs.50,000/-. The subsidy is payable after the satisfactory conduct of the
audit and upon its acceptance by both PCRA and the concerned party. A written
commitment from the party for the recommendation of the recommendations amounting
to 50% or more of the identified energy saving potential.
This subsidy can be availed by industries who consume more than 1000 tonnes of oil
equivalent per annum and where in majority of fuel consumption is constituted by petroleum
products.
The energy auditor has to be already empanelled by PCRA.
(b) Scheme for setting up of Energy Audit Centre / upgrading energy auditing facilities
Soft loans are available for procuring energy audit equipments and for upgrading energy
auditing facilities
A loan of 50% of the cost or Rs. 1 million, whichever is lower, is given. An interest rate
of 8 % is charged on a reduced principle basis. The repayment of loans begins 1 year
after it is disbursed in six equal annual installments.

Financial Mechanism
662
Industrial Development Bank of India (IDBI) Scheme

The scheme is available for financially sound industrial undertakings, which are in operation,
at least for the last five years. There are basically two schemes, which are operational.
(a) Energy Audit subsidy scheme
IDBI bears 50 % charges of an approved consultancy for detailed energy audits. For a
basic energy audit the subsidy is Rs. 10000/- or 0.1 % of the gross value of the fixed
assets, whichever is less.
IDBI will assess the whole process.
(b) Equipment finance
Assistance is available for improving energy efficiency only. An energy audit has to
precede the application. The assistance is limited to 50 % of the gross value of fixed
assets (excluding revenue reserves) or Rs. 40 million whichever is less. An interest @
Rs. 14 % per annum is charged. Interest can be funded for a period of up to 2 years from
a period of first disbursement on simple interest basis.
Repayment will commence after two years from the date of first disbursement to be
repaid in full within three years thereafter. The borrower can claim a rebate in interest
subject to actual energy saving.

663
IREDA’s Schemes for Financing of Energy Efficiency/

Conservation Projects
General Eligibility: All types of applicants, who have borrowing powers and powers to take
up energy efficiency projects as per their Charter, are eligible to avail financial assistance from
IREDA except the following:
• Government Departments and State Electricity Boards/ utilities unless they are restructured
or in the process of restructuring and are also eligible to borrow from REC/PFC.
• a) Individual, Proprietary concerns and Partnership firms; b) Loss making applicants; c)

Applicants with accumulated losses (without taking into account effect of revaluation of
assets, if any); and d) having erosion of paid up equity share capital as per audited Annual
Accounts of the immediate preceding financial year unless security of Bank Guarantee/
Pledge of FDR from scheduled commercial bank is provided.
• Applicants whose existing Debt Equity Ratio {total borrowings (other than unsecured loans
and working capital loans) to net worth} exceeds 3:1 after taking into account the proposed
borrowings from IREDA unless security of Bank Guarantee/ Pledge of FDR from scheduled
commercial bank is provided.
• Trust/Societies with accumulated revenue deficit or revenue deficit immediately during the
past year unless Bank Guarantee is provided unless security of Bank Guarantee/ Pledge
of FDR from scheduled commercial bank is provided.
• Applicants who are in default in payment of dues to Financial Institutions, Banks NBFCs
and/or IREDA at the time of submission of application.
• Applicants/Group Companies and/or main promoters of the applicants company which are
in default in payment of IREDA dues at the time of submission of application.
• Applicants/Group Companies classified as willful defaulters as defined by RBI/classified by

other FIs.
• Refinancing
• Projects Commissioned prior to the date of registration of application by IREDA.
• Second-hand project, equipment and machinery. Cost overrun financing.
• Applicants/Group companies who had availed OTS from IREDA.
• Applicants requesting financial assistance of less than Rs. 10 Lakhs
• Applicants/Group Companies and/or main promoters of the applicant Company convicted

by court for criminal/economic offences or under national security laws.
• Applicants registered outside India.
• Companies which do not have minimum paid up capital of Rs. 1.00 Lakh/Rs. 5.00 Lakhs
or such higher paid up capital as may be prescribed for private and public companies
respectively.
Terms: IREDA provides loan for Energy Efficiency/Conservation sector under following
categories:

Financial Mechanism
664
SCHEME Rate of Maximum Max. Minimum Maximum

Interest(%) repayment Moratorium Promoters IREDA
p.a. period (Years) Contribution(%) loan(%)
including
moratorium
(Years)
A. PROJECT FINANCING: (INCLUDING POWER PROJECTS BASED ON WASTE HEAT

RECOVERY, DSM AND ESCO)
Commercial and Upto 70% of

Industrial 13.00 10 2 30 total project cost
Domestic sector 12.00 5 1 30 - do -
Agricultural sector 12.00 10 2 30 - do -
B. MANUFACTURING OF ENERGY EFFICIENT EQUIPMENT/SYSTEMS:
All sectors 13.50 8 2 30 Upto 70% of

total project cost
C. EQUIPMENT FINANCING: ENERGY CONSERVATION/EFFICIENCY SYSTEMS &

EQUIPMENTS (INCLUDING DSM)
Commercial and 13.50 10 2 25 Upto 75% of

Industrial sector total eligible
equipment cost
Domestic Sector 12.50 5 1 25 - do -
Agricultural Sector 12.50 10 2 25 - do -
Concessions/Rebates and Special Provisions from IREDA

• Project financed by IREDA from the World Bank line of credit are likely to qualify for
excise/ custom duty exemptions as per notification issued by the Government of India
• Interest Rebate of 1.00% for furnishing security of Bank Guarantee/Pledge of FDR Or

unconditional and irrevocable guarantee of All India Public Financial Institution with “AAA”
or equivalent rating.
• Rebate of 0.5% in interest rate for timely payment of interest & repayment of loan instalment.
• Special Concessions for entrepreneurs belonging to SC/ST, Women, Physically Handicapped

and Ex-servicemen Categories and those setting up projects in North Eastern States,
Sikkim, Jammu & Kashmir, newly created states, Islands and Estuaries.
Other Charges Payable to IREDA after the Loan is Sanctioned (please check IREDA’s
Financing Guidelines for further Details):
• Front End Fee (@1.00% for loan upto Rs.1 Crores; @1.25% for Rs.1-10 Crores; @1.50%
for Rs.10-20 Crores; @1.75% for Rs.20-30 Crores and @2% for loan above Rs.30 Crores)

665
• Legal Charges (if incurred by IREDA) and Expenditure on Nominee Director (if incurred by
IREDA)
• Inspection and Monitoring Charges incurred by IREDA for the Project
IREDA also offers following Grant Assistance to the project financed by it:
Category of Project Purpose of Grant Eligible Amount Remarks

End User Energy Cost of carrying out Rs.10.00 Lakhs per Fund Utilisation
Efficiency & Energy Energy Audit and for project or 2% of the loan certificate in the format
Conservation projects Preparation of Bankable directly availed from prescribed by IREDA
Detailed Project Report IREDA, whichever is less shall be required to be
for availing Term Loan submitted
Utility DSM Projects Cost of carrying out Rs.10.00 Lakhs per --do--
Energy Audit and for project or 2% of the loan
Preparation of Bankable directly availed from
Detailed Project Report IREDA, whichever is less
for availing Term Loan
For Setting up a DSM Rs.10.00 Lakhs (provided --do--
Cell in the utility loan of minimum 100
Lakhs is availed.
ESCO Promoted Cost of carrying out Rs.10.00 Lakhs per --do--
Projects (with Energy Audit by ESCO project or 2% of the loan
performance and Preparation of availed from IREDA,
guarantee/ shared Bankable Detailed whichever is less
saving) Project Report
Cost of preparation of Rs.4.00 Lakhs per project --do--
Performance Contract or 1% of the loan availed
for the Project from IREDA, whichever is
less
Cost of Collaboration/ Rs.4.00 Lakhs per project --do--
Experience Sharing/ or 1% of the loan availed
Technology Transfer from IREDA, whichever is
less
Cost of Promotional/ Rs.2.00 Lakhs per project --do--
Outreach Efforts by the or ½% of the loan availed
ESCO from IREDA, whichever is
less
ecurity for IREDA’s Loan:
OPTION PROJECT FINANCING EQUIPMENT FINANCING

SET 1 Bank Guarantee/Pledge of FDR Bank Guarantee/Pledge of FDR from
from Scheduled Commercial Scheduled Commercial Bank
Bank
SET 2 State Government Guarantee State Government Guarantee
SET 3 Unconditional and irrevocable Unconditional and irrevocable guarantee
guarantee of All India Public of All India Public Financial Institution
Financial Institution with “AAA” with “AAA” or equivalent rating.
or equivalent rating.
SET 4 § Equitable Mortgage § Demand Promissory Note for the
(Mortgage by deposit of title amount of loan
deeds) of all immovable § Exclusive charge by way of
properties hypothecation of all movable assets
§ Hypothecation of movable acquired/ to be acquired out of

Financial Mechanism
666
assets, both existing and IREDA’s loan and Borrowers’ own

future, subject to prior funds under the project, both existing
charge of Banks on specified and future
current assets § Guarantees by promoters/ promoter
§ Guarantees by promoters/ directors and promoter companies
promoter directors and § Deposit of post dated cheques in
promoter companies accordance with repayment schedule
§ Deposit of post dated of principal loan amount and interest.
cheques in accordance with
repayment schedule of
principal loan amount and
interest.
Note:
1) All equipment financing loans (where mortgage of immovable properties either on exclusive
or pari-passu or second charge basis is not stipulated) will have to be secured by additional
security in the form of equitable mortgage of immovable non-agricultural properties located
either in urban or rural areas (excluding waste/barren lands) belonging to promoters/directors
of the borrower company and/or close relatives and friends of the promoters having market
value equivalent to at least 33% of IREDA’s Loan. The valuation of the property shall be
arranged from any of the approved and registered valuers/architects at the cost of the
borrowers to the satisfaction of IREDA and the borrower shall establish the title of such
property to the satisfaction of IREDA. Alternatively, Bank Guarantee from a scheduled bank
or pledge of Fixed Deposit Receipt (FDR) can be submitted.

667
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. Short title, extent
and commencement
(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.
Definitions 2. In this Act, unless the context otherwise requires: — 668
(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; 21 of 1860
(m) “energy manager” means any individual possessing the qualifications prescribed under
clause (m) of section 14;
(n) “ Governing Council” means the Governing Council referred to in section 4;
(o) “member” means the member of the Governing Council and includes the Chairperson;
(p) “notification” means a notification in the Gazette of India or, as the case may be, the
Official Gazette of a State;
(q) “prescribed” means prescribed by rules made under this Act;
(r) “regulations” means regulations made by the Bureau under this Act;
(s) “schedule” means the Schedule of this Act;
(t) “State Commission” means the State Electricity Regulatory Commission established 14 of 1998
under sub-section (l) of section 17 of the Electricity Regulatory Commissions Act,
1998;
9 of 1940 (u) words and expression used and not defined in this Act but defined in the Indian 669
54 of 1948
Electricity Act, 1910 or the Electricity (Supply) Act, 1948 or the Electricity
14 of 1998
Regulatory Commissions Act, 1998 shall have meanings respectively assigned to them
in those Acts.
CHAPTER II
BUREAU OF ENERGY EFFICIENCY
3. (1) With effect from such date as the Central Government may, by notification, Establishment and
incorporation of
appoint, there shall be established, for the purposes of this Act, a Bureau to be Bureau of Energy
called the Bureau of Energy Efficiency Efficiency
(2) The Bureau shall be a body corporate by the name aforesaid having perpetual
succession and a common seal, with power subject to the provisions of this Act, to
acquire, hold and dispose of property, both movable and immovable, and to contract,
and shall, by the said name, sue or be sued.
(3) The head office of the Bureau shall be at Delhi.
(4) The Bureau may establish offices at other places in India.
4. (1) The general superintendence, direction and management of the affairs of the Bureau Management of
Bureau
shall vest in the Governing Council which shall consists of not less than twenty, but
not exceeding twenty-six members to be appointed by the Central Government.
(2) The Governing Council shall consist of the following members, namely:-
(a) the Minister in charge of the Ministry or Department ex officio
of the Central Government dealing with the Power Chairperson;
(b) the Secretary to the Government of India, in charge of ex officio member;
the Ministry or Department of the Central
Government dealing with the Power
(c) the Secretary to the Government of India, in charge of ex officio member;
Government dealing with the Petroleum and Natural
Gas
(d) the Secretary to the Government of India, in charge of ex officio member;
Government dealing with the Coal
(e) the Secretary to the Government of India, in charge of ex officio member;
Government dealing with the Non-conventional
Energy Sources
(f) the Secretary to the Government of India, in charge of ex officio member;
Government dealing with the Atomic Energy
(g) the Secretary to the Government of India, in charge of ex officio member;
Government dealing with the Consumer Affairs
(h) Chairman of the Central Electricity Authority ex officio member;
54 of 1948
established under the Electricity (Supply) Act, 1948
(i) Director-General of the Central Power Research ex officio member;
Karnataka Act
Institute registered under the Karnataka Societies
17 of 1960 Act, 1960
(j) Executive Director of the Petroleum Conservation ex officio member;
Research Association, a society registered under the
XXI of 1860 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,
1 of 1956 1956
(l) Director-General of the Bureau of Indian Standards ex officio member;
established under the Bureau of Indian Standards 670
63 of 1986
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
1 of 1956
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
(r) Director-General of Bureau ex officio member
– secretary;
(3) The Governing Council may exercise all powers and do all acts and things which may
be exercised or done by the Bureau.
(4) Every member referred to in clause (o), (p) and (q) of sub-section (2) shall hold office
for a term of three years from the date on which he enters upon his office.
(5) The fee and allowances to be paid to the members referred to in clauses (o), (p)
and (q) of sub-section (2) and the manner of filling up of vacancies and the
procedure to be followed in the discharge of their functions shall be such as may
be prescribed.
Meetings of 5. (1) The Governing Council shall meet at such times and places, and shall observe such
Governing
rules of procedure in regard to the transaction of business as its meetings (including
Council
quorum of such meetings) as may be provided by regulations.
Meetings of (2) The Chairperson or, if for any reason, he is unable to attend a meeting of the
Governing Governing Council, any other member chosen by the members present from amongst
Council
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.
Vacancies etc., 6. No act or proceeding of the Bureau or the Governing Council or any Committee shall be
not to invalidate invalid merely by reason of -
proceedings of
Bureau, (a) any vacancy in, or any defect in the constitution of, the Bureau or the Governing
Governing Council or the Committee; or
Council or
Committee
(b) any defect in the appointment of a person acting as a Director -General or Secretary of
the Bureau or a member of the Governing Council or the Committee; or
(c) any irregularity in the procedure of the Bureau or the Governing Council or the
Committee not affecting the merits of the case.
Removal of 7. The Central Government shall remove a member referred to in clause (o), (p) and (q) of
member from
sub-section (2) of section 4 from office if he —
office
(a) is, or at any time has been, adjudicated as insolvent;
(b) is of unsound mind and stands so declared by a competent court; 671
(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 Constitution of
from the date of commencement of this Act, constitute Advisory Committees for the Advisory
Committees and
efficient discharge of its functions. other committees
(2) Each Advisory Committee shall consist of a Chairperson and such other members as
may be determined by regulations.
(3) Without prejudice to the powers contained in sub-section (1), the Bureau may
constitute, such number of technical committees of experts for the formulation of
energy consumption standards or norms in respect of equipment or processes, as it
considers necessary.
9. (1) The Central Government shall, by notification, appoint a Director -General from Director-General of
amongst persons of ability and standing, having adequate knowledge and experience Bureau
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 Officers and
employees of
Bureau as it considers necessary for the efficient discharge of its functions under this Bureau
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 Authentication of
orders and decisions
Director-General or any other officer of the Bureau authorised by the Director-General in of Bureau
this behalf.
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 - Transfer of assets,
liabilities and
(a) any reference to the Energy Management Centre in any law other than this Act or employees of
in any contract or other instrument shall be deemed as a reference to the Bureau; Energy
Management Centre
(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;
(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 672
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 14 of 1947
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.
CHAPTER IV
POWERS AND FUNCTIONS OF BUREAU
Powers and 13. (1) The Bureau shall, effectively co-ordinate with designated consumers, designated
functions of
Bureau
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
(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; 673
(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, — Power of Central
Government to
(a) specify the norms for processes and energy consumption standards for any equipment, enforce efficient
appliances which consumes, generates, transmits or supplies energy; use of energy and
its conservation
(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;
(i) direct, if considered necessary for efficient use of energy and its conservation, any 674
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
(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
(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 15. The State Government may, by notification, in consultation with the Bureau -
Government to
enforce certain (a) amend the energy conservation building codes to suit the regional and local climatic
provisions for conditions and may, by rules made by it, specify and notify energy conservation
efficient use of building codes with respect to use of energy in the buildings;
energy and its
conservation
(b) direct every owner or occupier of a building or building complex being a designated 675
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
(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 Establishment of
Fund by State
Conservation Fund for the purposes of promotion of efficient use of energy and its
Government
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 Power of
commencement of this Act, as many inspecting officers as may be necessary for the inspection
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;
(ii) to make an inventory of stock of any equipment or appliance checked or
verified by him; 676
(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 18. The Central Government or the State Government may, in the exercise of its powers and
Central performance of its functions under this Act and for efficient use of energy and its
Government conservation, issue such directions in writing as it deems fit for the purposes of thi s Act to
or State any person, officer, authority or any designated consumer and such person, officer or
Government
authority or any designated consumer shall be bound to comply with such directions.
to issue
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.
CHAPTER VII
FINANCE, ACCOUNT S AND AUDIT OF BUREAU
Grants and loans 19. The Central Government may, after due appropriation made by Parliament by law in this
by Central
behalf, make to the Bureau or to the State Government grants and loans of such sums or
Government
money as the Central Government may consider necessary.
Establishment of 20. (1) There shall be constituted a Fund to be called as the Central Energy Conservation Fund
Fund by Central
and there shall be credited thereto -
Government
(a) any grants and loans made to the Bureau by the Central Government under section
19;
(b) all fees received by the Bureau under this Act;
(c) all sums received by the Bureau from such other sources as may be decided upon
by the Central Government.
(2) The Fund shall be applied for meeting -
(a) the salary, allowances and other remuneration of Director -General, Secretary
officers and other employees of the Bureau,
(b) expenses of the Bureau in the discharge of its functions under section 13;
(c) fee and allowances to be paid to the members of the Governing Council under sub-
section (5) or section 4;
(d) expenses on objects and for purposes authorised by this Act
Borrowing 21. (1) The Bureau may, with the consent of the Central Government or in accordance with the
powers of
terms of any general or special authority given to it by the Central Government borrow
Bureau
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 Budget
prescribed, its budget for the next financial year, showing the estimated receipts and 677
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 Annual report
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 Annual report tobe
laid before
soon as may be after it is received, before each House of Parliament. Parliament
25. (1) The Bureau shall maintain proper accounts and other relevant records and prepare an Accounts and
annual statement of accounts in such form as may be prescribed by the Central Audit
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.
CHAPTER VIII
PENALTIES AND ADJUDICATION
26. (1) If any person fails to comply with the provision of clause (c) or the clause (d) or clause Penalty
(h) or clause (i) or clause (k) or clause (l) or clause (n) or clause (r) or clause (s) of
section 14 or clause (b) or clause (c) or clause (h) of section 15, he shall be liable to a
penalty which shall not exceed ten thousand rupees for each such failures and, in the
case of continuing failures, with an additional penalty which may extend t o one
thousand rupees for every day during which such failures continues:
Provided that no person shall be liable to pay penalty within five years from the
date of commencement of this Act.
(2) Any amount payable under this section, if not paid, may be recovered as if it were an
arrear of land revenue.
27. (1) For the purpose of adjudging section 26, the State Commission shall appoint any of its Power to
members to be an adjudicating officer for holding an inquiry in such manner as may be adjudicate
prescribed by the Central Government, after giving any person concerned a reasonable
opportunity of being heard for the purpose of imposing any penalty.
(2) While holding an inquiry the adjudicating officer shal l have power to summon and
enforce the attendance of any person acquainted with the facts and circumstances of the
case of give evidence or produce any document which in the opinion of the adjudicating
officer, may be useful for or relevant to the subject-matter of the inquiry, and if, on such
inquiry, he is satisfied that the person has failed to comply with the provisions of any of
the clauses of the sections specified in section 26, he may impose such penalty as he
thinks fit in accordance with the provi sions of any of those clauses of that section:
678
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 28. While adjudicating the quantum of penalty under section 26, the adjudicating officer shall
taken into have due regard to the following factors, namely:-
account by
adjudicating (a) the amount of disproportionate gain or unfair advantage, wherever quantifiable, made as
officer a result of the default;
(b) the repetitive nature of the default.
Civil court not 29. No civil court shall have jurisdiction to entertain any suit or proceeding in respect of any
to have matter which an adjudicating officer appointed under this Act or the Appellate Tribunal is
jurisdiction
empowered by or under this Act to determine and no injunction shall be granted by any
court or other authority in respect of any action taken or to be taken in pursuance of any
power conferred by or under this Act.
CHAPTER IX
APPELLATE TRIBUNAL FOR ENERGY CONSERVATION
Establishment 30. The Central Government shall, by notification, establish an Appellate Tribunal to be known
of Appellate
as the Appellate Tribunal for Energy Conservation to hear appeals against the orders of the
Tribunal
adjudicating officer or the Central Government or the State Government or any other
authority under this Act.
Appeal to 31. (1) Any person aggrieved, by an order made by an adjudicating officer or the Central
Appellate
Tribunal
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 679
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 Composition of
Appellate Tribunal
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 Qualifications for
Tribunal or a Member of the Appellate Tribunal unless he - appointment of
Chairperson and
(a) in the case of Chairperson of the Appellate Tribunal, is or has been, a judge of Members of
the Supreme Court or the Chief Justice of a High Court; and Appellate Tribunal
(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
(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 680
energy production and supply, energy management, standardisation and
efficient use of energy and its conservation, and has shown capacity in
dealing with problems relating to engineering, finance, commerce,
economics, law or management
Term of office 34. The Chairperson of the Appellate Tribunal and every Member of the Appellate Tribunal
shall hold office as such for a term of five years from the date on which he enters upon his
office:
Provided that no Chairperson of the Appellate Tribunal or Mem ber of the
Appellate Tribunal shall hold office as such after he has attained, –
(a) in the case of the Chairperson of the Appellate Tribunal, the age of seventy
years;
(b) in the case of any Member of the Appellate Tribunal, the age of sixty-five
years.
Terms and 35. The salary and allowances payable to and the other terms and conditions of service of the
conditions of Chairperson of the Appellate Tribunal, Members of the Appellate Tribunal shall be such as
service
may be prescribed:
Provided that neither the salary and allowances nor the other terms and conditions of
service of the Chairperson of the Appellate Tribunal or a Member of the Appellate Tribunal
shall be varied to his disadvantage after appointment.
Vacancies 36. If for reason other than temporary absence any vacancy occurs in the office of the
Chairperson of the Appellate Tribunal or the Member of the Appellate Tribunal, the Central
Government shall appoint another person in accordance with the provisions of this Act to fill
the vacancy and the proceedings may be continued before the Appellate Tribunal from the
stage at which the vacancy is filled.
Registration 37. (1) The Chairperson or a Member of the Appellate Tribunal may, by notice in writing under
and removal
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.
681
38. (1) In the event of the occurrence of vacancy in the office of the Chairperson of the Member to act as
Chairperson in
Appellate Tribunal by reason of his death, resignation or otherwise, the senior-most
certain
member of the Appellate Tribunal shall act as the Chairperson of the Appellate Tribunal circumstances
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 Staff of Appellate
Tribunal
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 Procedure and
5 of 1908 civil Procedure, 1908 but shall be guided by the principles of natural justice and subject powers of
Appellate Tribunal
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
5 of 1908 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;
(d) subject to the provisions of section 123 and 124 of the Indian Evidence Act, 1872,
1 of 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.
(5) All proceedings before the Appellate Tribunal shall be deemed to be judicial
45 of 1860
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
2 of 1974 and 346 of the Code of Criminal Procedure, 1973.
Distribution of 41. Where Benches are constituted, the Chairperson of the Appellate Tribunal may, from time to 682
business amongst
time, by notification, make provisions as to the distribution of the business of the Appellate
Benches.
Tribunal amongst the Benches and also provide for the matters which ma y be dealt with by
each Bench.
Power of 42. On the application of any of the parties and after notice to the parties, and after hearing such
Chairpersont to of them as he may desire to be heard, or on his own motion without such notice, the
transfer cases
Chairperson of the Appellate Tribunal may transfer any case pending before one Bench for
disposal, to any other Bench.
Decision to be by 43. If the Members of the Appellate Tribunal of a Bench consisting of two Members differ in
majority
opinion on any point, they shall state the point or points on which they differ, and make a
reference to the Chairperson of the Appellate Tribunal who shall either hear the point or
points himself or refer the case for hearing on such point or points b y one or more of the
other Members of the Appellate Tribunal and such point or points shall be decided
according to the opinion of the majority of the Members of the Appellate Tribunal who have
heard the case, including those who first heard it.
Right to 44. (1) A person preferring an appeal to the Appellate Tribunal under this Act may either
appellant to take appear in person or take assistance of a legal practitioner or an accredited energy
assistance of
legal practitioner auditor of his choice to present his case before the Appellate Tribunal, as the case may
or accredited be.
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.
Appeal to 45. Any person aggrieved by any decision or order of the Appellate Tribunal may, file an appeal
Supreme Court
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: 5 of 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.
CHAPTER X
MISCELLANEOUS
Power of 46. (1) Without prejudice to the foregoing provisions of this Act, the Bureau shall, in exercise
Central
of its powers or the performance of its functions under this Act, be bound by such
Government to
issue directions directions on questions of policy as the Central Government may give in writing to it
to Bureau 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.
Power of 47. (1) If at any time the Central Government is of opinion -
Central
Government to (a) that on account of grave emergency, the Bureau is unable to discharge the functions
supersede and duties imposed on it by or under the provisions of this Act; or
Bureau
(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 683
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 Default by
companies
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 49. Notwithstanding anything contained in the Income -tax Act, 1961 or any other enactment for Exemption from
the time being in force relating to tax on income, profits or gains - tax on income
(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. 684
Protection of 50. No suit, prosecution or other legal proceedings shall lie against the Central Government or
action taken in Director-General or Secretary or State Government or any officer of those Governments or
good faith
State Commission or its members or any member or officer or other employee of the Bureau
for anything which is in good faith done or intended to be done under this Act or the rules or
regulations made thereunder.
Delegation 51. The Bureau may, by general or special order in writing, delegate to any member, member of
the committee, officer of the Bureau or any other person subject to such conditions, if any,
as may be specified in the order, such of its powers and functions under this Act (except the
powers under section (58) as it may deem necessary
Power to obtain 52. Every designated consumer or manufacturer of equipment or appliances specified under
information
clause (b) of section 14 shall supply the Bureau with such information, and with such
samples of any material or substance used in relation to any equipment or appliance, as the
Bureau may require.
Power to 53. If the Central Government or the Stat e Government is of the opinion that it is necessary or
exempt
expedient so to do in the public interest, it may, by notification and subject to such
conditions as may be specified in the notification, exempt any designated consumer or class
of designated consumers from application of all or any of the provisions of this Act:
Provided that the Central Government or the State Government, as the case may be, shall
not grant exemption to any designated consumer or class of designated consumers for the
period exceeding five years:
Provided further that the Central Government or State Government, as the case may be
shall consult the Bureau of Energy Efficiency before granting such exemption.
Chairperson, 54. The Chairperson of the Appellate Tribunal or the Members of the Appellate Tribunal or
Members,
officers or employees of the Appellate Tribunal or the members of the State Commission or
officers and
employees of the members, Director-General, Secretary, officers and other employees of the Bureau shall
the Appellate be deemed, when acting or purporting to act in pursuance of any of the provisions of the
Tribunal, Act, to be public servants within the meaning of section 21 of the Indian Penal Code. 45 0f 1860
Members of
State
Commission,
Director-
General,
Secretary,
members,
officers and
employees to be
public servants.
Power of 55. The Central Government may give directions to a State Gover nment or the Bureau as to
Central carrying out into execution of this Act in the State
Government to
issue directions.
Power of 56. (1) The Central Government may, by notification, make rules for carrying out the
Central
Government to
provisions of this Act.
make rules.
(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; 685
(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 Power of State
of this Act and not inconsistent with the rules, if any, made by the Central Government. Government to
make rules
(2) In particular, and without prej udice to the generality of the foregoing power, such rules
may provide for all or any of the following matters, namely: -
(a) energy conservation building codes under clause (a) of section 15;
(b) the form, the manner and the period within which information with regard to energy
consumption shall be furnished under clause (h) of section 15;
(c) the person or any authority who shall administer the Fund and the manner in which
the Fund shall be administered under sub-section (4) of section 16;
(d) the matters to be included for the purposes of inspection under sub-section (2) of
section 17
(e) any other matter which is to be, or may be, prescribed, or in respect of which
provision is to be made, or may be made, by rules.
Power of 58. (1) The Bureau may, with the previous approval of the Central Government and subject to
Bureau to make
the condition of previous publication, by notification, make regulations not inconsistent 686
regulations
with the provisions of this Act and the rules made thereunder to carry out the pur poses
of this Act.
(2) In particular, and without prejudice to the generality of the foregoing power, such
regulations may provide for all or any of the following matters, namely:-
(a) the times and places of the meetings of the Governing Council and the procedure to
be followed at such meetings under sub-section (1) of section 5;
(b) the members of advisory committees constituted under sub-section (2) of section 8;
(c) the powers and duties that maybe exercised and discharged by the Director-General
of the Bureau under sub-section (6) of section 9;
(d) the levy of fee for services provided for promoting efficient use of energy and its
conservation under clause (n) of sub-section (2) of section 13;
(e) the list of accredited energy auditors under clause (o) of sub-section (2) of section
13;
(f) the qualifications for accredited energy auditors under clause (p) of sub-section (2)
of section 13;
(g) the manner and the intervals or time in which the energy audit shall be conducted
under clause (q) of sub-section (2) of section 13;
(h) certification procedure for energy managers under clause (r) of sub-section (2) of
section (13);
(i) particulars required to be displayed on label and the manner of their display under
clause (d) of section 14;
(j) the manner and the intervals of time for conduct of energy audit under clause (h) or
clause (s) of section 14;
(k) the manner and the intervals of time for conducting energy audit by an accredited
energy auditor under clause (c) of section 15;
(l) any other matter which is required to be, or may be, specified.
Rules and 59. (1) Every rule made by the Central Government and every regulation made under this Act
regulations to
be laid before
shall be laid, as soon as may be after it is made, before each House of Parliament while
Parliament and it is in session, for a total period of thirty days which may be comprised in one session
State or in two or more successive session, and if, before the expiry of the session
Legislature immediately following the session or the successive sessions aforesaid, both Houses
agree in making any modification in the rule or regulation, or both Houses agree that
the rule or regulation should not be made, the rule or regulation shall thereafter have
effect only in such modified form or be of no effect, as the case may be; so however
that any such modification or annulment shall be without prejudice to the validity of
anything previously done under that rule or regulation.
(2) Every rule made by the State Government shall be laid, as soon as may be after it is
made, before each House of the State Legislature where it consists of two Houses, or
where such Legislature consists of one House, before that House.
Application of 60. The provisions of this Act shall be in addition to, and not in derogation of, the provisions of
other laws not
any other law for the time being in force.
barred.
687
61. The provisions of this Act shall not apply to the Ministry or Department of the Central Provisions of Act
not to apply in
Government dealing with Defence, Atomic Energy or such other similar Ministries or
certain cases
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 Power to remove
difficulty.
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.
THE SCHEDULE 688
[See section 2 (s)]
List of Energy Intensive Industries and other establishments specified

as designated consumers
1. Aluminium;
2. Fertilizers;
3. Iron and Steel;
4. Cement;
5. Pulp and paper;
6. Chlor Akali;
7. Sugar;
8. Textile;
9. Chemicals;
10. Railways;
11. Port Trust;
12. Transport Sector (industries and services);
13. Petrochemicals, Gas Crackers, Naphtha Crackers and Petroleum Refineries;
14. Thermal Power Stations, hydel power stations, electricity transmission companies
and distribution companies;
15. Commercial buildings or establishments;
SUBHASH C.JAIN,
Secy. to the Govt. of India.
MGIP(PLU)MRND— 2995GI— 19-10-2001

689
References

References
690
REFERENCES
• Detailed Energy Audit reports
CII – Energy management cell has carried out detailed energy audits in over 360 Industries
in India, comprising of various sectors such as cement, paper, sugar, fertilizer, ceramics,
engineering, power plants, commercial buildings, synthetic fibre, caustic chlor, etc.
The feedback from the audited units indicated a saving of Rs 850 million based on 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 – EMC 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 Cement Paper, Sugar, Fertilizer,
Ceramic & Textile
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

691
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
Fertilizer
Database - www.Eco-web.com
Petroleum Conservation & Research Association - www.pcra.org
Alkali Manufacturers Association - www.amaionline.org
Ministry of Chemicals - www.chemicals.nic.in
Chemical Manufacturers Association - www.icmaindia.com
Chemical Technology - www.chemicals-technology.com
Gujarat Alkalies - www.gujaratalkalies.com
Equipment Suppliers
Bharat Heavy Electricals Limited – www.bhel.com
Thermax – www.thermax.com
Asea Brown Boveri – www.abb.com
Siemens www.siemens.com
Financial Institutions
Indian Renewable Energy Development Agency www.iredaltd.com
World Bank – www.worldbank.org
The Energy & Resources Institute – www.teriin.org
USAID – www.usaid.gov

References
692
Resource person consulted /organisation visited

The Associated Cement Companies
Petroleum Conservation Research Association
Mr C V Chalam, Director, C V Chalam Consultants Pvt Ltd
Indian Institute of Technology, Chennai
Mr N Srinivasan, President, Thiru Arooran Sugars Limited
SIEL – Caustic Chlor company
Mr C Sitaram, Manager – Technical, Coromandel Fertilisers Limited
Bombay Dyeing Manufacturing Co Ltd
ITC – Bhadrachalam Paper Boards Ltd, Bhadrachalam and Secunderabad
Fuller India Limited, Chennai
Mr K S Kasi Viswanathan, President (Operations), Seshasayee Paper Boards Ltd, Erode
Visits made
Financial Institutions
Industrial Credit and Investment Corporation of India (ICICI), Bandra Kurla Complex, Mumbai
Industrial Development Bank of India (IDBI), Mumbai
Indian Renewable Energy Development Agency (IREDA), New Delhi
State Bank of India (SBI) – Energy Business Division, Chennai
Visit to companies
Arunachalam Sugar Mills Ltd, Mallappambady
Lanco Power, Kondappalli
JK Pharmaceuticals Ltd, Cuddalore
EID Parry Ltd (Sugar Division), Nellikuppam
Tata Power Ltd, Trombay
Birla Tyres Ltd, Balasore
Gujarat Ambuja Cements Ltd, Kodinar
Apollo Tyres Ltd, Perambara
Shriram Fibres Ltd, Chennai
Indian Aluminium Ltd (INDAL), Kalwa
Larsen & Toubro Ltd – AP Cement Works, Tadpatri
Ennore Foundries Ltd, Chennai
Larsen & Toubro Ltd, Rajula Cement works
Grasim Industries Limited (Staple Fibre Division), Nagda
Jindal Vijayanagar Steel Ltd, Bellary
Motor Industries Company Limited (MICO), Adugodi, Bangalore
Sundaram Clayton Ltd, Chennai
Coromandel Fertilisers Ltd, Vizag
Sterlite Industries Ltd, Tuticorin
Century Pulp & Paper Ltd, Lalkua
SPIC Pharmaceuticals Ltd, Cuddalore
Rieter LMW Ltd, Coimbatore

Conclusion
693
Conclusion
Indian Renewable Energy Development Agency (IREDA) has received a line of credit from the
International Bank for Reconstruction and Development (IBRD) / Global environmental facility
(GEF) towards the cost of India: second renewable energy project.
As a part of this line of credit, technical assistance plan (TAP) is envisaged for institutional
development and technical support to IREDA. Preparation of this investors’ manual for
energy efficiency sector – industrial sub sector, as a guide to intending entrepreneurs, is one
of these TAP activities.
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
based on inputs from various stakeholders in energy efficiency sector.
Confederation of Indian Industry (CII) – Energy Management Cell (EMC) was awarded the
task of preparing this manual by IREDA.
CII – EMC adopted the following methodology in preparing this manual:
1. Analyze the existing data available with CII and develop a detailed action plan for execution
2. Identify industries under energy intensive and non-intensive categories
3. Review the detailed energy audits carried out by CII in various sectors and estimate
energy saving potential possible in identified energy intensive and non-intensive sectors
4. Analyze literature available with CII
5. Discuss with industry experts / Consultants
6. Identify list of energy saving measures to be undertaken in each industry
7. Evaluate technical details for each of the proposed energy saving measures in various
industries
8. Prepare / identify the list of equipment suppliers (National & International), EPS Contractors,
Energy Service Companies, etc., who can take up these energy saving measures
industries
10. Prepare / identify the list of consultants / energy auditors etc., who can be approached
for conducting energy audit, preparation of DPR, etc.
11. Interacting with IREDA and other financial institutions
12. Preparation of a brief note of finance mechanism available for taking up energy efficiency
projects from IREDA and other financial institutions

Conclusion
694
13. Preparation of a brief description of government policy / incentives / concessions available

for identified energy saving projects / equipment identified in various energy intensive and
non-intensive sectors
industries
The various sectors identified under this project, and the share of energy in the manufacturing
cost, is as under:
Sector Power & Fuel cost as

% of Production cost
1 Cement 43.7
2 Caustic Chlor 40.7
3 Aluminium 33.4
4 Glass 30.9
5 Ceramic 25.3
6 Copper 24.0
7 Paper 23.7
8 Fertiliser 18.4
9 Foundry 13.7
10 Steel 13.3
11 Sponge Iron 12.8
12 Synthetic Textiles 11.3
13 Textile 10.3
14 Engineering 6.0
15 Tyre 7.7
16 Drugs & Pharma 4.6
17 Dairy 4.2
18 Sugar 2.0
19 Petro Chemical 2.0
20 Refinery 2.0
The list of sectors identified under this project comprises of about 68% of India’s total
industrial energy consumption.
Energy saving – Case Studies

The objective of highlighting these projects & case studies is to facilitate the potential investors,
in having a quick reference of the various energy saving measures and also enable them
make decisions on investment.

Conclusion
695
These projects are all proven projects, which have been implemented successfully in Indian
industry.
Majority of the plants have still not implemented these projects, due to lack of suitable incentives
and financing.
The projects have been described in detail, highlighting the earlier & current practice, benefits
achieved, financial analysis and also its replication potential, wherever applicable.
Some of these projects / case studies are sector specific. But, majority of these projects have
potential to find an application in different sectors. These projects are not limiting to the
sector under which they are described. The idea can be replicated in other sectors also.
Summary of this report

The various sectors highlighted in this report offer an annual saving potential of
Rs 37510 million (USD 750 million). This, in turn, creates an investment opportunity of
Rs 82575 million (USD 1650 million), to achieve the projected energy savings.
S.No Sector Annual saving Investment opportunity

Potential Rs. Million, Rs. Million,
(US $, Million) (US $, Million)
1 Cement 3500 (70) 7000 (140)

2 Caustic Chlor 8600 (172) 30000 (600)
3 Aluminium 500 (10) 1000 (20)
4 Glass 550 (11) 800 (16)
5 Ceramic 350 (7) 725 (14.5)
6 Paper 3000 (60) 5000 (100)
7 Fertiliser 2000 (40) 6000 (120)
8 Foundry 1800 (36) 3500 (70)
9 Sythetic Fibre 1300 (26) 2500 (50)
10 Textile
11 Tyre 860 (17) 1750 (35)
12 Drugs & Pharma 1100 (22) 1800 (36)
13 Sugar 4200 (84) 6000 (120)
14 Engineering 5000 (100) 10.000 (200)
15 Copper 750 (15) 1500 (30)
16 Power Plants 3000 (60) 5000 (100)
Total 37,510 (750) 82,575 (1650)
This report will serve the objective of its preparation, in promoting / development of market for
energy efficient equipment & suppliers in Indian industry.

Confederation of Indian Industry
#35/1 Abhiramapuram 3rd Street, Alwarpet, Chennai 600 018.
Tel: 2466 1311 / 0570 / 0291 / 0430 (D) Fax: 24660312
E-Mail : gbc@ciionline.org Website : www.greenbusinesscentre.com

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2. Energy Saving Opportunities in Various Sectors

Power Plant 596

3. List of Suppliers Address 628

4. List of Energy Auditors 650

5. List of Energy Service Companies 654

6. Financial Mechanism 655

7. Government incentives 667

Indian Renewable Energy Development Agency Limited is a Public Limited Government

About Investors’ Manual

Objective of this Manual:

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

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

4. Analyze literature available with CII

5. Discuss with industry experts / Consultants

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

Confederation of Indian Industry - Energy Management Cell

11. Interacting with IREDA and other financial institutions

13. Preparation of a brief description of government policy / incentives / concessions available

Sector Power & Fuel cost as

* cost equivalent of bagassee consumed

Investors Manual for Energy Efficiency

Summary of this report

The energy intensive sectors not included in this report are:

The reason for exclusion of these sectors is:

• These sectors are technology specific

• The players in this sector are very few in number

S.No Sector Annual saving Investment opportunity

1 Cement 3500 (70) 7000 (140)

Investors Manual for Energy Efficiency

Confederation of Indian Industry - Energy Management Cell

India’s Energy scenario

Confederation of Indian Industry - Energy Management Cell

Energy Consumed in kJ per $ of GDP

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

Capacity Addition in last 5 yr Plan (MW) T & D Losses

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

Price (Rs./kWh) Avg. SEB Rate of Return

Investors Manual for Energy Efficiency

Electricity consumption in India

Electricity Consumption - Profile

Confederation of Indian Industry - Energy Management Cell

Energy Saving Opportunities in

Investors Manual for Energy Efficiency

Per Capita Consumption 100 kg

Energy Intensity 45% of manufacturing cost

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

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

Investment potential on energy

Confederation of Indian Industry - Energy Management Cell

2.0 Present Capacity & Capacity Utilisation

3.0 Growth Potential

Investors Manual for Energy Efficiency

4.0 Cement Manufacturing – technologies

• Wet process < 5% of the production

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

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