Indian Industry - Investor Manual for Energy Efficiency

8/22/2019 Indian Industry - Investor Manual for Energy Efficiency

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Confederation of Indian IndustryEnergy Management Cell



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C O N T E N T S

Page No.

Executive Summary

1. Introduction 1

2. Energy Saving Opportunities in Various Sectors

Cement 5

Caustic Chlorine 58

Aluminium 89

Glass 121

Ceramics 161

Copper 199

Paper 229

Fertilizer 310

Foundry 400

Textiles 448

Engineering 484

Sugar 530

Power Plant 596

3. List of Suppliers Address 628

4. List of Energy Auditors 650

5. List of Energy Service Companies 654

6. Financial Mechanism 655

7. Government incentives 667

8. Reference 689

9. Conclusion 693



Confederation of Indian Industry - Energy Management Cell

521

EXECUTIVE 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



Investors Manual for Energy Efficiency

522Introduction

8. Prepare / identify the list of equipment suppliers (National & International), EPS Contractors,

Energy Service Companies, etc., who can take up these energy saving measures

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

industries

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

11. Interacting with IREDA and other financial institutions

12. Preparation of a brief note of finance mechanism available for taking up energy 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

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

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 33.44 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 10.314 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




524Introduction

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

BackgroundIndia’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.




2Introduction

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.

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

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

average tariff

0

10000

20000

30000

40000

50000

60000

70000

R u s s i a

C h i n a

I n d i a

P o l a n d

S A f r i c a

I n d o n e s i a

T u r k e y

U S

U K

G e r m a n y

J a p a n

S w i t z e r l a n d

Energy Consumed in kJ per $ of GDP

Capacity Addition in last 5 yr Plan (MW)

30000

16000

Target Actual

T & D Losses

35%

10%

India Benchmark

Price (Rs./kWh)

3.4

1.41

0.22

1.922.42

Industry Domestic Agriculture Avg Price Cost

Avg. SEB Rate of Return

-12%

-18%

1992-93 1998-99




3

Energy conservation is one of the prime areas of focus to overcome the supply – demand gap.

Whilst the generation increase has been steady, the consumption pattern has also been

steady.

Electricity consumption in India

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.

010

20

30

40

50

P e r c e n t a g e

DOMESTIC IRRIGATION OTHERS

Electricity Consumption - Profile

1996-97

2001-02




4Introduction

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)




6Energy Conservation in Cement Industry

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 capitaconsumption of 255 kg in the developed countries.

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

India has the requisite quantity of cement grade limestone deposits, backed by 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 energyefficient.

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





Raw Mill Blending

& Storage

Coalstorage

CoalCrusher

CoalMill

Pyroprocessing

Clinker

storage

Cement

mill Packing & Despatch

Purchasedcoal

Slag or Fly-ash

Gypsum

Fine

Additives

Raw Meal

Fine

Mines Crushing Pre-blending

Block Diagram – Cement Industry – Dry Process Precalciner Process

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 kilnsystem. 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 manufacturingcost 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).





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





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 levelMedium-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





• 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

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

Limestone into fine raw meal powder. The older plants had Ball 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 theseparator 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.





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 highefficiency 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





Case Study - 2

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









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 pressuredrop. 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 stagesof 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 couldnot afford such a long stoppage and the consequent loss of production.





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

• Lower pressure drop across P.H.

• Reduction in P.H. fan power consumption

• Increase in clinker production

• Reduction in thermal energy consumption.


• Annual Savings - Rs.2.4 millions

• Investment - Rs.2.2 millions







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 cyclonesper 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

BackgroundThe 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.





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





Case Study - 5

Usage of Cheaper Fuels for Calciner Firing

BackgroundThe Kiln and the Calciner are major consumers of fuel in a Cement plant. The fuel 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 possibleto 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








31

Case Study - 6

Variable Speed Fluid Coupling for Cooler ID Fan andReplacement 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.







• Investment - Rs. 0.5 millions


• 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 VFCin manual fashion, it was put in closed loop with the hood draught.

The project took about 2 week for installation. This was taken up along with the annual 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. Theinvestment 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




33





Case Study - 7

Variable Frequency Drives for Cooler Fans

BackgroundThe 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.





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


NoteThough 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





Case Study - 8

Replacement of Existing Cooler I Grate with High EfficiencyCooler 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 replacedwith 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 benefitsachieved are as below.

Parameter Before Implementation After Implementation

Clinker Production 2800 TPD 3000 TPD

Cooler air 2.6 Nm3 / kg 2.1 Nm3/ kg

PH outlet air 1.475 Nm3/ kg 1.444 Nm3/ kg

Clinker Temperature 180. C 120. C

PH outlet Temperature 370. C 336. C

PH loss 217 kcal / kg 191 kcal / kg

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

Radiation loss 69 kcal / kg 65 kcal / kg

Heat Consumption 780 kcal / kg 745 kcal / kg

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

• Compact - hence less radiation losses

• 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).


• Annual Savings - Rs. 12 millions

• Investment - Rs. 29 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 40mill ions. 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









Case Study - 9

Installation of Low Primary Air Burner in Place of ExistingConventional 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 theimplementation 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)












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 wereconveyed 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)


• Annual Savings - Rs. 15 millions• Investment - Rs. 40 millions

• Simple payback – 32 months








49

Case Study - 11

Conversion of Open Circuit Cement Mills to Closed Circuit byInstalling 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 theseparator 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. Thecapacity and other details of the mills are shown below.

The total production of the two Cement Mills was 70.8 TPH at a specific power 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. Theseparator 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 toRs 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.

Thermal Energy Balance - Typical

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%

170 kCal/kg

330

o

C

Kiln – Theoretical –requirement – 420 kCal/kg

300°C

Radiation loss70 Kcal/kg

Preheater

Cooler

750 Kcal/kgCoal firing

140 kCal/kg(Recoverable)





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





Supplier Address

High-efficiency separator Mr V C RaoManaging Director LNV Technology Private Limited

I-E, Alsa Regency (1 floor)165, Eldams Road

Chennai - 600 018

Tel: 2431 4259/69/79

Fax: 2431 4289

[email protected]

AUMUND ENGINEERING PVT. LTD.LAKSHMI NEELA RITE CHOICE CHAMBERS

5, BAZULLAH ROAD, T. NAGAR,

CHENNAI - 600017

Tel. No. : 91-44-28222048/49

Fax : 91-44-28222046

Material Handling EquipmentMr K.J.PuetzChairman & Managing Director

Mr. Rajiv ManchandaSr. Vice President - Corporate

Enexco Teknologies India LimitedB-17, Geetanjali Enclave

New Delhi -110017

Phone: +91-11-2669 2847- 50 (4 lines) / 2669

1524 / 2669 2425(2 lines)

Fax: +91-11-2669 1543

Email: [email protected]

Bharat Heavy Plate &Vessels Limited(Ministry of Industry, Department of Heavy

Industry)

B.H.P.V Post

Visakhapatnam –12

Andhra Pradesh

Phone : 0891-517381 - 91 (10 lines)

Fax : 0891 – 517626

Mr. R G Kumar Director

BHP ENGINEERS LTD.F-42A,1st Main Road,

Annanagar East

Chennai-600102

Tel: +91(044) 26208176

Fax: +91(044) 26203328

Email: [email protected] /

[email protected]/

[email protected]

All cement plant machineryMr. A K DemblaPresident - Marketing

Humboldt Wedag India Ltd.

C-29, Ground Floor, Nehru Enclave

Opp Paras Cinema

New Delhi 110019

Tel: 011 26426031/5037/26416578

Fax: 011 26443175


Mr Rakesh SharmaVP - Mktg & Business Dev

Fuller India LimitedCapital Towers

180, Kodambakkam High Road

Chennai 600034

Tel: +91 (44) 28253182 (D) / 8276030 / 8276343 /8279569Fax: +91 (44) 28279393


Mr R. K SharmaHead Marketing

Larsen & Toubro LimitedCement & Allied Machinery

G4 Building, 2nd Floor

Powai Works, Saki-Vihar Road

Mumbai 400 072, India

Tel:+91-22-28581401/11 Extn:2423 / Direct line:

+91-22-2858 1752

Fax: +91-22-28581633 / 28581126

e-mail: [email protected]

Automation SystemsMr. Arjun Gupta

Techfab Systems507 Eros Apartments, 56 Nehru Place

New Dehli - 110 019

Tel.:+91.129.527 29 95

email: [email protected]

Prof Mathai JosephExecutive Director

Tata Consultancy Service1, Mangaldas Road,

Pune - 411 001

Phone: +91 20 612 2809

Fax: 91 20 612 3713


Mr Jayant KulkarniManager – MktgSystems

Tata Honeywell Limited55-A/8 & 9, Hadapsar Industrial Estate

Pune 411 013

Tel: +91 (020) 2675531 / 672612

Fax: +91 (020) 2679404 / 672205


Mr Debashish Ghosh

Manager Commercial MarketingAllen-Bradley India LtdC-11, Industrial Area




57

Site 4

Sahibabad

Ghaziabad 201010

Tel; +91 (120) 2895247 – 52


Mr K S Krishna Kumar Product Executive

Ramco Systems LimitedSBU Head - Enterprise Process Solutions

No 64, Sardar Patel Road

Taramani

Chennai 600113

Tel; +91 (44) 2354510

Fax: +91 (44) 2352884


Fly-ash conveying systemMICAW BEEKAY LTDBeekay House, L-8,

Green Park Extension

New Delhi -110016

ConsultantsMr. VasudevaUnit Director

National Council for Cement and BuildingMaterials A-135, Defence Colony

New Delhi-110 024

Tel:0129- 5241963,5310909,5312423

Fax: 91-129-5242100Email: [email protected]

Mr A K PathakPresident & Chief Executive

Research and Consultancy Directorate

ACC-RCD ACC Campus

LBS MARG

Thane 400 604

Tel: 022 25823631

Mr Kapil WadhawaDeputy Manager

Holtec Engineers Pvt LtdHoltec Center,

A Block, Sushant Lok

Gurgoan-122001

Phone: (91) 124-638-5095

Fax: (91) 124-638-5114

E-mail: [email protected]

Vertical Roller MillsMr. K B SharmaVice President - Marketing

LOESCHE INDIA Ltd.E-2, First Floor, Defence Colony

New Delhi-110 024

Telf:91 11 2464 76 70

Fax:91 11 2464 76 74

[email protected]

Waste Heat Recovery Systems

Mr Edward J. LoringSales & Marketing Manager

Exergy IncorporatedPost Office Box 209

Hanson, MA 02341

Tel: (781) 294-8838

Fax: (781) 294-8144

[email protected]

Mr Yehuda Lucien BronitzckyChairman

Ormat Industries LimitedPO Box 68, 81100 Yavne

Israel

Tel: 972 8 943 3777

Fax: 972 8 943 9901

[email protected]

Dr J M ChawlaManaging Director

Caldyn Thermowir Pvt. Ltd. A-102 Satya Apartments

Masab Tank

Hyderabad 500028

Mr Tadashi NishimuraExecutive Vice President - Marketing

Kawasaki Heavy Industries Ltd.8, Niijima, Harima-cho, Kako-gun,

Hyogo 675-0155, Japan

Phone : 81-794-35-2131

Fax : 81-794-35-2132

Mr A K SundararajanDy General Manager

Bharat Heavy Electricals Limited

Tiruchirapalli-620014Phone - 91(431) 2520713, 2520642

Fax - 91(431) 2520306

Mr S V PendseSr Manager – Sales & Marketing

Thermax LtdEnergy systems DivisionD-1, MIDC Industrial Area

Chinchwad,

Pune 411 019

Tel : (020) 4126349

Fax : (020) 7474640

Email : [email protected]




58Energy Conservation in Caustic Chlorine Industry

Caustic Chlorine

Per Capita Consumption 1.5 kg

Growth percentage 5.5%


Energy Costs Rs 17900 million (US $360 million)

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


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 usedin 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%.





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)

Globally the chlor-alkali industry

is driven by the demand-supply

of chlorine unlike in India and

therefore globally, caustic soda is

considered as a byproduct.

Demand for chlorine is higher than

that of caustic and many a times

a part of caustic produced in the

process is wasted.

Domestic Consumption Pattern of Caustic Soda in Various Sectors

9%

30%

12%14%

25%

2%

8%

0%

5%

10%

15%

20%

25%

30%

35%

C h e

m i c

a l

P a p e r &

P u l p

A l u m

i n a

S o a p

I n d u

s t r y

M a n m a d e F i b r

e s

W a t e r

T r e a t m

e n t

O t h e

r s

P e r c e n t a g e




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.





Domestic Consumption Pattern of Caustic Soda in Various Sectors

9%

30%

12%14%

25%

2%

8%

0%

5%

10%

15%

20%

25%

30%

35%

C h e

m i c

a l

P a p e r &

P u l p

A l u m i n

a

S o a p

I n d u

s t r y

M a n m a d e F i b r

e s

W a t e r

T r e a t m

e n t

O t h e

r s

P e r c e n t a g e

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:

1343.8

1481.3 1480

1200

1300

1400

1500

000'Metric

Tonne

Year

Year wise Production for Caustic Soda

Series1 1343.8 1481.3 1480

1999-2000 2000-2001 2001-2002




63

Conventional 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:





Mercury Cell

Raw SaltDiluted Brine

Raw Brine

Caustic PrecipitantsSolution

Dechlorination Residue

Purified Brine

Hydrochloric Hydrochloric AcidAcid

Anolyte

Amalgam MercuryWater

CausticSolution(47.5%) Hydrogen

Dispatch/ Flaking Unit Hydrogen Dispatch

Bottling/ BoilerFlaking Unit

BrineSaturation

Precipitation

Filtration

HeatExchangers

Cooling

Drying

Compression

Liquefaction

Bottling

Electrolysis

Amalgam

Decompositio

Cooling

Storage

Mercury

Removal

Mercury

Removal

Cooling




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:

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 findsmore market like in pharmaceuticals, semiconductor,

biotech etc.

The disadvantages of this process are:

• Itis more capital intensive

• It requires dependence on imports for technology.

• The selectively permeable membrane is manufactured under patent by only a select

companies in the world. The three major names in this business are Dupont, ICI Chemicals

and Asahi Chemical Co under different brand names.

Na+Æ

H2OÆ

CathodeAnode

Weak

NaOH

Soln

Feed Brine Dilute caustic soln (28%)

Lean brine, Cl2 H2, NaOH (32%)





350-370o CTo Vacuum

Caustic Molten(47.5 %) Salt

(400-450o C)

66 % 98 %

Vacuum

Caustic Flakes

Pre

concentrationFinal

concentration

Flaking

D rum

Salt

Heater

• 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:

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 90-180Total 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 membraneprocess. In a caustic chlorine process, all the energy consumption is measured on 100%

caustic output basis.

1) Cell house:

Two kinds of cell configurations are preferred in the manufacturing process. Depending on 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.





View of membrane cell house

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.

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

concentrator unit. The energy consumption in the

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.

Brine Distribution arrangement in cell

house




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.





CASE STUDY 1

Avoid Valve Throttling at the Identified Pumps of Brine Sectionby 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

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

about a quarter of this potential has been tapped. The

potential for replication is therefore very high for this

project.








71





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






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.












77

CASE STUDY 4

Install Thermocompressor And Utilise Flash Steam in theI- 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 livesteam 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

Rs. 3.20 million. This required an investment of

Rs. 4.50 million and got paid back in 17 months.












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%.





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 withinvestment of Rs. 7.0 million (including civil work and controls), which had a simple payback

period of 15 Months.








81





Case study 6

Install commercial Co-generation system for Caustic ChlorineIndustry

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

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.

Flue gas180-200oC

Flue gas380-400

o

C

Steam for evaporator (12 KSC)

Jacket Jacket 5.8 TPHwater water

50oC-55oC 75oC-80 oC

Steam for brine house3.3 TPH (5-6 Ksc)

Steam for flaking unit1.7 TPH (12 Ksc)

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

1.5 TPH

Waste heatrecovery boilers

Chilled water 8-

10 Deg C

DG Set 25 MW

VAM

Chlorine

liquefaction





• Cooling the DG room by cool air at 24-25 Deg C will increase the efficiency of DG by 1-

1.5 % as for every 6 Deg C reduction in room temperature there is a increase in 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





CASE STUDY

Convert existing mercury cell based plant to membrane cellbased 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 anold 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% to47.5% (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.








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)




90Energy Conservation in Aluminium Industry

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

3.2 Energy consumption is Smelting process

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.

Alumina

Bauxite

Preparation

0.37 GJ/T

2.3%

Precipitation

1.06 GJ/T

6.5%

Digestion

4.79 GJ/T

29.5%

Settling

Washing

0.65 GJ/T

4.0%

Evaporation

4.3 GJ/T

26.5%

Calcination

5.07 GJ/T

31.2%

Electrolysis Process

Process heat

29.2 GJ/T

16.2 KG/Ton

5.8 GJ/T

Electricit

Molten metal

14.9 GT/T

through

Radiation,

Convection &

Other losses

Al2O3





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 (Al2O

3. 3H

2O),

boehmite (Al2O

3), Diaspore (Al

2O

3.H

2O) 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 processThe 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):

Al2O

3.xH

2O + 2NaOH —> 2NaAlO

2+ (x+1) H

2O

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 —> Al

2O

3.3H

2O + 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.





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

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

(Na3 Al F

6) 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 the350-400,000 tonne range.

ALUMINA REFININGS

90.9%

CaO 39 kg

Na2Co3 74 kg

Water 921 l

REDMUD

1963 kg

Bauxite49%

A12032247 k

Alumina1000 kg




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.

2Al2O

3+ 3C —> 4Al + 3CO

2

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

—> Al2O

3+ 3CO

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

The electrolyte used is cryolite (Na3 AlF

6) 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





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.

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

Bath

Make – up

99%

Alumina

Carbon

Anode

Electrolytic

Reduction

Gas

1340 kg

Molten

Aluminium

Blendin

Slag

A1=A1203

A1

INGOTS

Flux





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 pumps11. 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 LIQUORPUMP 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

40%

1752 – ½

100 m3

/h75 m

75 kW

(58.5 kW)

Spent liquor

tank





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





Case study –2

INSTALL THERMO-COMPRESSOR AND RECOVER FLASHSTEAM 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 consumptionin the digesters is about 58-60 TPH at a pressure of 70 kg/cm 2.

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/cm 2 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/cm 2 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

140°C

4 – 6 ksc

Condensate to

Steam Plant

100°C

PureCondensate

Tank

Vent

Steam

Flash

Steam

60 TPH

70 ksc

260°C

Digester

Flash

Vessel

3 TPH

Steam Plant

Flash

Steam

Evaporator or

LP header

ThermoCompressor

Motive Steam 14

– 15 ksc

PCT


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/cm 2.

The schematic diagram of the modified system is shown below.





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





Case study – 3

INSTALL SEAL POT SYSTEM FOR CONDENSATE RECOVERY

BackgroundConventional 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

Sealpot

Airvent

Digester

MP steam

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


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














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 O

2level 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.





Financial analysis










111





Case study -5

SEGREGATE PICK-UP AND DRYING ZONE VACUUMS IN REDMUD 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 completeand drying takes place. This zone typically requires a vacuum of about 250-280 mm Hg.

Typically in this system one set of vacuum pumps are used for maintaining the same 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 arededicated 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.

Benefits

Segregation of vacuum pumps for the pick up and drying zone resulted in electrical energy

saving of 1800 units/day.

Financial analysis

This amounted to an annual monetary saving of Rs 0.79 million. The investment made wasRs 2.00 million. The simple payback period for this project was 31 Months.

250 mm Hg

1320 m /h

510 mm Hg

125 HP

11 Nos. (6↑)

400 mm Hg

400 mm Hg

400 mm Hg

300 mm Hg

RMF












115

Case study –6

SWEETEN THE DIGESTION PROCESS BY ADDING GIBBSITICBAUXITE 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.





Gibbsitic slurry addition in the downstream of slurry addition


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, 16,985MT 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

million. The simple payback period for this project was

1 Month.

Boehmitic

Bxt. Slurry

FREQUENY

DRIVE FOR

FLOW

CONTROL

Gibbsitic Bxt.

Slurry

Sweetening

S.H.Tic

600 psig steam

243 C 243

0C 243

0C 243

0C

1 2 3 4 5 7 6

Spent Liquor




• Simple payback - 1 month




117





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 “pointfeeders” 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

Financial Analysis

The annual energy saving potential @ Rs 1.80/unit is

Rs 84.10 million.


• Annual Savings - Rs.84.10 million








120Energy Conservation in Glass Industry

Glass

Growth percentage 7.2 %

Energy Intensity 30 % of manufacturing cost

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

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


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 3 00 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.





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.





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 themelter.

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.





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 regenerativefurnaces.

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 FibreThe 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.





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 andgeneral 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 andmethod of operation. However, the majority of glass is produced in large furnaces and the

energy requirement for melting is generally below 8 GJ/tonne.





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 ruleeach 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 lossesand 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.




131

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 industry1. 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





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 pumpsfor hp compressor cooling

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

in the flue gas

15. Preventing cold air from entering through the inlet opening of the lehr and reducing 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 load26. 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 UsingWaste 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 presentlevels and to preheat the batch to 400 oC. Depending upon the specific operating conditions,

5-10% of the energy necessary to melt glass could be obtained from waste heat.

By this method, the total fuel consumption by the furnace can be reduced by 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.





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 preheatingThe 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).




135

• 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 energyconsumption of about 4000 kJ/kg of glass. The temperature of exit flue gas from the furnace,

after the regenerator is about 450-500oC.

The fuel consumption of the plant was about 35kl/day. The cullet in the feed amounted 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






137

Case study - 2

The installation of preheater have successfully implementedin 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.





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 sizeand 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. Theflame 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





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

Losses through theCrown and walls 20 –40%

Melting Furnace

Combustion AirRecup

erato

Exhasust Gas LossesApprox 40%

Energy Recovered

through the

preheating of thecombustion air

approx 30%

Energy input

from Gas / Fuel

oil 100%

Melting andRefining energy 20

–

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 tospecific 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.





Case study – Install Regenerators for glass meltingfurnaces

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 consumptionby the furnace. The new specific fuel consumption is about 310 lit/ton of glass melted.

The cost economics of the project is as below:

Investment – Rs 30.0 million

Savings – Rs 20.0 million

Payback – 18 months

Majority of the organized sectors in India have adopted this technology of regeneration in 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





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




145





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 energyefficient.

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

Case study: A 200 tpd container glass manufacturing industry had

a melting furnace with its sidewalls at a temperature

of 230oC initially. The total surface area at this

temperature was about 6 m2. The amount of heat

loss with this surface temperature is 12000 kCal/h

(@6100 kcal/m2h).

The plant team increased the insulation levels, by

incorporating AZS refractory bricks supported with high

alumina and ceramic fibre layers and reduced the

high alumina

block

= 120oC

950




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 excelglass proposal in backup)



Payback - 8 months








149

Case study - 5

Modifications in the design of crown to reduce radiation lossand improved quality of glass

a. Reduce gap in the crown of melting furnace and reduce radiation of loss

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 refurbishingthe 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








151

Redesigning the crown to minimize contamination of glass

The raw material fed into the glass-melting furnace consists of small quantities of Na2CO

3,

added as flux to reduce the melting temperature of glass.

At high temperatures Na2CO

3vaporizes 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 corrodingthe 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.

4820

Size of the crown bricks

375 x 150 x 75 / 65 2592375 x 230 x 75 / 65 144





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 % O2should 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.




153

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 cfmof compressed air at a pressure of about 3.5 kg/cm2.





The plant had four nos. of reciprocating compressors of 2500 cfm capacity each to meet 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





Case study - 8

Replace pneumatic conveying with mechanical conveyingsystem 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 pneumaticsystems 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





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 thecost of oxygen and the possible effect of the higher flame temperatures on the furnace life,

particularly on the silica crown roof.

Typically, the cost of supplying O2

when compared with the cost of reduced fuel firing 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 andthe 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.





Supplier Address

Preheaters :

Zippe Industrieanlagen GmbH, Alfred-Zippe-Strasse,

D – 97877 Wertheim, Germany,

P.O Box 1665, D – 97866 Werthim,

Germany

Tel: + 49 9342 8040

Fax: + 49 9342 804138


www.zippe.de

SORG (Melting furnaces, preheaters)Nikololaus Sorg GmbH & Co KG

PO Box 1520

97805 Lohr am Main

Germany

Tel: 0 9352 / 5 07-0

Fax: 0 93 52/5 07-196 / 507-204-507-234

email : [email protected]

www.sorg.de

Indian representative for Zippe & SorgMascot Engg. Company

World Trade Centre

Cuffe Parade

Tel: + 91 22 2187165

Fax: + 91 22 2187166


www.mascotindia.com

Crown, regerators, recuperators, refractory

materials

Vesavius VGT – DYKO

Wieesenstr, 61

40549 Dusseldorf – Germany

Tel: +49-211-502900

Fax: +49-211-502659


Refractories:

Carborundum Universal Ltd – cross check

address

Tiam House Annexe,28 rajaji Road, Chennai

600 001, India

Tel: +91 44 2511652

Fax +91 44 2510378

Glass Fabrication equipment manufacturer

Oilvotto

10051 Avigliana (Torino) Italy

Tel: +39 011 9343511

Fax: +39 011 9343593


www.olivotto.it

Indian Representative for Olivotto

CV Chalam & Consultants

Fuller

Ingenieurburo

Dipl-Ing(FH) Herman Fuller

Schulstrabe 39

D – 94518 Spiegelau

Tel. +49 – 0 –8553518

Fax +49 – 0 –8553514


www. f-gt.de

Instrumentation & Control

Glass Service Inc

Rokytrive,60,75501,Vsetin

Czech replublic


www.gsl.cz

Oxygen suppliers

BOC Gases/India Oxygen ltd

Oxygen House, P43 Taratala road,

Kolkatta700-088, India

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)




162Energy Conservation in Ceramic Industry

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





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 (Al2O

3), Silica (SiO

2), Zirconia (ZrO

2) and silicon

Nitride (Si3N

4) 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 pugmills 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.





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.





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 motors2. Use transluscent sheets to make use of day lighting






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 byother units also to achieve the benefits.





A word of caution here. Each plant is unique in its own way and what is applicable in one 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 withInsulating 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 thicklayers 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.





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





Case Study 2

Provision of Insulation for the Furnace Shell Electric arc furnaceinsulated 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 coolingthe 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

Cost benefit analysis• Annual Savings - Rs. 1.08 millions










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 StatusThe 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 – 110 oC,

resulting in high radiation losses.


The practise of constructing single layered insulating brick for thetemporary door was changed to a multi-layer (3 Layers) insulating

brick construction. An air gap was also maintained between the layers. The concept 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.





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





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 stackingpattern plays a vital role in energy consumption of

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

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.

Optimised load on kiln car

Kiln




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 consumptionCost benefit analysis














• 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)


The use of low thermal mass materials (cordierite

etc.) in kiln cars resulted in thermal mass reduction,

thereby resulting in fuel savings.

The other advantages of LTM materials are Fuel

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

Hollow Corderite holding structure with ceramic

coated pipe supports

Hollow

corderite Ceramic fiber

Hollow

ceramic pipe




185

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












187

Case Study 6

Installation of Recuperators at the Cooling End of Kiln andUtilising 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.





Benefits of recuperators• Waste heat from kiln cooler utilised

• Elimination of fuel for drying raw wares








189





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 200-250 oC.

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.


240°C

3000 – 3500 kg/hr

HAG

Pro osed Line

Kiln

E




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












193

Case study 8

Install Variable Frequency Drive For Circulating Air Fans InVertical 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












195

VD – 1

VD – 2

HAG

HAGHAG





Case study 9

Replace conventional tunnel kiln with energy saving roller kilnfor 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

appropriate residence time. The roller kiln consists

of a firing section and a cooling section.

Schematic slice of the roller kiln




197

The products are fired at a maximum temperature of 1250°C. The burners and all the 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












199

Copper

Per Capita Consumption 400 gms


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

Energy saving potential Rs 750 million (US $ 15 million)

Investment potential onenergy saving projects Rs.1500 million (US $ 30 Million)




200Energy Conservation in Copper Smelters

1.0 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 wasestablished 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.




201

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 TPATamil 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%.





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 InvestmentThe 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:

Energy

Oxygen

Copper

FluxCopper

Anodes

Sulphuric

Acid

SO2

Sulphuric

Acid

Rock Phosphate

Pure

CopperPhosphoricAcid

Copper Smelter

SulphuricAcid Plant

Phosphoric

Acid Plant

Refinery




203

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 theproduction of Sulphuric acid (H

2SO

4.). 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 SO 2.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.





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 byutilising 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





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 210volts

Medium Term

1. Installation of automatic power factor controllers and maintaing high PF

2. Installation of separate lighting transformers and optimising the lighting voltage

3. Replace old rewound motors with energy efficient motors

4. Installation of Soft Starter cum Energy saver for lightly loaded motors

Long Term1. 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 exhaustgases 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 condensingturbine to generate 6.5 MW of power. This is about 20% of total power requirement of the plant.





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 theproduction 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 - IIThe 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





Case study – 2

Install Vapour Absorption Machine (VAM) for refrigerationsystem in Sulphuric Acid Plant (SAP) by utilising the heat

of ISA furnace exhaust gasesBackground

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 throughflue 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

pay back in 23 months.








211





Case study – 3

Installation of Variable Fluid Coupling for SO2

blower atSulphuric 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.

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.

-151MM -770MM -969MM

Mixer Quencher Vent.. Humidif.

ESP

Mixer

-156MM

-10 to –20 MM

2300 kW

2728 MM




213


The plant team installed a variable fluid coupling for the SO2

blower and avoided the operation

of inlet guide vane

Implementation Methodology 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

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.












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 wasconsuming 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 wasinstalled 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.

BenefitsThe 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.












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 StatusThe 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.


This project has a replication potential in four more

plants.












219

Case Study-6

Replacing Electrical Heating with Steam Heating for F.O Heatersand 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 investmentmade was around Rs.1.00 million. The simple payback period was 13 months.








221

Case Study –7

Installation of Variable Fluid Coupling for converter blower

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 theblower.

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.












223

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.

Case study 8

Utilise heat of smelter furnace exhaust gases to preheat thecombustion 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












225

Case Study – 9Install waste heat recovery system for anode furnace exhaustand 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.












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 PlantMassluisedijk,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


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.






ME Engineering Limited Waste Heat Recovery systems

Sai Chambers for copper smelters

15 Mumbai Pune Road,

Wakadewadi,Pune 411 003,India

Tel: 00-91-20-5511010Fax: 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


Thermal Systems (Hyd) Pvt. Ltd. Waste Heat Recovery Steam GeneratingPlot No.1, Apuroopa TownshipI Systems for S.A. Plants, Nitric Acid,

DA, Jeedimetla Ammonia, Hydrogen plants 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 RoadNew 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 / 7374Fax: +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




229

Paper

Per Capita Consumption 5 kg


Energy Intensity Rs 1500 million (US $ 300 million)

Energy Costs 25% of manufacturing cost

Energy saving potential Rs.300 Million (US $ 6 Million)


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




230Energy Conservation in Pulp and Paper Industry

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:

3.10%2.50%

4.40%

3.10%

2.10%

6.50%

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

7.00%

A fr ic a A si a A ust ra li a Eu ro pe L a tin

A me ri ca

North

A me ri ca




231

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





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, Orissa24. 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




233

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%.


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.

519 28.4 34 39.6

331.7

215.8

249.9

0

50

100

150

200

250

300

350

I n d i a

I n d o

n e s i a

C h i n a

T h a i l

a n d

B r a z i l

J a p a

n U S

A U K





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 m3/ MT of FNP 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




235

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 estimatedinvestment required to realize this savings potential is Rs.5000 million.

The pulp and paper industry has an attractive cogeneration potential of over 100 MW,

in addition to the existing cogeneration plants.

5.1 Major factors that affect energy consumption in paper 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





- 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 2.0Chemical 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) 100Effluent 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:





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.





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 andpaper 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




241

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

1. Install delta to star convertors for lightly loaded motors2. Use transluscent sheets to make use of day lighting








E. Miscellaneous






5. Install level indictor controllers to maintain chest level

6. Install hour meters on all material handling equipment, such, pulpers, beaters etc.





8.1.2 Medium Term Measures - Savings Potential upto 10%


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 pumps15. 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




243

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 Areas1. Install maximum demand controller to optimise maximum demand

2. Install capacitor banks to improve power factor

3. Installation of thyristorised rectifiers

4. Replace rewound motors with energy efficient motors

5. Install energy efficient motors as a replacement policy

6. Thyristor room AC units provided wit timer control

7. Replace HRC fuses with HN type fuses

8. Replace 40 Watts fluorescent lamps with 36 Watts fluorescent lamps





9. Replace conventional ballast with high efficiency electronic ballasts in all discharge lamps

10. Install SV lamps at wood and coal yard areas instead of MV lamps

11. Install LED lamps for panel indication instead of filament lamps

12. Install CFL’s for lighting in non-critical areas, such as, toilets, corridors, canteens etc.

13. Installation of neutral compensator in lighting circuit

14. Optimise voltage in lighting circuit by installing servo stabilisers

15. Minimising overall distribution losses, by proper cable sizing and addition of 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




245

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





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




247

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.





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

BackgroundThe 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 capacityrequirements, 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.




251


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. Thetime 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.












253

Case Study No.3

Replacement of Suction Couch Roll by Solid Couch Roll in thePaper 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.






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:




257

• 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 stat ic 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.








259

Case Study No.5

Recovery of Chemicals from Spent Liquor Obtained fromCounter 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 generallyconsidered 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.





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 theproblem 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 Na2CO

3= 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




261

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.












263

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.






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

boiler ID fan.

Concept of the projectThe 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.










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.




265




267

Case Study No.8

Conversion of Spreader Stoker Boilers to Fluidised Bed Boilers

BackgroundThe paper plant is a major consumer of thermal energy in the form of steam. This 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.






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 andintegrated paper mills, particularly, those plants which is looking at augmenting its boiler

capacities and adopting high pressure cogeneration systems.








269





Case Study No.9

Conversion of MP Steam Users to LP Steam Users to MaximiseCogeneration

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 theextent 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 statusOne 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.




271

The comparison of power generation with MP steam and LP steam are as follows:

• 1 MT of HP steam extracted as MP steam generates 67 kWh

• 1 MT of HP steam extracted as LP steam generates100 kWh

Hence, replacement of 1 MT of MP steam with 1 MT of LP steam can aid in generating about23 kWh of extra power.


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.


This project has very good replication potential in almost all the paper plants have a commercial

cogeneration system.



• Investment - negligeble








273

Case Study No.10

Utilisation of Bamboo Dust along with Coal Firing in the CoalFired 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 statusIn 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.

Concept of the projectThis is an excellent cost reduction and waste disposal method.

Even though, there are several proven cases of utilisation of alternate forms of fuel, 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 analysisThe 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.




275





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 rawwater requirements of the entire plant. The pumps were of the following specification:

Three pumps Three pumps

• Capacity = 772 m3/h • Capacity = 522 m3/h

• Head = 35 m WC • Head = 35 m WC

• Motor rating =125 HP • Motor rating = 75 HP

• Design efficiency = 86.5% • Design efficiency = 80%

To meet the normal plant requirements, the operating pattern of the pumps were as follows:

• 3 pumps of 125 HP, run for 24 hrs/day


• 1 pump of 75 HP, kept as stand-by pump, to take care of any exigencies.

On detailed analysis of the pumps, it was observed that the three 125 HP pumps 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%.




277

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 patternof the pumps changed to:

• Three 125 HP pumps, run for 24 hrs/day

• One 125 HP pump, run for 12 hrs/day

• Two 125 HP pumps, kept as stand-by

No problems were faced during the installation of the new pumps, since there was a stand-

by pump available. The new pumps were installed one-by-one. The total time taken 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.












279

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/cm

2

and 4 kg/cm

2

(assuming therequired 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.






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.








281






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 alsoincluded 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 inthe 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.



• Investment - negligible




283

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 rawwater requirements of the entire plant. The pumps were of the following specification:

Three pumps Three pumps

• Capacity = 772 m3/h • Capacity = 522 m3/h

• Head = 35 m WC • Head = 35 m WC

• Motor rating =125 HP • Motor rating = 75 HP

• Design efficiency = 86.5% • Design efficiency = 80%

To meet the normal plant requirements, the operating pattern of the pumps were as follows:



• 1 pump of 75 HP, kept as stand-by pump, to take care of any exigencies.

On detailed analysis of the pumps, it was observed that the three 125 HP pumps 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 highas 87%.





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 patternof the pumps changed to:

• Three 125 HP pumps, run for 24 hrs/day

• One 125 HP pump, run for 12 hrs/day

• Two 125 HP pumps, kept as stand-by

No problems were faced during the installation of the new pumps, since there was a stand-

by pump available. The new pumps were installed one-by-one. The total time taken 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.








285

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/cm

2

and 4 kg/cm

2

(assuming therequired 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.






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.








287

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 investmenton 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






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 themedium size paper mills.








289





Case Study No.14

Installation of Heat of Compression (HOC) Air Dryers

BackgroundCompressed 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.












293

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:





• 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.








295





Case Study No.16

Installation of Extended De-lignification Pulping Process insteadof 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 takesplace, 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%




297


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%.





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.








299





Case Study No.17

Improved Paper Machine Design to Improve Production

BackgroundThe success of a paper mill is determined not only on the basis of quality and quantity of 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.








303


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 : [email protected] 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 RecausticizersFax : 044 – 24322412 Desilication plant


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 : [email protected] : 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 pumpsTel. : 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



9.0 List of Contractors/ Suppliers






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


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


Alfa Laval India Ltd. EvaporatorsMumbai -Pune Road

Dapodi Pune - 411 012

Tel. : (020) - 24116100 / 27107100


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 - 2442692Fax : 0422 - 2456177


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


Pap-Tech Engineers & Associates Controls for paper machine pH, FlatR-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 : [email protected] 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


Web : www.rubymacons.com




305


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


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


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


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


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 systemTel. : 044 - 26252191/ 3191 Screw presses

Fax : 044 – 26250836 UTM pulpers

Email : [email protected] Agitators Multi effect evaporators

Indo Gears and Machinery (India) Tri Disc refiners

48, New Arya NagarChowk Meerut Road

Ghaziabad – 201 001

Telfax : 0120 – 22714877






Nash Water Technology Private Limited67-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


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


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 – 25820771Web : 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




307

10.0 List of Consultants


Indian Companies v Project consultancy in paper plants &

SPB Projects and Consultancy Limited power plantsEsvin House, Perungudi v Management services

Chennai – 600 096

Tel. : 044 – 24961056/ 1079/ 0359

Fax : 044 – 24961625


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 : [email protected] 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 : [email protected] 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


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


Web : www.uhdeindia.com






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 boilersFax : +65 6392 8511


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


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


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: [email protected]

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


Contact : Mr Yngve Lundahl

Regional Sales Manager - Fiberline




309


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 : [email protected]

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 : [email protected] • 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 : [email protected] • 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


Web : www.voith.com




310Energy Conservation in Fertilizer

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%P2O

5) 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%K

2O) or as a complex

NPK fertilizer component.

3.0 Types of fertilizersThe key fertilizers used in India are:

Urea supplies around 83% of the total nitrogen requirements. It is manufactured from 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%





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 increaseduse 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%.





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 thecountry is unevenly distributed, being much higher in regions with assured irrigation.

The region-wise break-up of number of industries and capacity is highlighted below:

Nitrogeneous Fertilizers Phosphatic Fertilizers

Region Numbers % share to Numbers % share 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)





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)




317

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)





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.




319

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 H2using 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 oftenremains 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.





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 unitsThe 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





- 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

1. Install delta to star convertors for lightly loaded motors

2. Use transluscent sheets to make use of day lighting












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 pumps8. 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

1. Install maximum demand controller to optimise maximum demand


3. Installation of thyristorised rectifiers

4. Replace rewound motors with energy efficient motors5. 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





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 ammoniastorage system

4. Floating type aerator in place of fixed aerators

5. High efficiency diffuser aerators instead of conventional aerators

6. Treatment of effluent through activated sludge lagoon resulting in stopping of aerators

7. Use of ETP filter cakes in boilers

8. Solar water heating for canteen and guest house

9. Convert V-belt to flat belt drives

10.1.3 Long term Measures – Energy Savings Potential of 10-15%

1. Maintaining 42 kg/cm2 pressure at reformers outlet with the latest manurite 36M material

for reformer tubes and operating with low S/C ratio

2. Utilization of superior catalysts in reformer

3. Installation of pre-reformer

4. Utilization of latest and active HTS and LTS catalysts for shift conversion

5. Utilization of efficient CO2 removal process

6. Installation of radial flow converters with active catalysts in the synthesis conversion7. 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





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 duringimplementation 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.


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.



• Investment - Rs.15.0 millions









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Case Study No.2

Installation of Variable Frequency Drive (VFD) for Sulphur Pump

BackgroundThe phosphatic fertiliser plants use sulphuric acid for reacting with rock phosphate to 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.






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 analysisThe implementation of this project resulted in a net annual saving (@ Rs.350/ MT of steam)

of Rs 0.75 million. The investment made was about Rs 0.50 million, which had a simple



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.




• ISimple payback - 8 months




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Case Study No.3

Installation of Right Size Hot Sump Pump

BackgroundIn the phosphatic fertiliser plants, the phosphoric acid is produced from rock phosphate 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 replacedwith 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

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

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 silicaand AlF

3.

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.





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 analysisThis 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.






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Case Study No.5

Installation of a Pipe Reactor in Complex Plant

BackgroundThe complex fertiliser is produced by reacting the different components such as 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 aproduction 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.


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

BackgroundThe 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





• 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 analysisThis 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

BackgroundThe 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.

Energy saving project 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.




347


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.












349

Case Study No.8

Replacement of Old PRDS Valves with Superior Design Valves

BackgroundThe nitrogenous fertiliser plant is a major consumer of thermal energy for meeting the 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 atasteam.


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.






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.

CnH

m+ nH

2O ——>

<——- 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 existingReformers.




353

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 investmentmade was around Rs. 50.00 million. The simple payback period for this project was

40 months.












355

Case Study No.10

Modernisation of the Ammonia Converter Basket

BackgroundThe Hydrogen generated by reforming of hydro-carbons is reacted with Nitrogen in the

atmospheric air in the presence of a catalyst 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.






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.





359

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.












361

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. Asthe 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 theplant.





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 amountedto 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.








363





Case study No.13

Replacement of Air Inter-coolers in the Ammonia Plant

BackgroundThe 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.




365

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













367

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/cm 2.


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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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

V2O

5catalyst 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 notpose 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 toonce per year




371

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

around Rs 40.00 million. The simple ayback













373

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 requirementof 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, thepower 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.






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 heatrecovery 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.






The project has excellent replication potential in all

fertilizer plants, which operate large size DG sets on

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.




377





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/cm 2, 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.




379


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.












381

Case study No.19

Installation of Hydraulic Turbine in the CO2

Removal Section

BackgroundThe Ammonia in a nitrogenous fertiliser plant is manufactured by synthesising Hydrogen 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/

cm2.

This rich MEA exchanges heat with the hot lean MEA coming from the stripper, its pressurereduced in a pressure reducing valve after which it enters the stripper. The rich MEA 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 lostacross 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.





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.












385

Case study No.20

Installation of Plate heat exchangers for drying tower cooler in

sulphuric acid plant

Background

SO3gas from “Converter” is absorbed in the Intermediate and Final Absorption Towers (IAT &

FAT) with sulphuric acid from the respective absorption tanks. The absorption of SO3being 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.






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.








387





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 acidplant 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.












391

Case study No.22

Replacement of steam ejectors with vacuum pumps

BackgroundIn 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.





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





9.0 List of Contractors/ Suppliers


Alfa Laval India Ltd. • Evaporators

Mumbai - Pune Road

Dapodi

Pune - 411 012

Tel. : (020) - 24116100 / 27107100


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


Johnson India • Steam engineering and consultancy

3, Abirami Nagar, G.N. Mills Post

Coimbatore – 641 029

Tel. : 0422 - 2442692

Fax : 0422 - 2456177


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



Nash International Company • Water ring vacuum pumps

No. 1 Gul Link Singapore 629371

Rep. of Singapore

Tel. : (65) 861 6801

Fax : (65) 861 5091


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


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


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 & expeditingFax : 033 - 22492340/3338 • Project construction and management

Email : [email protected] • Structural engineering

• Technical management





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


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


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 : [email protected] • 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 : [email protected] • 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


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 : [email protected] • 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 : [email protected]

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





Haldor Topsoe A/S

PO Box 213 Nymøllevej 55DK-2800

Lyngby, Denmark

Tel. : +45 45 27 20 00

Fax : +45 45 27 29 99


Web : www.haldortopsoe.com

Contact : Mr Peter Søgaard-Andersen

Director – Mktg. & Sales- Technology Division

Tel. : +45 45 27 20 97


INCRO S.A

Serrano, 27 - 28001 Madrid Spain

Tel. : (34) 91 435 08 20

Fax : (34) 91 435 79 21


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


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 : [email protected]

Linde AG Coporate Center

Abraham-Lincoln-Strasse 2165189

Wiesbaden Germany

Tel. : +49 611 770 0

Fax : +49 611 770 269

E-Mail : [email protected]




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


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


University Technologies Intl. Inc.

Suite 130, 3553 - 31st Street NW,

Calgary, AlbertaCanada, T2L 2K7

Tel. : +403-270-7027

Fax : +403-270-2384





400Energy Conservation in Foundry Industry

Foundry

Growth percentage 3-5%

Energy Intensity 25% of total manufacturing cost

Energy Costs Rs.45000 million (US $ 900 million)

Energy saving potential Rs.4500 million (US $ 90 million)

Investment potential on energysaving projects Rs. 5000 million (US $ 100 million)




401

1.0 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.





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.

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.

Power Input

100%

Melting86%

Lighting1.4%

Furnace83%

Auxiliary3%

Moulding3.6%

Sand

Plant1.6%

Mixer

2%

Melting73%

Holding10%

CoolingPumps2.5%

Crane & Hoists0.5%

Utilities4.4%

Others4.6%




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.





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

Molten

Metal

Sand Plant MouldPreparation

RawMaterial

Induction Furnace & Arc Furnace

Casting

MouldCooling

Shake outSandReclamation

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 usedas 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 strongoxidation 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





• 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.




407

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.





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, attentionshall 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.




409

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 providedwith back tilting facility for de-slagging.

Quick slag removal using back tilting mechanism in the induction furnace results in atleast 1-

2% reduction in energy consumption.

7.1.6 Reduce the time of composition 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.





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 100 oC 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.




411

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





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




413

Case study - 1

INSTALL KWH INDICATOR CUM INTEGRATOR FOR INDUCTIONFURNACE

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





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 /batchreduction 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.




415





Case study – 2

INSTALL MEDIUM FREQUENCY INDUCTION FURNACEOF 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 thanthe 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.




417


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 analysisThe 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.Cost benefit analysis











419

Case study - 3

INSTALL SPECTRO METER FOR ANALYSING THE MOLTENMETAL

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 moltenmetal.

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.












421

Case study – 4

INSTALL ONLINE SHOT BLASTING MACHINE FOR CLEANINGTHE 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 consumptiondue 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 metalloss 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.

Financial analysis

This amounted to an annual monetary saving (@

Rs 3.50/unit) of Rs 0.52 million. The investment

made was around Rs 2.00 million. The simple

payback period for this project was 46 Months.












423

Case study -5

REPLACE ARC FURNACE WITH MEDIUM FREQUENCYINDUCTION 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.





The specific power consumption of medium frequency furnace is 610 units/ton of molten

metal.

BenefitsThe 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.








425





Case study - 6

MONITOR TEMPERTURE OF MOLTEN METAL CONTINUOUSLYSUING 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 1460o

C. The molten temperature overshootsbeyond 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 about5 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





427





Case study – 7

INSTALL WASTE HEAT RECOVERY SYSTEM FOR THE STRESSRELIEVING 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. Thiscan 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









429





Case study -8

SEGREGATE HIGH PRESSURE AND LOW PRESSURECOMPRESSED 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 proportionalto 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 operatedat a pressure of 3.0 kg/cm2.

Benefits

Implementation of the project resulted in atleast 30% reduction in compressor power

consumption.




431

Financial analysis

















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 resultedin reduction in operating pressure of 0.5 kg/cm2 and hence corresponding reduction in load

power consumption.

Financial analysis










435





Case study -10

REPLACE PNEUMATIC TOOLS WITH ELECTRICAL TOOLS

Back groundIn 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.











439

Case study -11

INSTALL OIL FIRED CORE DRYING OVENS FOR DRYING THECORES

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 –200 oC.

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 iscirculated 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









Financial analysis






441





Case study -12

REPLACE EXISTING OIL FIRED ALUMINIUM MELTINGFURNACES 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 800 oC. 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 rangeof 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









445

List of Contractors / Suppliers

Name of the Company and Address Area of expertise

INDUCTOTHERM INDIA LTD

Bopal, Ahmedabad - 380 058Gujarat (India)Tel:91-79-3731961 (8 Lines)

Fax: 91-79-3731266, 91-79-3731268Email: [email protected]

URL: www.inductothermindia.com

Induction Furnaces,

Controls for thefurnaces

M/S ENCON INTERNATIONAL (P) LTD.

Mr. R.P. Sood 14/6, Mathura Road,Faridabad - 121 003 (Haryana) Tel: +91-129-2275307

Fax: +91-129-2276448 E mail: [email protected]

Induction furnaces

PILLAR INDUCTION (I) LIMITED

EXPORTERS OF FURNACES. A-13, 2nd Avenue Anna Nagar, Chennai - 600102,India

Tel(44)6261703/26261704/2621705Fax: +(91)-(44)-26260189

Induction furnaces

WESMAN GROUP OF COMPANIES

"Wesman Center", 8, Mayfair Road,Kolkata - 700 019,Tel:(91)-(33)-22405320

Fax: +(91)-(33)-22478050

Burners

ADVANCE HEATING SYSTEMS

d1/23 (back side) Mayapuri ind. area, phase-ii, New

Delhi -110064Tel: 91-11-5139315Email:[email protected]

Industrial furnaces,ovens, oil fired

systems, heattreatment furnaces

ASSOCIATED INDUSTRIAL FURNACES

f-9, sector-xi, Noida -201301Tel:91-11-84529169Fax: + 91-11-84555703


Shuttle & Tunnel

kilns, pit typeannealing furnaces,continuous ovens

and driers





ENGINEERS ASSOCIATE

10-d, Garpar road, Calcutta -700009Tel: 91-33-3510690


Muffle furnaces,

oven, drier, thermocouple

HEATCON SENSORS (P) LTD. mes road, bangalore -560013Tel:+ 91-80-8384564

Fax: + 91-80-8382914E-mail: [email protected]

Website http://www.heatc onsensors.com

Temperaturecontrollers,thermocouples etc

INDUSTRIAL FURNACE & CONTROLS

Vempu road, Bangalore -560021

Tel:+ 91-80-3329840Fax: + 91-80-3329840E-mail: [email protected]

Website http://www.indfurnace.com

Electrical and oilfired furnaces,temperaturecontrollers,thermocouples

MACRO FURNACES PVT. LTD.

16/2, mathura road, faridabad -121002Tel:+ 91-129-5260004Fax: + 91-129-5260146


Electrical and gasfired industrialfurnaces

PYROTHERM ENGINEERS PVT. LTD.245/2b, 2b-vanagaram road, athipet,

Chennai -600058Tel:+ 91-44-6358038Fax: + 91-44-6358038

Aluminium meltingfurnaces, ovens

THERMOTHERM ENGINEERS455, 12th cross, 4th phase,peenya indl. area,

bangalore -560058Tel:+ 91-80-8362507Fax: + 91-80-8362919E-mail:[email protected]

Industrial furnaces,heat treatmentfurnaces and ovens

PADAM ELECTRONICS

Plot No 1/103,

West Kanti Nagar, St No 3,

New Delhi - 110 051, IndiaTel:+(91)-(11)-22001791/22003581Fax: +(91)-(11)-22003581Website: http://www.indiamart.com/padam -electronics

Muffle furnaces,electrical furnaces,diesel firedfurnaces and heat

treatment furnaces

NORTH-WEST INDUSTRIES

Opp. Indo Bulger, Meerut Road,

Sihani Chungi,

Ghaziabad - 201 001, India

annealing furnaces.




447

Tel:+(91)-(120)-2736650/9810367173

Website: http://www.indiamart.com/northwest

ALIDIA POWERTRONICS PRIVATE LIMITED

Address: Shed 1, Computer Complex, DSIDC Scheme

1, Okhla Industrial Area Phase II,

New Delhi - 110 020, India

Tel:+(91)-(11)-4963017/4963028/4963163

Fax: +(91)-(11)-26386602

Website: http://www.indiamart.com/alidia

Medium frequency

induction meltingand heating

furnaces, portable

high frequency

Induction heating

equipment.

METROPOLITAN EQUIPMENTS & CONSULTANTS

PVT. LTD.

Plot No. A - 486,Wagle Industrial Estate, Road 24,

Thane - 400 604, India

Tel:+(91)-(22)-5823294/5800799/5814654

Fax: +(91)-(22)-5800801

Website: http://www.indiamart.com/metropolitan

Roller hearth tunnel

furnaces, material

handling systemsetc

ENCON INTERNATIONAL (P) LTD.

Address: 14/6, Mathura Road,

Faridabad - 121 003, India

Tel:+(91)-(129)-2275307/2275607

Fax: +(91)-(129)-2276448

Website: http://www.indiamart.com/enconindia

All types of

furnaces

Precision Controls

Manufacturer & exporters of furnaces.

20, SIDCO Industrial Estate,

Ambattur, Chennai - 600098, India

Tel: +(91)-(44)-26250370

Fax: +(91)-(44)-26257835

All types of

furnaces

REFRACTORIES & FURNACES COMPANY

P.O.Box:80, Kezhakkenada,

Chengannur - 689 121, India

Tel: +(91)-(479]-454310 Fax: +(91)-(479]-452481

Furnaces andrefractories




448Energy Conservation in Textile Sector & Technology in Textile Industry

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%.





Process Flow Diagram for High Value Cotton Fabric

Raw Material

Blow Room

Cardin

Combing

Draw Frame

Rin Frame

Windin Yarn D ein

War in

Sizin

Weavin

Sin ein

Bleachin

Mercerizin

Finishin

YarnPreparation




451

Process Flow Diagram for Denim Fabric

Raw Material

Blow Room

Card

Drawframe

Autocore

Dyeing & Sizing

Weavin

Finishin

Foldin

Packin

Dis atch

Processing





Textile Manufacturing

The manufacturing process in a composite textile mill involves three broad categories:

1. Spinning

2. Weaving3. 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) CardingDuring 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) WeavingThe 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.





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 highflow 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 1011 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


Nozzle

Air FlowFan

Water

S ra

Wate

HumiDif i

ed

Ai r












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 getpaid back in 6 months.








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 favorableclimatic condition, like – Monsoon & winter – when humidity in out side air is good (@90 – 98

% - Monsoon) and temperature is also less, some of the pumps and fans will be stopped.

During favorable condition, normally one fan is stopped and one fan is kept “ON”. This 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 12.385 % 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





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.

BenefitsReducing the speed of the fan by installation of VFD will result in annual savings in the tune

of 25 – 30%.








461





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

The annual savings potential will be @ 4% / machine.








463





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 backin 19 months.








465





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

back in 30 months.




467





Case study - VII

Reduce the Speed of Exhaust Fans in Stenters

Background

• In Stenters centrifugal fans are kept in continuous operation for removing the exhaust air

after the drying process. The air is collected from various zones and sent to atmosphere.

• It is observed that the dampers provided in ducts from various collection zones are 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.

The annual energy saving potential is Rs 0.10 million. This requires an investment of

Rs 0.03 million for changing the pulleys, which gets paid back in 3 Months.

CCost benefit analysis







469





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.

RecommendIt 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

The annual energy saving potential is Rs 0.13 million. This requires an investment of Rs 0.05 million for changing the pulleys, which gets paid back in 5 Months.












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.








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.












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.












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/-





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








481





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 operatein 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.




483




484Energy Conservation in Engineering Sector

Engineering Sector

Energy Intensity 3.7% of the manufacturing cost

Energy Costs Rs. 25000 Million

Energy saving potential Rs. 5000 million.

Investment potential onenergy saving projects Rs.10000 million




485

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.





Short, Medium and The Long term Projects

Long term projects

Compressors1. Replace old energy inefficient compressors with new energy efficient compressors

2. Install variable Frequency Drives for Screw compressors catering to varying demands 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-term1. Arrest compressed air leakages by vigorous maintenance

2. Optimise overall operating pressure of compressors based on the system requirement

3. Provide ball valves at the user ends of compressed air cleaning hoses and other 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

Short-term & Medium-term

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




487

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 minimizeheat 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.





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 fans3. 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




489


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)





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




491

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 operationas 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.





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 anannual savings of Rs.0.95 million. The investment

(for new reciprocating type air compressors)

amounted to Rs.1.5 million, which had a simple

payback period of 20 Months


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.








493





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

The annual savings achieved amounted to

Rs 0.43 million . The required an investment of

Rs 0.7 million for installing variable frequency drive

with feed back control, was paid back in 20 Months.












497


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.





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/cm2 Cfm

Unit1 4.0 1900

Instrumentation in unit 2 4.5 600

The fall in pressures at the receiving end was mainly due to the losses, which were 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












501

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.






Heat of Compression (HOC) dryers were Installed in place of the desiccant / heatless type

dryers.

BenefitsThis 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 tobe used as a retrofit for screw compressors also.







503





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.

BenefitsInstallation of VFD for oil pumps in Hydraulic power

pacs resulted in an annual saving of Rs. 0.3 million.

This required an investment of Rs 0.35 million for

variable frequency drives with feed back control,

which got paid back in 15 Months.


The project can be replicated in all the units where

oil pumps are installed for pumping oil in the hydraulic power packs.








505





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 settemperature was achieved, the thermic fluid was recirculated, without going to the process.

The thermic fluid pump therefore was in continuous operation at its full capacity, 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.












509

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 gasesin a given system. In electroplating sections, fumes, which are produced during the process,

are forcefully sucked and let out into the atmosphere using exhaust fans. This is a 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 m 3/s, consuming17.8 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.





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.








511





Case study 8

INSTALL VFD’s for HOT AIR CIRCULATION FANS IN PREHEATING FURNACES

BackgroundHeat treatment is the process of altering the properties of a metal by subjecting it to a 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 alignedwith the operating cycle of the furnace, to optimise energy savings.

VFDs find applications in optimising the speed of the circulation air fans based on the 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.0.36million. 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.












515

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.





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.



• Investment - Rs. 0.15millions



The project can be replicated in all furnaces,

which are using either refractory bricks or

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.




517





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.










521

Case study 11

REPLACE MOTOR – GENERATOR SETS WITH STATIC INVERTORS

Back groundWard-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.

Energy saving Project 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.





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.


The project can be implemented in all the areas where the colour-rendering index is not critical

to the plant operations.



• Investment - Rs. 0.08 million









527

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:





BenefitsThe implementation of this project resulted in the following 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.

Project implementationProject 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.

Pressurised

water to

preheat oil

Preheated Air

Air topreheat

Flue gas tostack

Aquatherm

F.OHeater

Flue gas


• Annual Savings - Rs.0.30 million

• Investment - Rs.0.60 million





529




530Energy Conservation in Sugar Industry

Sugar

Per Capita Consumption 17.75 kg/annum

Growth percentage 7.5%


Energy Costs Rs. 14000 million (US $ 290 million)

Energy saving potential Rs. 4200 Million (US $ 84 Million)


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. Thegovernment 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 equivalentpower of about 3250 MW (considering average crushing of 175 days).





Energy efficiency in sugar industry offers the following benefits:

• In plants having cogeneration facility and where the state utility is able to purchase 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 carbonemissions.

• In plants having cogeneration facility, but the state utility is not ready to purchase power,

improvement in energy efficiency in the plant results in saving in bagasse. This 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.




533

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 andhas 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





• 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 requirementof the plant is met from the grid.

iv. Commercial co-generation system – Both season and non-season

These are the latest systems installed very recently and operating in the sugar plants,

predominantly in the state of Tamil Nadu.

These plants are characterised by

• 42 kg/cm2 / 64 kg/cm2 / 82 kg/cm2 boiler

• Bagasse firing during season & firing with other fuel during non-season• Mill drives are hydraulic or DC drives

• One / two extraction - cum - condensing turbine

• Turbine operates with nil condensing during season and maximum condensing 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 thevarying load. The shredders have, either a steam turbine or a dynodrive for varying the speed,

while the cane-carriers have a dynodrive. Both these systems are energy inefficient.

Hence, it is recommended to install DC motors or AC variable speed drives for the 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

other three depend on the hydraulic

pressure applied and the fibre loading.

The bearing loss of 15% in the case

of white metal bearings, can be totally

avoided, by replacing them with anti-friction roller bearings.

The power spent for compression of

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

Breakup of Energy Consumption

64%

15%14%2%

5%

Compression of bagasse

Bearing loss

Trash plate

Scrapper

Pinion loss





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 rapidpopularity 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 69 oC to 90oC.

iii. The diffusion percolation bed is a moving conveyor on which the cane bed height isbetween 1200 mm to 1400 mm.




537

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





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.




539

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 inthe 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 hasbeen a reduction in the steam consumption to the extent of 15 – 20%.

Apart from the steam reduction, the utilization of continuous vacuum pans also result in

• Improved grain

• Reduced sugar loss

• Better control and systems.

• Reduced power consumption for injection water pumps.

Hence, by design all new plants should install only continuous vacuum pans. Other steamconsumers The other miscellaneous steam consumers in a sugar plant are

• Sugar dryers

• Sugar melter

• Centrifuge wash water super heater

• Other washing /cleaning application





6.0 Energy Saving Projects in Sugar 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




541

• 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





• 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





• 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 havebeen chosen as they have high saving and investment potential with high replication possibility.




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Case study 1

Install diffusers in lieu of milling tandem

Background

Installation of milling tandem is practiced conventionallyin 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 tolower 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 C7. 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.






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

BackgroundThe sugar manufacturing process needs substantial amount of thermal energy, in the form of

steam. The majority of steam requirement is

at low pressures (0.6 to 1.5 ksc), while a small

percentage of the steam consumption is at

medium pressure of about 7.0 ksc.

In the sugar mills, the requirement of steam

at lower pressures is met from the exhaust of

the turbine; while the medium pressure (MP)

steam, in most of the plants, is generated bypassing the live steam generated from the

boiler, through a 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 followingprocess users:

• Hot water superheating for use in the centrifuges

• Sugar drier blower

• Sugar melter

The temperature requirements for sugar drier blower and sugar melter are about 80°C 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

BackgroundThe 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 pumpsof 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.





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 thisproject.

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 HighSpeed 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 thecorrect 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 centrifugalof 1200 kg/h capacity used for A - massecuite separation.

Benefits of regenerative type continuous centrifuge

Reduction in centrifuge power consumption

These centrifugal had the conventional type of braking system, with no provisions for 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.

Concept of the projectOne 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. Theimplementation 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.





Case study 5

Installation of Jet Condenser with External Extraction of Air

BackgroundThe evaporators and pans are maintained at low pressures,

through injection water pumps. These are one of the 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 crushingcapacity 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 noteasily 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 250HP 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

BackgroundThe 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 MW1 number 1.5 MW





Mill drives

• 6 numbers 750 BHP steam turbines

• 1 number 900 BHP shredder turbine

The plant had an average steam consumption of 52%. The powerrequirement of the plant

during the sugar-season was met by the internal generation and during the non- season fromthe 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 surplusbagasse 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 thepower generation from 9 MW to 23 MW. Thus, surplus power of 14 MW is available for

exporting to the grid.




561

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 asfollows:

• 1% drop in bagasse % in cane : 18300 units

• 1% increase in moisture content of bagasse : 6800 to 10200 units

• 1% increase in process steam consumption : 4200 units

• 1% drop in crushing rate : 5000 to 7400 units

• 1 hour downtime : 20600 units

• Drop in 1 ton of cane availability : 60 units

The above figures are based on the following operational parameters:

• Crushing rate : 5000 TCD

• Steam to bagasse ratio : 1 : 2.2

• NCV of bagasse (50% moisture) : 1804 kCal/kg

• Bagasse content, in % cane : 27%

Replication PotentialThe sugar plants in India have tremendous potential for commercial cogeneration ie 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.





Case study 7

Replacement of Steam Driven Mill Drives with Electric DCMotor

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.




565


The plant team contemplated the replacement of the steam driven mills with electric DC

motors, along with the commissioning of the cogeneration plant.

Concept of the projectThe conventional single stage impulse type steam turbines have very low efficiencies of 35%.

Hence, the steam consumption per unit of power output is very high.

A single high capacity steam turbine is more efficient as compared to multiple number 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:





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.








567





Case study 8

Installation of an Extensive Vapour Bleeding System at theEvaporators

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 themaximum 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.




569

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 45to 53 % on cane, depending on the crushing rate. However, maximum steam economy is

achieved, if the vapour from the last two effects can be effectively 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





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 anattractive simple payback period of 8 months.








571





Case study 9

Installation of Variable Speed Drive (VSD) for the WeighedJuice 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 maintainedby periodically throttling and adjusting the control valve in the recirculation line.










575

Case study 10

Installation of Thermo-compressor for use of Low PressureSteam

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 theENA 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.





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.




577

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.












579

Case Study 11

Installation of Hydraulic Drives for Mill Prime Movers

BackgroundThe 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 turbinedriven 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





• 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 largeThe 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.




581


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 monthstime.

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.







Case study 12

Install nozzle governing system for multi jet condensers

BackgroundSugar Syrups are normally boiled at 0.15 bar absolute pressure generating water vapours 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 primarilyneeded 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 thedesired 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.








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 bybatch process in the Indian sugar industry.

These pans are characterised by the following:

• The hydrostatic head requirement is high

• Higher hydrostatic heads necessitate higher massecuite boiling temperatures, which 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





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 reducestowards the end of the batch cycle

• The S/V ratio is low (~ 6)

• Hydrostatic head requirement is high (about 3.0 - 3.5 m)

• Average retention time is very high

• Requires very frequent cleaning of the pan body

• Less adaptable to automation

To overcome these inherent shortcomings and to cater to their capacity upgradation plans to8000 TCD, continuous vacuum pans were installed for all three types of massecuite curing.


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 spacerequirement 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, therewere 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.





• 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





Sugar Consultants

BoilersAVANT – GARDE ENGINEERS ANDCONSULTANTS (P) LTD.No. 58, Fourth Avenue,

Ashok Nagar,Chennai – 600083,INDIATel : 91 44 4894457, 4894460, 4894474,Fax : 91 44 4894432E Mail :[email protected],Web Site : www.ag-india.com

M/S J . P. MUKERJEE & ASSOCIATES PVT.LTD.JYOTI HOUSE,172, DHANUKAR COLONY,KOTHRUD , ‘PUNE - 411029,INDIATEL: 91 212 347303,FAX : 91 212 347307

M/S K.S.PROJECTS & PROCESSENGINEERS (P) LTD. A-1/18, SECTOR - B ALIGANJ EXTENSION,LUCKNOW - 226024.INDIATEL : 91 522 375042, 377166.

FAX : 91 522 377166

P.J.INTERNATIONAL GROUP CONSULTANTS A-101,YAMUNA APARTMENTS, ALAKNANDA,NEW DELHI-110019INDIATEL: 91 11 6461081,FAX:91 11 6474514

M/S SUCRO CONSULT INTERNATIONALSACCHARUM ,

E- 1, Greater Kailash Enclave 1,New Delhi - 110048,INDIATel : 91 11 641616

NATIONAL FEDERATION OFCOOP.SUGAR MILLSVAIKUNTH, IIIRD FLOOR,82-83, NEHRU PLACE,NEW DELHI-110 019INDIA

Shri A.P.ChinnaswamyPonn Ram Sugar House,Krishnamal Cross Street No 1, PO :

K.K.Pudur, Sai Baba ColonyCOIMBATORE - 641038,INDIA

SHRI M.G.JOSHI3, Vasant Bagh Society,

Bimbewadi,PUNE- 411037INDIATel: 91 20 4214945

Shri Mydur Anand27/106, 11-B, 11th Main,Malleshwar,BANGLORE - 560 003INDIATel : 91 11 3311223, 3346873Fax : 91 11 3349573

SHRI P.K.JHINGANM/S SUPRABHAT CONSULTANTS43-B,Pocket A,SFS Flats, Mayur Vihar Phase 3NEW DELHI - 110049,INDIATEL: 91 11 2610094,2610072,Fax: 91 11 2614559E Mail: [email protected]

SHRI VIKRAM SINGH

C-2/2305,VASANT KUNJNEW DELHI.INDIATel: 91 11 6898884

Alfred BartholomaiHansen Consulting Atlanta, Georgia USA

Consultants to the food industrywww.hansenconsulting.com

Equipment ManufacturersATV PROJECTS INDIA LIMITEDD-8, MIDC, STREETNO.16, MAROL, ANDHERI (EAST),MUMBAI-400 093.INDIATEL : 91 22 8351761,FAX : 91 22 8365786, 8387592

FCB-K.C.P.LTD.RAMAKRISHNA BUILDING,2, DR.P.V.CHERIAN CRESCENT,CHENNAI-600 105.INDIATEL : 91 44 8241633,




591

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KRUPP INDUSTRIES INDIA LTD.PIMPRI,PUNE-411 018, INDIA

TEL : 91 212 774461,FAX : 91 212 771150EMAIL : [email protected]

NATIONAL HEAVY ENGINEERINGCO-OPERATIVE LTD.16, MAHATMA GANDHI ROAD,PUNE-411 001, INDIATEL : 91 2114 22261,FAX : (0212) 644920E Mail : [email protected]

PRAJ INDUSTRIES LIMITEDPRAJ HOUSE, BAVDHAN,PUNE- 411 021, INDIATEL: 91 2139 51511, 52214,FAX: 91 2139 51718, 51515E MAIL : [email protected] : www.praj.net

ALCOHOL / DISTILLERY PLANT :Turnkey plant and equipment supplier for molasses and starch based alcohol plantsB-196, OKHLA INDL.AREA,

PHASE-I, NEW DELHI-110 020. INDIATEL : 91 11 6811878, 6811721, 6815047,FAX : 91 11 6812280E Mail: [email protected]

TEXMACO LTD.Sugar Division, Birla Bldg.,9/1,R.N.Mukerjee Marg,CALCUTTA - 700 001,INDIATEL: 91 33 205712, 205553

UTTAM INDUSTRIAL ENGG. LTD.7C, J-BLOCK SHOPPING CENTRE,SAKET, NEW DELHI-110 017.INDIA TEL : 91 11 6563860, 6856721, 6858578,FAX : 91 11 6856721

WALCHANDNAGAR INDUSTRIES LTD.16, M.G. ROAD, PUNE-411 001.INDIA TEL : 91 212 631801,FAX : 91 212 631747

Chemical suppliers for sugar industryAQUA CHEMICALSB-237 A, Road No :6-D,V.K.Industrial Area,

Jaipur 302013, Rajashtan,INDIA Tel:91-141-331542,260183260184(O)517574,700909(R),FAX:91-141-331543E Mail: [email protected] Person: Mr.Jayant Rajvanshi

SPECIALIST IN: Boiler Water TreatmentChemicals, Cooling Water TreatmentChemicals, Effluent Treatment Chemicals ,Sugar Specialty Chemicals, Industrial SafetyEquipments

AISHWARYAA CHEMICALS101/12, Om Apartments,Medavakkam Tank Road,Kilpauck, Chennai 600010,INDIA TEL: 91 44 6422851,6414419,FAX: 91 44 6431605E mail: [email protected] IN:Process Chemicals

CENTRAL AGENCIES All kind of Sugar Process Chemicals4672 / 21, DARYA GANJ,NEW DELHI - 110002 - INDIATEL : 91 11 3273662,3266023,FAX : 91 11 3278554EMAIL : [email protected]

INDUSTRY AID PRODUCTS160, Dr. D N ROAD, FORT,

MUMBAI 400001 - INDIATEL : 91 22 207747,FAX : 91 22 2074249E Mail: [email protected]

CHEMICAL SYSTEMSD 57-58, Amar Colony,Lajpat Nagar-IV,New Delhi – 110024, INDIATel : 91 11 6476344, 6438807Fax : 91 11 6476352E Mail [email protected]

SPECIALISTS IN: CHEMICALS FORBETTER SUGAR PRODUCTION

ION EXCHANGE (INDIA) LTD.Tiecicon House, Dr. E Moses Road,Mahalaxmi Mumbai – 400011Tel :91 22 4939520/23/25,Fax : 91 22 4938737SPECIALISTS IN: Process Chemicals

MULTITRADE CORPORATION401, GORADIA HOUSE,100/104, KAZI SAYAD STREET,MUMBAI 400003 - INDIATEL : 91 22 3439360,





FAX : 91 22 3429140

CHEMICAL CENTRE (INDIA)7/26 ANSARI ROADDARYA GANJNEW DELHI -110002 - INDIA

TEL : 91 11 3267775 3253336,FAX : 98-11 -3268834

KULKARNI ORGANICS PVT. LTD172, SHANIWAR PETH,TRIMBAKESHWAR CO-OP. HOUSINGSOCIETY,PUNE - 411 030 - INDIATEL : 91 212 450934 / 532090

P.K.B. TRADERS75, NAGDEVI CROSS LANE,2ND FLOOR, R B. NO. 13043,MUMBAI - 400003 - INDIATEL : 91-22-3400581, 344T228, 3 (R) 5163635 ,FAX : 91-22-3401630

King – Win Hydro Chem Ltd.C-26-B, Malviya Industrial Area,JAIPUR 302017, INDIATel : 91 141 521205, 522924 ,Fax : 91 141 522694E Mail :[email protected]

SURYA CORPORATION

27, Chetty Street,PONDICHERRY 605001, INDIATEL: 91 413 220309, 345221FAX: 91 413 339733,345221E MAIL: [email protected]

Sugar MachineryAVANT – GARDE ENGINEERS ANDCONSULTANTS (P) LTD.No. 58, Fourth Avenue, Ashok Nagar, Chennai – 600083,Tel : 91 44 4894457, 4894460, 4894474,

Fax : 91 44 4894432E Mail :[email protected],Web Site : www.ag-india.comSPECIALIST IN :’CONTINUOUSBAGASSE FEEDING SYSTEM FOR BOILERS”.,

Abrasion Resistant Materials Pty LtdPO Box 546, Archerfield,Queensland, 4108, AUSTRALIA39 Randolph Street, Rocklea,Queensland, 4106, AUSTRALIAPhone: 07 3277 9630,Fax: 07 3277 9640

International callers:Phone: +61 7 3277 9630,Fax: +61 7 3277 9640 E Mail:[email protected] IN : Maintenance free sugar millrollers

GOEL TRADELINES14 RANI JHANSI ROAD,NEW DELHI 110055INDIATEL: 91 11 3551444,3679444,3613075,FAX: 91 11 3613075E MAIL : [email protected] IN : WEDGE WIRE SCREENS,ROTARY JUICE SCREENS

FLENDER LIMITED41, Nelson Manickam Road, AminjikaraiChennai – 600029,INDIATel : 91 44 4810476/78/79/80Fax : 91 44 4810473SPECIALISTS IN Hydraulic Drives

Hagglunds Hydraulic Drives (India) Pvt. Ltd.18/4 & 19/4, Hadpasar Industrial Estate, Hadapsar ,PUNE -411013, INDIATEL: 91 212 613841, 613842FAX: 91 212 613844

Jeffress Engineering Pty Ltd351 Melton Road, NorthgateQueensland Australia 4013Phone +61 7 3266 1677,Fax:+61 7 3260 5487Email: [email protected] Grinders, Disintegrators

KAMAL ENGINERRING CORPORATION56, Industrial Estate,Yamuna Nagar –135001

Tel : 91 1732 50300/1/2/3,Fax : 91 1732 50304SPECIALISTS IN: Weighing Scales, Sugar Graders etc.

NATIONAL HEAVY ENGINEERINGCO-OPERATIVE LTD.16, MAHATMA GANDHI ROAD,PUNE-411 001,INDIA TEL : 91 2114 22261,FAX : 91 212 644920, 91 2114 22762E Mail: [email protected] IN : CENTRIFUGAL MACHINES




593

NEON INNOVATIVE PVT. LTD.31. Latif House, S.T.Road,Carnac Bunder,MUMBAI 400009 .INDIATEL : 91 22 3426851,

FAX : 91 22 3429011E Mail: [email protected] IN: CANE MILLINGLow Pressure Extraction Systems

Maddocks and Associates Pty Ltd,GDT Lining Systems SPECIALIST IN :LOW COST MOLASSES STORAGE

PRAJ INDUSTRIES LIMITEDPRAJ HOUSE, BAVDHANPUNE- 411 021, INDIATEL: 91 2139 51511, 52214,FAX: 91 2139 51718, 51515E MAIL : [email protected] : www.praj.netALCOHAL / DISTILLERY PLANT :Turnkey plant and equipment supplier for molasses and starch based alcohol plants Single Tray Juice ClarifiersFiltrate Clarification SystemsRotary Juice Screen

Suviron Equipments Pvt.Ltd.Swaroop Kala, 23/11, Renavikarnagar, Savedi, Ahmednagar 414 003 (India)Telephone 91 241-423582 / 778711 Fax : 91241-778711E-mail : [email protected] Web :www.suviron.comPerson : Shri Subodh V. Joshi

SPRAY ENGINEERING DEVICESCooling & Condensing systems for Sugar & Processing Plants

25, Industrial Area, Phase- IIChandigarh INDIA – 160002Tel : 91 172 652415Fax : 91 172 653247

S.S. ENGINEERSJ – 179, M.I.D.C. Bhosari,Pune – 411026,INDIATel :91 212 327567,Fax : 91 212 328572E Mail: [email protected] IN: Five/Six Roller MILLS

SNEHA ENGINEERSF – 46, M.I.D.C.Industrial Area,Waluj, Aurangabad –431136,MAHARASHTRAINDIA

Tel : 0240 – 332585, 331695,Fax : 332796 SPECIALISTS IN:Evaporators & Vacuum Pans

SHRIJEE ENGINEERING WORKS1-9, Everest, 156 Tardeo Road,MUMBAI - 400034, INDIATel:91 22 4952248,4954699,4954715,Fax: 91 22 4952249E Mail: [email protected] IN: Process House

Equipments, Sugar Driers526, Narayan Peth,PUNE 411030 INDIATel: 91 20 453360,454790,Fax: 91 20 453970SPECIALISTS IN: TRFCane Mill Feeding System.UTTAM INDUSTRIAL ENGG.LTD.7C, J-BLOCK SHOPPING CENTRE,SAKET, NEW DELHI-110 017.INDIA TEL : 91 11 6563860, 6856721, 6858578,FAX : 91 11 6856721 SPECIALISTS IN: CANEMILLING

GOEL ENGINEERS (INDIA)INDIA’S FIRST MANUFACTURERSOF CENTRIFUGAL LINERSF-11/A OKHLA IND. AREA, PHASE 1,NEW DELHI 110020 INDIATEL: 91 11 2 6815109, 2 6812004,FAX: 91 11 2 6811176E MAIL : [email protected]: www.goelka.comSPECIALIST IN : Screens for BATCH CENTRIFUGALS &

FILTERS, BACKING WIRES Suviron Equipments Pvt.Ltd.Swaroop Kala, 23/11, Renavikarnagar, Savedi, Ahmednagar 414 003 (India)Telephone 91 241-2423582 / 2 Fax : 91 241-2778711E-mail : [email protected] Web :www.suviron.comPerson : Shri Subodh V. JoshiRotary Juice Screens,Single Tray JuiceClarifiersFiltrate Clarification Systems Rotary JuiceScreens





ATUL ELECTROFORMERS PVT. LTD11,KUBERA ESTATE , 408/14 ,CTS 10, Gultekadi Road,PUNE 411037,INDIATEL : 91 20 2466398, 2464589 , 2468982,Fax : 91 20 2462835

E Mail:[email protected] IN : Nickel Screens

FINE PERFORATORS14 RANI JHANSI ROAD,NEW DELHI 110055 INDIATEL: 91 11 23551444, 23679444,FAX: 91 11 23613075E MAIL : [email protected] IN : Batch Centrifugal & Filter Screens

SHRADDHA ENGINEERING COMPANY.11,Rajgrah Apt. Krushinager,College Road, Nashik-422005.India“Jyoti” Sitarramnager,Near Jaikranti College, Latur-4413531Telefax : 91 253 355009 , 91 238 240759.E Mail :[email protected],[email protected], [email protected] :Satish S. Sonar, Kishor M.Bhujbal.Product Details : Designer and manufacturer of Continuous Sulphur Burner, PressureReducing and Desuperheather ,Juiceand Syrup Sulphitation Unit, Mollasses

conditioner, Superheated Wash Water System,Boiler Automation, Auto Mill Imbibition ControlSystem.

CHEMICAL SYSTEMSD 57-58, Amar Colony,Lajpat Nagar-IV,New Delhi – 110024, INDIATel : 91 11 6476344, 6438807Fax : 91 11 6476352E Mail :[email protected] Electric Controls Pvt. Ltd

SUGAR PROCESS ENGINEERSE / 12-13, M.I.D.CIndustrial Area,NASHIK – 422 007, INDIATel : 91 253 351072 / 77, Fax : 91 253 351079E Mail :[email protected]

SPRAY ENGINEERING DEVICES25, Industrial Area, Phase- IIChandigarh 160002 INDIATel : 91 172 652415Fax : 91 172 653247SPECIALIST IN Cooling & Condensingsystems for Sugar & Processing Plants

SHIVA HITECH NON CONVENTIONALSYSTEMS PVT. LTD.107, Vijaya Towers,Nagarjunanagar, Ameerpet,Hyderabad 500073 INDIATel : 91 40 3744675, 3740224, 3740432

Fax : 91 40 3745833SPECIALISTS IN Magneto Hydro DynamicSystems

VISHWA Systems Pvt LtdW-155, M.I.D.C., Ambad,Nashik 422010, INDIATel: 91 253 385243, 380802, 380673.Fax: 91 253 385243E Mail: [email protected] IN: Process Control Equipment& Control Systems.Manufacturer of Sulphur Burner, PRD Station, Transient Heater /PH Control Systems, Molasses conditioner /Juice Flow Stablisation Systems, SuperheatedWash water Systems, Lime Classifier

FORBES MARSHALLKasarwadi, , Pune – 411034, INDIATel :91 212 794495, Fax : 91 212797413SPECIALISTS IN: INSTRUMENTATION &FLOW TECHNOLOGY

BELLISS INDIA LIMITED18, Community Centre,

East Of Kailash,NEW DELHI 110065, INDIATEL: 91 11 6431836,FAX: 91 11 6468089E Mail : [email protected] IN Steam Turbine

DLF Industries Ltd.Model Town, Sector 11,FARIDABAD 121 006, INDIASPECIALIST IN Steam TurbineTRIVENI ENGINEERING & INDUSTRIES LTD.

12-A, Peenya Industrial Area,Peenya, Bangalore 560058,INDIATel :91 80 8394721, 8394771, 8395278Fax : 91 80 8395211E Mail: [email protected] IN Steam Turbine

Associations in IndiaTHE SUGAR TECHNOLOGISTS’ASSOCIATION OF INDIAC Block, 2nd Floor, Ansal Plaza, August Kranti Marg,New DelhiI-110 049,India.TEL : 91 11 6263694-95






596Energy Conservation in Power Plant Sector

Power plant

Per Capita Consumption 350 kWh (277 kg of oil equivalent)

Energy Intensity 6 – 8% of power generation

Energy saving potential Rs.3000 Million (US $ 60 Million)


energy saving projects Rs. 5000 Million (US $ 1000 Million)




597

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.





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 anincreasing 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)




599

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.





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)




601

CHAPTER II

PROCESS, TECHNOLOGY AND TRENDS

2.1 Technology TrendsThermal power generation started with ratings of 60/70 MW rating units in the year 1965,

simultaneously raised to 110/120 MW units by the year 1966. The next size of 200/210 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.





Table 5: Turbine Sizes and Heat Rate

Unit capacity Turbine inlet Turbine Heat Rate

parameter (Kcal/Kwh)

60/100 MW 90 ata 535o

C 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 thefollowing 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.




603

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)





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




605

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





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




607

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





C) Electrical & Miscellaneous Areas

1. Install maximum demand controller to optimise maximum demand


3. Replace rewound motors with energy efficient motors


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




609

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.






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),


Implementation Strategy

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





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 thefan 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

Implementation Strategy

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 10.0million 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












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.





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.








617





Case Study: 4

INSTALL VAPOUR ABSORPTION HEAT PUMP IN PLACE OF VAPOURCOMPRESSION 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 lowpressure 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 absorptionsystem system

Rating TR 60 60

Power consumption kW 60 60

Steam consumption at

4 ksc kg/h - 300

Annual operating cost * Rs.lakhs 16.80 6.60

Annual savings Rs.lakhs - 10.20

Investment required Rs.lakhs 12.00 19.00

* Operating cost based on steam cost @ Rs.250/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.












621

CHAPTER IV

Service Agencies in the sector

4.1 List Of Suppliers

1. Bharat Heavy Electricals Ltd (BHEL)

Building BHEL Building

Street Siri Fort Road

City 110 049 New Delhi

Country India

Telephone (+91) 11 - 649 30 31

Facsimile (+91) 11 - 649 30 21

E-Mail [email protected]

Internet www.bhelis.com

Description Power Generation and New & Renewable Energy Technologies

2. Thermax Babcock & Wilcox Ltd (TBW)

Building Sagar Complex

Street Mumbai Pune Road

Place Kasarwadi, Nasik Phata

City 411 034 Pune

Country India

Telephone (+91) 20 - 712 57 45

Facsimile (+91) 20 - 712 55 33


Internet www.tbwindia.com

Description Heat Recovery Steam Generators, Circulating Fluid Bed Boilers,

Grate & Gas Fired Boilers

3. Thermax Ltd

Building Thermax House

Street 4, Mumbai Pune Road

Place Shivaji nagar

City 411 005 Pune





Country India

Telephone (+91) 20 - 551 21 22

Facsimile (+91) 20 - 551 22 42


Internet www.thermaxindia.com

Description Boilers & Heaters, Captive Power, Cooling, Water & 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 [email protected],

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


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


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


Internet www.neptunus-power.com

Description Captive Power Plants, Power Generation, Co-

Generation etc

8. Aravinthraajan Energy SystemsBuilding Madhurams Flat

Street 17/1 Senthil Andavar Street

Place Vadapalani


Country India

Telephone (+91) 44 - 484 46 27

Facsimile (+91) 44 - 484 46 27






Internet www.geocities.com/powerfulsolution/

Description Power Plant System Design and 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


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


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


Internet www.tce.co.in

Description Consultancy Services in Power Generation, Transmission& Distribution

2. Avant-Garde Engineers and Consultants Pvt Ltd (AGEC)

Street 68a, Porur-Kundrathur High Road

Place Porur


Country India

Telephone (+91) 44 - 482 87 17

Facsimile (+91) 44 - 482 85 31


Internet www.avantgarde-india.com

Description Concept to Commissioning of Renewable Energy Projects

3. FICHTNER Consulting Engineers (India) Private Ltd

Street 64, Eldams Road


Country India

Telephone (+91) 44 – 2435 9158

Facsimile (+91) 44 – 2434 4579


Internet www.fichtner.co.in

Description Consultancy Services in Gas & Thermal Power Plants

4. Acon Power Consultants

Street 45 Satyanand Vihar

District Rampur

City 482 008 Jabalpur

Country India

Telephone (+91) 761 - 66 72 61





Facsimile (+91) 761 - 66 42 07


Internet www.acon4power.com

Description Engineering Consultancy Services, Specializing in Power (Thermal/Hydro/Non-Conventional Energy Source)

5. Mitsui Babcock Energy (India) Private Ltd

Building Alsa Tower

Street 186-187 Poonamalle High Road

Place Kilpauk


Country India

Telephone (+91) 44 - 26612901

Facsimile (+91) 44 - 26612907


Internet www.mitsuibabcock.com

Description Thermal Power Plants

6. L&T - Sargent & Lundy 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


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


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


Description Consulting Services for Cogeneration Plants, Distribution Loss

Reduction, Waste Minimisation




628List of Suppliers

List of Suppliers

List of Energy Auditors

List of Energy Service Companies




629

AC DRIVES

Mr Ranjan Kumar De

Country Manager

ALLEN BRADLEY INDIA LTD

C - 11, Industrial AreaSite IV,shahiabad

Ghaziabad 201 010

Tel: +91-120-471112 / 0103 / 0105 / 0164

Fax: +91-120-4770822

Email: [email protected],

[email protected]

Cegelec India Ltd.

A - 21/24, Sector 16

Noida 201 301

Tel: 011 - 852 5643

Fax: 011 - 852 0405

Mr Sandeep MaityBusiness Unit Manager (VSD)

Danfoss Industries Pvt. Ltd.

296, Old Mahabalipuram Road

Sholinganallur, Chennai 600 119

Tel: 44 450 3511

Fax: 44 450 351844 450 3521


EMCO Lenze Pvt. Ltd.

106, Sion Koliwada Road

Sion (East)

Mumbai 400 022

Tel: 022 - 407 6432/ 1816

Fax: 022 - 409 0423

Energytek Electronics Pvt. Ltd.

A - 31, GIDC Electronics Zone

Gandhinagar 382 044

Tel: 02712 - 25562

Fax: 02712 – 30544

Messung Systems Pvt Ltd

S - 615, 6th Floor, Manipal Centre

Dickinson Road

Bangalore 560042

080 – 5320480


Ador Powertron Industries Ltd.

Plot 51, Ramnagar Complex

D - 11 Block,

MIDC, Chinchwad

Pune 411 019

Tel: 020 - 772 532, 773 778

Fax: 020 - 775 817

Mr K N Balaji

Chief Operating Officer

Eurotherm Del India Ltd

152, Developed Plots Estate

PerungudiChennai - 600 096

Tel: 044-4961129Fax: 044-4961831


Mr. Sudhir Naik

Vice President - Corporate Mktg.

Hi-Rel Electronics Limited

B -117 & 118, GIDC,

Electronics Zone, Sector-25

Gandhi Nagar 382044Tel: 02712-21636, 22531

Fax: 02712-24698Email:

[email protected]

Mr N C Agrawal

Managing Director MEDITRON

SIRTDO Industrial Estate

P O BIT, Mesra

Ranchi 835 215

Tel: +91-651-275875 / 628

Fax: +91-651-275841

Email: [email protected], [email protected]

Adsorption Dryers.

Mr. Rajnish Joshi

Exe. Vice President

Delair India Pvt. Ltd.

20, Rajpur Road,New Delhi 110054

Tel: 011-2912800

Fax: 011-2915127, 2521754


AFBC Boilers,

Mr K Kuppuraju

President-TechnicalCetharVessels Pvt ltd

4,Dindigul road,

tiruchirappilly

Tel: 0431-482452/53

Fax: 0431-481079


air & gas compressors,Mr Andre Schmitz

Managing Director

Atlas Copco (India) Ltd

Mahatma Gandhi Memorial Building

Netaji Subhas Road

Mumbai 400 002Tel: +91-22-796416 / 17Fax: +91-22-797928


Air compressors

Mr M Raveendran

Director

Coimbatore Compressor Engineering CoPvt Ltd

S F No 429, Thanneerpandal

Peelamedu

Coimbatore 641 004

Tel: +91-422-570323

Fax: +91-422-571447Email: [email protected]

Dr Jairam Varadaraj

Managing Director

ELGI EQUIPMENT LTD

Elgi Industrial Complex

Trichy Road

Singanallur P OCoimbatore 641 005

Tel: +91-422-574691 to 5Fax: +91-422-573697


Mr. Rahul C Kirloskar

Chairman & Managing Director Kirloskar Pneumatic Co Limited

Hadapsar Industrial Estate

Pune 411 031

Tel: 91-20-670133, 670341

Fax: 91-20-670297, 670634


Mr Amol Parkhe

Product manager

Kirlosker Copeland (EE)

1202/1,Ghole Road

Near Ramchandra Sabhagurha

Pune-411004

Tel: 020-5536350Fax: 020-5534988


Air conditioning systems

Mr Anand EkbotePresident

TATA LIEBERT LTD

Plot No C - 20, Road No 19Wagle Industrial Estate

Thane (W)

Mumbai 400 604

Tel: +91-22-5828405, 5802388

Fax: +91-22-5828358, 5800829


Ms Sajitha M Nair Marketing executive

Presvi Controls Pvt ltd

no 8, 2nd street,Venkatram nagar extn

Adayar

Chennai 600 020

Tel: 91-044-24420977/ 93Fax: 91-044-24410289

Mr J P Singh

Managing Director

YOKOGAWA BLUE STAR LTD

40/4, Lavelle Road

Bangalore 560 001

Tel: +91-80-2271513Fax: +91-80-2274270






Mr. B G Raghupathy

Vice Chairman

GEA Cooling Tower Technologies (India) Pvt

Ltd

443, Anna Salai, Teynampet

Chennai-600018Tel: 044-4326171

Fax: 044-4360576Email: [email protected]

Mr Ashok M Advani

Chairman & Chief Executive

BLUE STAR LTDKasturi Buildings

Mohan T Advani Chowk

J Tata Road

Mumbai 400 020

Tel: +91-22-2020868

Fax: +91-22-2874498, 2824043


Mr Anil K Srivastava

Managing Director

CARRIER AIRCON LTD

Chiller Business Unit

114, Shahpur Jat

Near Asian Games VillageNew Delhi 110 049

Tel: +91-11-6497131 to 34

Fax: +91-11-6497140

K N A Chandrasekar Regional Manager

Amtrex Hitachi Appliances Ltd

Tulsi Apartments47,II Main Road, R A Puram

Chennai 600 028

Tel: 044 - 4937483

Fax: 044- 4935534

Email:

[email protected]

Mr T NakamotoManaging Director

Daikin-Shriram Air Conditioning Pvt Ltd

12th floor, Surya Kiran Building

19KG Marg

New Delhi 110 001

Tel: 011-375-2647Fax: 011-375-2646

Mr. Seichi Yoshii

Managing Director

Matsushita Air-conditioning India Pvt Ltd

A 11& 12, SIPCOT Industrial Park

Irungattukottai

Chennai 600 001Tel: (91)-(44)-56039/5603940/5603941/

5603942

Fax: (91)-(44)-56041

Ambiator

Mr. A Vaidyanathan

Managing Director

HMX - SUMAYA Systems

A 422, Peenya Industrial estate

!st cross, 1 st stageBangalore 560058

Tel: 080-3722325, 1065Fax: 080-3722326


Ash handling systems; high alumina

ceramicsMr K R Natu

Managing Director

DEMECH LTD

78, Bhosari Industrial Estate

Pune 411 026

Tel: +91-20-7120994, 7120020

Fax: +91-20-7120774, 5654185Email:

ATOMISERS FOR HUMIDIFICATION

SYSTEMS

Techno Plast

Spin free System

No.1 Krishna flatsB/H Ambika hotel,Near Mothibai High

school,Amraiwadi

Ahmedabad – 26

Tel: 079 – 5850898

Automatic oil fired burners

Mr. R. Rawat

Partner Burnax India

338, Balmukund Khand,

Giri Nagar, Kalkaji,

New Delhi 110019

Tel: 011-6215124, 6230498

Fax: 011-6215124

Automatic Power Factor Controller Mr. Vipin SuriI

Managing Director

Sylvan Electronics

A-92/1, Naraina Indl. Area,

Phase-I

New Delhi 110028Tel: 011-5791044/2324Fax: 011-5794617

A Square Incorporation

11 (Old: 7) ‘Subramanyaa”

1st Floor, 3rd Street

Santhi Nagar,Aadambakkam

Chennai 600 088Tel: 044 – 2451853


Automatic voltage regulators (AVR)

Mr B.V.Subba Rao

Addl. GM

BHEL

RC Puram

Hyderabad

AUTOMATIC VOLTAGE STABILIZERMr Dilip Dharmasthal

Managing Director

Alacrity Electronics Limited

“Suresh Mahal”, 12 - B

Valmiki StreetT Nagar

Chennai 600 017

Tel: 044 - 823 6620

Fax: 044 - 825 9406

Consul Consolidated Pvt., Ltd.,

4/329-A, Old Mahabalipuram RoadThiruvanmiyur

Chennai 600 041

Tel: 044 – 4926651 / 2 / 3

Fax: 044- 4925754


Automation /Mr P S Sridharan

Managing Director

MEGATECH CONTROL PVT LTD

Alsha Complex

51, 1st Main RoadGandhi Nagar

Chennai 600 020

Tel: +91-44-4996733 / 5654Fax: +91-44-4341668, 4996215


AXIAL FLOW FANS

Amalgamated Indl. Composites Pvt. Ltd.

Unit No.111/112

Ashok Service Industrial Estate

L B S Marg, Bhandup (West)Mumbai 400 078

Tel: 022-591 3591/04565, 534 6919

Fax: 022-591 3611, 5346920

Mr V S Rajendran

In charge- Engg and marketing,After marketbusinessFlakt India ltd

147, Poonamalle high road

Village Numbal

Chennai 600077

Tel: 044-26272023, 2216

Fax: 044-26272606


Paru Engineers Private Limited

B-56, Durgabai Deshmukh Colony

Hyderabad 500 007

Tel: 040 - 764 4174

Fax: 040 - 764 4174




631

Basic Refractories

Mr V K Gopalakrishnan

Director

VRW INDUSTRIES LTD

No 15, Reddy StreetVirugambakkam

Chennai 600 092Tel: +91-44-4838638 / 385

Fax: +91-44-4833153

Blowers

Mr R P SoodManaging Director

ENCON FURNANCES PVT LTD

14/6, Mathura Road

Faridabad 121 003

Tel: +91-129-274408, 275307 / 607

Fax: +91-129-276448

Mr L Chandrashekar

Managing Partner

MYSORE ENGINEERING

ENTERPRISES

No 169, Industrial Suburb

II Stage

P B No 5859, Peenya PostBangalore 560 058

Tel: +91-80-8394423

Fax: +91-80-3349746


Boilers & Axuliaries

Mr. Ashok Tanna

Managing Director Vinosha Boilers Pvt. Ltd. And Taurus Heat

Systems

Baarat House, Ist Floor,

104, Apollo Street, Fort,

Mumbai 400001

Tel: 022-2674590, 2676447

Fax: 022-2611515:

Mr Michael H W Band

Executive Director

Mitsui Babcock Energy (India) Pvt Ltd

516-520, International Trade Tower

Nehru Place

New Delhi 110 019Tel: +91-11-6436790, 6446118Fax: +91-11-6489793

Email:

[email protected]

Krupp Industries India Ltd.

V Floor, Temple Tower,

672, Anna Salai, NandanamChennai 600 035

Tel: (91)-(44)-4339482/4346993

Fax: 91)-(44)-4348198

Mr J P Singh

Managing Director YOKOGAWA BLUE STAR LTD40/4, Lavelle Road

Bangalore 560 001

Tel: +91-80-2271513

Fax: +91-80-2274270


Mr K C RanaManaging Director

AVU ENGINEERING PVT LTD A - 15, APIE

Balanagar

Hyderabad 500 037

Tel: +91-40-3773235 / 2343

Fax: +91-40-3772343 / 3235Email: [email protected]

MrC S Radhakrishnan

Executive Director

Foster Wheeler India Pvt

Prakash Presidium

110 Mahatma Gandhi Road, NungambakkamChennai 600 034

Tel: 91-44-822-7341

Fax: 91-44-822-7340


Mr B Pattabhiraman

Managing Director GB Engineering Enterprises Pvt Ltd

D - 99, Developed Plots Estate

Thuvakudi

Trichy 620 015

Tel: +91-431-501111 (8 lines)Fax: +91-431-500311


Mr Ranjit Puri

Chairman & Mg Director

INDIAN SUGAR & GENERAL

ENGINEERING CORPORATION (THE)

A - 4, Sector 24

Noida 201 301

Tel: +91-118-4524071 / 72

Fax: +91-118-4528630, 4529215Email: [email protected]

Mr. Cyrus Engineer

Vice President

Industrial Boilers Ltd.

701-C, Poonam Chambers,Dr. Annie Besant Road, Worli,Mumbai 400018

Tel: 022-4926629

Fax: 022-4937505

Mr Prakash Kulkarni

Managing Director

THERMAX BABCOCK & WILCOX LTDSagar Complex

Kasarwadi

Pune 411 034

Tel: +91-20-7125745

Fax: +91-20-7125533

Email: [email protected],[email protected]

Mr Chakor L Doshi

Chairman

WALCHANDNAGAR INDUSTRIES LTD

3, Walchand Terraces

Opp Air Conditioned Market

TardeoMumbai 400 034

Tel: +91-22-4939498, 4934800Fax: +91-22-4936655

Mr. Arun Gandhi

Proprietor

Crescent Engineering Corporation49, H-32, Sector - 3,

Rohini,

New Delhi 110085

Tel: 011-7164109, 7276448

Fax: 011-7274553, 7162490

Krupp Industries India Ltd.V Floor, Temple Tower,

672, Anna Salai, Nandanam

Chennai 600 035

Tel: (91)-(44)-4339482/4346993

Fax: 91)-(44)-4348198

BurnersMr S M Jain

Vice President

ADOR TECHNOLOGIES LTD

Plot No 53, 54 & 55

F - II Block, MIDC Area, pimpriPune 411 018

Tel: +91-20-7470225, 7476009


Mr B S Adishesh

Wholetime Director

IAEC INDUSTRIES MADRAS LTD

Rajamangalam

Villivakkam

Chennai 600 049Tel: +91-44-655725, 6257783

Fax: +91-44-4451537, 4995762


Calorifiers

Mr. Dinesh HarjaiPartner Crupp Metals

Kh. No. 56/1, Mundka,

Rohtak Road,

New Delhi 110041

Tel: 011-5189024, 5474133

Fax: 011-5183085

Capacitors Auric Engineering Pvt ltd

8-4-368/A Sanathnagar

Hyderabad 500018

Tel: 040-3814035






Mr R G Deshpande

Managing Director

BC COMPONENTS INDIA PVT LTD

Loni - Kalbhor, (Central Railway)

Pune 412 201Tel: +91-20-6913451, 6913285


Shri. S K Nevatia

Hind Rectifiers Ltd

Lake RoadBhandup West

Mumbai

Tel: 22 - 564 41 22

Fax: 22 - 564 41 14


Momaya Capacitors401, Madhav Apartments

Jawahar Road, Opp. Rly. Stn.

Ghatkopar (East)

Mumbai 400 077

Tel: 022 - 516 2899/ 1005/ 0745

Fax: 022 - 516 0758

Shakti Capacitors Pvt LtdPlot No 104/105

PB No 176

Industrial Estate

Sangli 416 416

Tel: 91-233-310-915Fax: 91-233-310-984


Mr. S. Jayaraman

Sr. General Manager-Mktg.

Kapsales Electricals Limited

Khatau House,

Plot No. 410-411, Mogul Lane, Mahim,

Mumbai 400016

Tel: 022-4461975, 4450050

Fax: 022-4450016

Centrifugal & axial fans

Mr J B Kamdar

Chief Executive

NADI AIRTECHNICS

26, G N T RoadErukkencheryChennai 600 118

Tel: +91-44-5570264 / 771

Fax: +91-44-5371149


Mr A P Gokhale

Director Autowin systems povt ltd

Plot no 2, Vedant Nagari

Karve nagar

Pune-411052

Tel: 020-5431052, 5423358


Centrifugal Pumps

Mr BSS Rao/rajiv

Sr General manager

Beacon Weir ltd

no 28, Industrial estate Ambattur

chennai-600098Tel: 044-6250739


Mr P U K Menon

Executive Director

MATHER & PLATT INDIA LTDP B No 7

Chinchwad

Pune 411 019

Tel: +91-20-7476196 to 98, 7477434 (D)

Fax: +91-20-7462519


CERAMIC COATINGRAVI Thermal Engineers Pvt. Ltd.

No.11, 4th Cross, Central Excise Layout

Vijaynagar

Bangalore 560 047

Tel: 080 - 330 5794

Fax: 080 - 330 3964

CERAMIC FIBRE

Minwool Rock Fibres Limited

204, Kings Apartments

Juhu Tara RoadJuhu

Mumbai 400 049

Tel: 022-6154809Fax: 022-6178921

Ceramic Fibre products

Mr.Mahesh Chavda

Sales Manager

Murugappa Morgan Thermal Ceramics Ltd

Tiam House-Annexe Building’-3rd Floor

No.28 Rajaji Salai,Chennai-600001

Tel: 044-5224897,5272781

Fax: 044-5213709,5227093


CFLMr Vinay Mahendru

A-39, Hosiery Complex

Indo Asian fuse gear ltd

phase II extn

Noida-201305

Tel: 0120-2568471, 2568093-98

Fax: 0120-2568473


Chillers

Harshlal Suragne

Er-Marketing

Kirloskar Mcquay pvt ltd

PB No 1239,Hadapsar industrial estatepune 411013

Tel: 020 6821502,03-06

Fax: 020-6821509


CLEATED BELT CONVEYOR

Kraft Engg. & Projects Ltd189, Arcot Road, Vadapalani

Chennai 600 026Tel: 044 - 484 5811

Fax: 044 - 484 7838

coalesor

Siemag Hi tech filtersR k Industry house

Walbhat Road

Goregaon (E)

Mumbai 400 063

Tel: 022-26851885, 3231

Fax: 022-26851048


cogeneration power plants based on

waste heat

Mr Pinaki Bhadury

Senior Manager

Thermax Limited Cogen Division

Sai Chambers, 15 Mumbai-Pune RoadWakdewadi

Pune 411003

Tel: 020-205511010

Fax: 020-205511042

COMPRESSED AIR SYSTEM

MAINTENANCE

Orchid Energy Systems1141 – B, Trichy Road

Coimbatore 641 045

Tel: 0422 – 318389

Fax: 0422 – 312073

Compressed air systems

Mr K.S. Natarajan

Managing Director Trident Pneumatics Pvt Ltd.

5/232, K.N.G. Pudur Road

Somayampalayam Post

Coimbatore 641 108

Tel: 0422 2400492

Fax: 0422 2401376Email: [email protected]

Condenser

Mr M Sreenivasan

Chief Executive

SUPER ENGINEERING COMPANYB - 1, Industrial Estate

Ariamangalam

Trichy 620 010

Tel: +91-431-441131

Fax: +91-431-441366

Cooling Tower




633

Mr Raviselvan

Managing Director

Gem Cooling Towers Private Limited

SF. No. 100/A

Arasur

Coimbatore 641407Tel: 0422-887059/880129

Fax: 0422-888247

Mr Vikram Swarup

Managing Director

Paharpur Cooling Towers Ltd.

Paharpur House8/1/B Diamond Harbour Road

Kolkata 700027

Tel: 91-33-24792050

Fax: 91-33-24792188


Mr S BansalChief Executive

Paltech Cooling Towers & Equipments Ltd.

A-502 & 601

ANSAL CHAMBER - I

BHIKAJI CAMA PLACE

NEW DELHI 110066

Tel: 011-6108114 / 6174250Fax: 91-11-6174250

Mr Pankaj Bhargava

Managing Director

Parag Fans & Cooling Systems LimitedPlot no. 1/2b & 1b/3a

Industrial Area no. 1

A.B. roadDewas 455 001

Tel: 07272-58135 / 58131

Fax: 91 - 7272 - 30273, 58850


Cooling Tower water treatment

Hercules Speciality Chemicals Ltd

5TH FLOOR, VAYUDNOOTHCHAMBERS

15/16, MAHATMA GANDHI ROAD

BANGALORE 560001

Cooling water Systems

Mr M Amjad Shariff Director Shriram Epc Ltd

No 9 Vanagaram Road,

Ayanambakkam

Chennai 602 102

Tel: 6533109/3313/1592

Fax: 653 2780/826 2416


Cooling water treatment chemicals

Mr JayantRajvanshi

Director

Aqua Chemicals

B-237A Road No. 6DV.K.I.Area

Jaipur 302013

Tel: 0141-2331542,5061909

Fax: 0141-2331543

Email: JayantRajvanshi@aqua-

chemicals.com

Nalco chemicals india ltd

20/A Park StreetKOLKATA 700 016

Tel: 033-2172494

Fax: 033-2171709

DC DRIVESSiemens Ltd.

Motors, Drives & UPS Division

Sector - 11, Plot 11

Kharghar Mode

Navi Mumbai 410 208

Tel: 022 – 757 7030/ 31/ 32

Fax: 022 – 757 7106:

DC DRIVES

Larsen & Toubro Ltd

Control & Automation Section

10, Club House Road

Anna Salai

Chennai 600 002Tel: 044 – 852 2141

Fax: 044 – 852 0769

DG sets

Mr Mohan M Gujrar Managing Director

Gurjar Power Engineers Pvt ltd

no 18, Ist Floor,Corporation BuildingResidency Road

Bangalore-560025

Tel: 080-2216416, 7469

Fax: 022-2216416


Powerica Limited

115 Mittal CourtB-Wing Nariman Point

Mumbai 400021

Tel: 022-2825949

Fax: 91-22-22043782

Mr Pradeep MallickManaging Director WARTSILA INDIA LTD

76, Free Press House

Nariman Point

Mumbai 400 021

Tel: +91-22-2815601 / 5598, 28175995 / 5601

Fax: +91-22-2842083


Mr D R Dhingra

Managing Director

CONTINENTAL GENERATORS PVT LTD

3869, Behind Primary School

G B RoadDelhi 110 006

Tel: +91-11-7535566 to 68, 525632, 522983,

528510

Fax: +91-11-7516598, 528510

Mr Girish Mohan

Director TIMKEN SERVICES PVT LTD

725, Udyog Vihar Phase V

Gurgaon 122 016

Tel: +91-124-347725 / 6, 342840

Fax: +91-124-342320, 348086

Mr K C Dhingra

Managing Director

WESTERN INDIA MACHINERY CO PVT

LTD

Park Plaza

North Block, 6E, 6th Floor

71, Park StreetKolkata 700 016

Tel: +91-33-2468913 / 9674

Fax: +91-33-2468914

Mr Sumit Mazumder

Managing Director

TIL LTD1, Taratolla Road

Garden Reach

Kolkata 700 024

Tel: +91-33-4693732 to 36, 4696497 to 99


Mr Anand KothanethGeneral Manager

BATLIBOI ENGINEERS PVT LTD

99/2 & 99/3, N R Road

Bangalore 560 002

Tel: +91-80-2235061 to 63

Fax: +91-80-2235085


Diffuser

Siemag Hi tech filters

R k Industry house

Walbhat Road

Goregaon (E)

Mumbai 400 063Tel: 022-26851885, 3231Fax: 022-26851048


Dryers

Mr A D Parekh

General Manager

HDO PROCESS EQUIPMENT ANDSYSTEMS LTD

5/1/2, GIDC Industrial Estate

Vatva

Ahmedabad 382 445

Tel: +91-79-5830591 to 94






ECONOMISERS

Megatherm Engineers & Consultants Pvt.

Ltd.

10, Kodambakkam High Road

Chennai 600 034Tel: 044 - 823 3528/ 3707

Fax: 044 - 825 8559

Mr B P Deboo

Managing Partner

ALBAJ ENGINEERING CORPORATION

340, Clover CentreMoledina Road

Pune 411 001

Tel: +91-20-6131511, 6133018, 6121542

Fax: +91-20-6137255


Eddy current control systemsDr. M. J. Davis

Executive Director

Eddy Current Controls (India) Limited

Eddypuram, Chalakudy,

District Thrissur

Thrissur 680722

Tel: 0488-842882/716/698Fax: 0488-842716

Efficiency enhancement coating for

pumps

Mr G V MuralidharaSBU Head(Anti Corrosion Products

Division)

Kirloskar Brothers Limited408/15, Chintan

Mukundnagar

Pune-411037

Tel: 020-4402137


Electric motors

Mr Rahul N AminChairman & Mg Director

JYOTI LTD

Industrial Area

P O Chemical Industries

Vadodara 390 003

Tel: +91-265-380633, 380627Fax: +91-265-380671, 381871Email: [email protected]

Electrical Measuring Instruments

Mr R R Dhoot

Chairman

IMP POWER LTD

Advent, 7th Floor 12 - A, General J Bhosale Marg

Nariman Point

Mumbai 400 021

Tel: +91-22-2021890 / 886 / 697

Fax: +91-22-2026775


Electronic ballasts

Mr Shantilal patel

Propreitor

Nishan Power converters

Krishna Vijay saw mill compound

Opp S T stand, Agra RoadBhivandi-421302

Tel: 91-2522-257201Fax: 91-2522-222032


Mr V Ramaraj

Managing Partner OPAL

NO 5, rajeswari street

Mehta nagar

chennai 600029

Tel: 044-23742036 / 1218

Fax: 044-23742036 / 1218


Mr. K. G. Madhu

Managing Director

Ammini Energy System Pvt. Ltd.

Industrial Estate,

Pappanamcode,

Trivandrum 695019Tel: 0471-490508

Fax: 0471-490832


Mr.P.S.SasidharanManaging Director

Pamba Electronic Systems Pvt Ltd.

1/40A, Pamba House, Kureekkad P.OThiruvankulam

Ernakulam-682 305

Tel: 0484-711129,712721

Fax: 0484-711398


Electronic energy meters

Mr I C AgarwalChairman & Mg Director

GENUS OVERSEAS ELECTRONICS

LTD

SPL - 3, RIICO Industrial Area

Tonk Road

SitapuraJaipur 302 022Tel: +91-141-580003 / 4 / 9

Fax: +91-141-580319


Energy Efficiency & ESCO Services

Mr R B Sinha

Chief ExecutiveEnergy Audit Services

1116

Sector No 17

Faridabad -121 002

Tel: 0129 - 2282132/2284125/2224504

Fax: 0129 2262576Email: [email protected]

Energy efficient coolers for cement

Industry

MR. PRADEEP KAPOOR

Director

Fuller India ltdJ-11, IIND FLOOR,

REAR FLAT, SAKETNEW DELHI 110017

Mr Madhusudan Rasiraju

I K N engineering India pvt ltd

Three star Business Centre A14 A, II nd Avenue

Anna Nagar

Chennai 600102

Tel: 044-26218994,6210960

Fax: 044-26284567,0439


Energy efficient drying systemMukesh Shah

Director

Mecord Systems and Services (P) Ltd.

314 Hill View Industrial Estate

Ghatkopar West

Mumbai 400086Tel: (022)-5008604

Fax: (022)-5007560

Energy Efficient Induction Motors

Mr. Sanjeev GuptaProprietor

Oxford Engineering Industries

G-27, East Gokalpur,Loni Road,

New Delhi 110094

Tel: 011-2280434, 2299979

Fax: 011-2293370

Energy efficient lighting systems

Mr R Nandakishore

Sr General Manager MarketingPhilips India Ltd

Motorola excellence centre, 5th floor 415/2,

Mehrauli Gurgaon Road, Sector 14,

Gurgaon-122001

Tel: 0124-8991980


ENERGY EFFICIENT MOTORS

Asea Brown Boveri ltd

Plot No 5 & 6, II Phase

Peenya Industrial Area

P B no 5806, Peenya

Bangalore 560058Tel: 080-8370416 / 8394734 extn 2322 /

6691375

Fax: 080-8399178 / 8396537

Mr N J Danani

Vice Chairman & Mg Director BHARAT BIJLEE LTD




635

Central Marketing Office (Motor)

P O Box 100

Kalwe, Thane Belapur Road

Mumbai 400 601

Tel: +91-215-7691656

Fax: +91-215-7691401 / 2:

Crompton Greaves LimitedCG Industrial Systems

ETD Building, 2nd Floor

Kanjur Marg (E)

Mumbai 400 042

Tel: 022-5782451 Extn 8956/ 5795688Fax: 022-5789169

Energy efficient Pumps

Mr G Rajendran

Managing Director

C.R.I. Pumps (PVT) Limited

Athipalayam Road,Chinnavedampatti

Coimbatore 641 006

Tel: (422) 867051 /2/6395

Mr N K Ranganath

Chief Executive

Grundfos Pumps India Pvt LtdGround floor

Chamiers apartment

119/121, Chamiers road

Chennai 600028

Tel: 044-4323487 / 4357065Fax: 044-4323489

Mr N C Tiwari Assistant General Manager, Product

Development & Mangement

Kirloskar Brothers Limited

Ujjain Road

Dewas-455001

Tel: 07272-27315

Fax: 07272-27347


Energy management & Control systems

Mr Lalit Seth

Chief Executive

HPL-SOCOMEC PVT LTD

Atma Ram Mansion, 2nd Floor 1/21, Asaf Ali RoadNew Delhi 110 002

Tel: +91-11-3236811 / 4811

Fax: +91-11-3232639


CMS ENERGY Management systems

W 324, Rabale MIDC

Mumbai 400701Tel: 91-022-27696720,86

Fax: 91-022-27694585

Energy meters

Mr Qimat Rai Gupta

Chairman & Mg Director HAVELL‘S INDIA LTD

1, Raj Narain Marg

Civil Lines

Delhi 110 054

Tel: +91-11-3935237 to 40, 2944469 to 72,

3981101 to 05


Mr Lalit Seth

Chief Executive

HPL-SOCOMEC PVT LTD

Atma Ram Mansion, 2nd Floor

1/21, Asaf Ali RoadNew Delhi 110 002

Tel: +91-11-3236811 / 4811

Fax: +91-11-3232639


Energy Recovery Ventilator (ERV),

Mr. Rajnish JoshiExe. Vice President

Arctic India Engineering Pvt. Ltd.

20, Rajpur Road,

New Delhi 110054

Tel: 011-2912800

Fax: 011-2915127, 2521754


Energy saver for air conditioners

Dr V K Koshy


BHARAT ELECTRONICS LTDShankaranarayan Building, 2nd Floor

25, M G Road

Bangalore 560 001Tel: +91-80-5595729

Fax: +91-80-5584911


Energy saver for Lighting

Mr R Sekar

Chairman & Managing Director

ES Electronics (India) Pvt Ltd438,4th Main Road

Nagendra Block,B.S.K.I Stage,

Bangalore 560050

Tel: 080-6727836 / 8761

CLIPSAL Lighting India (P) LtdBajaj NiwasOpP. C.K.P. Club,

712 , Linking Road, Khar (W)

Mumbai

Tel: 022-6046483

energy savers for AC Induction motors

Santronix india pvt ltd

unit no 12Electronic sadan III

MIDC, Bhosari

Pune 411026

Tel: 020-7122758

Fax: 020-7129518


Energy Saving Lighting Systems.

Mr. Praveen Kumar Sood

Managing Director

Linear Technologies India Pvt. Ltd.

K-37, Green Park,Main Basement,

New Delhi 110016Tel: 011-6854395, 6854946

Fax: 011-6854057

Mr. Ajit R. Shah

Managing Director Eurolight Electricals Limited

20,Sadashiv Peth, Rahi Chambers,

L B S Road,

Pune 411030

Tel: 0212-531287, 534128

Fax: 0212-532787

Email: yantra @ bom3vsnl.net.in

Energy Services Consultancy

Mr P S Sankaranayaran

Director

Avant Garde Engineers & Consultants (p)

Ltd.

68A Porur Kundarathur High roadPorur

Chennai 600 116

Tel: 044-4828717,18,19,22

Fax: 91-44-4828531


ESCO

Mr B S PuniaJr Vice President

DCM Shriram Consolidated Ltd

5th floor,Kanchenjunga Building

18,Barakhamba Road

New Delhi-110001

Tel: 011-3316801

Fax: 011-3318261


Mr Nalin Kanshal

Business Director

Elpro energy Dimensions Pvt ltd

6,7,8 IV N Block

Dr RajKumar Road, Rajaji Nagar entranceBangalore-560010Tel: 080-3122676,3123238,3132035,3132036

Fax: 080-3487396


EVAPORATIVE CONDENSERS

Baltimore Aircoil Company Inc.

122, Hema Industrial EstateSarvodaya Nagar

Jogeshwari (E)

Mumbai 400 060

Tel: 824 5714

Fax: 824 5713






Systems & Components (India) Private

Limited

110, Gautam Udyog Bhavan

L.B.S Marg, Bhandup (West)

Mumbai 400 078

Tel: 022-564 0166-67Fax: 022-564 5896


Evaporative Cooling Pad (ECP) and

Control Panel heat Extractor

Mr. Rajnish Joshi

Exe. Vice President Arctic India Engineering Pvt. Ltd.

20, Rajpur Road,

New Delhi 110054

Tel: 011-2912800

Fax: 011-2915127, 2521754


FansMr Saroj Poddar

Chairman

ALSTOM LTD

14th Floor, Pragati Devika Tower

6, Nehru Place

New Delhi 110 019Tel: +91-11-6449906, 6449907, 6449902 / 3

Fax: +91-11-6449447

Mr A M Naik

Mg Director & CEOLARSEN & TOUBRO LTD

L & T House

Ballard EstateMumbai 400 001

Tel: +91-22-2618181

Fax: +91-22-2620223, 2610396, 2622285


filters for Air Compressors

Mr. Sanjay Joshi

Managing Director Domnick Hunter India Pvt Limited

B-214, ANSAL CHAMBER-I

3, BHIKAIJI CAMA PLACE

NEW DELHI 110066

Tel: 11 61 92172

Fax: 011-6185279

Flue Gas Analysers

Mr T V Krishnamurthy

Chief Executive

Marvel Engineering company

28,Deivasigamani road

Roypettah

Chennai-600014Tel: 044-8110582,2297

Fax: 044-8117559


Fluid Bed Dryer

Mr Subodh S NadkarniPresident & CEO

SULZER INDIA LTD

Sulzer House

Baner Road, Aundh

Pune 411 007

Tel: +91-20-5888991 / 98

Fax: +91-20-5886393Email:

[email protected]

Aerotherm Systems Pvt Ltd

Plot no 1517 Phase III

GIDC Vatwa

Aheemedabad 382445Tel: 079-5890158

Fax: 079-5834987


Mr K C Patel

General Manager

Gujarat Perfect Engineering Ltd301, Shailja Complex II, Akota Road

Vadodara 390 020

Tel: +91-265-334861, 645786

Fax: +91-265-646880


FRP BLADES Amalgamated Indl. Composites Pvt. Ltd.

Unit No.111/112

Ashok Service Industrial Estate

L B S Marg, Bhandup (West)

Mumbai 400 078Tel: 022-591 3591/04565, 534 6919

Fax: 022-591 3611, 5346920

Encon (India)

2 - B/17, Shivkripa

N C Kelkar Road

Dadar (West)

Mumbai 400 028

Tel: 022 - 437 2949, 4306578

Fax: 022 - 431 0992, 4321929

Furnace

Mr Saroj Poddar

Chairman

ALSTOM LTD


6, Nehru PlaceNew Delhi 110 019Tel: +91-11-6449906, 6449907, 6449902 / 3

Fax: +91-11-6449447

Mr Mithu S Malaney


VULCAN ENGINEERS LTD

427, Unique Industrial EstateOff Veer Savarkar Marg

Prabhadevi

Mumbai 400 025

Tel: +91-22-4304529 / 3671

Fax: +91-22-4225814

Email:[email protected]

Mr. Arun Gandhi

Proprietor

Crescent Engineering Corporation

49, H-32, Sector - 3,

Rohini,

New Delhi 110085Tel: 011-7164109, 7276448

Fax: 011-7274553, 7162490

Mr Vilas H Patil

Managing Director

DYNAMIC FURNACES PVT LTD

65, Universal Industrial EstateI B Patel Road

Goregaon (E)

Mumbai 400 063

Tel: +91-22-8733516, 8746138

Fax: +91-22-8733021


Mr R P Sood

Managing Director


14/6, Mathura Road

Faridabad 121 003

Tel: +91-129-274408, 275307 / 607

Fax: +91-129-276448

Mr C P Maheshwari

Managing Director

HC GIDDINGS PVT LTD

3, Chittaranjan AvenueKolkata 700 013

Tel: +91-33-272820, 261740

Fax: +91-33-2372820, 2361740

Mr M Gopal

Managing Director

HIGHTEMP FURNACES LTD

I - C, Phase II

P B No 5809

Peenya Industrial Area

Bangalore 560 058Tel: +91-80-8395917 / 4076 / 1446

Fax: +91-80-8397798 / 2661


Mr M K Sen

Managing Director INCORPORATED ENGINEERS LTDD - 400, Gayatri

MIDC, Uran Phata

Nerul

Navi Mumbai 400 706

Tel: +91-22-7619352, 7619366

Fax: +91-22-7619368


Mr N Gopinath

Managing Director

FLUIDTHERM TECHNOLOGY PVT LTD

SP - 132, III Main Road

Ambattur Industrial EstateChennai 600 058




637

Tel: +91-44-6357390, 6357391

Fax: +91-44-6257632


generators and boilers

Mr K G RamachandranChairman & Mg Director

BHARAT HEAVY ELECTRICALS LTDBHEL House

Siri Fort

New Delhi 110 049

Tel: +91-11-6001010

Fax: +91-11-6493021, 6492534

Mr Praveen Sachdev

Mg Director & CEO

GREAVES LTD

1, Dr V B Gandhi Marg

P O Box 91

Mumbai 400 001Tel: +91-22-2671524 / 4913

Fax: +91-22-2677850, 2652853

Harmoic analyser

Neptune India ltd

Neptune house

C 270 SFS Sheikh saraiPhase I

New delhi 110017

Tel: 011-6013367-70

Fax: 011-6013371


Mr Dilip Dharmasthal

Managing Director Alacrity Electronics Limited


Valmiki Street

T Nagar

Chennai 600 017

Tel: 044 - 823 6620

Fax: 044 - 825 9406

Avante Global services

225, Prakash Mohalla

East of Kailash,

New Delhi 110065

Tel: 011-26233259,26443097


Mr. P Anil Kumar

Managing Director

TOWLER ENTERPRISE SOLUTIONS

PVT.LTD

HARMAN HOUSE

482, 80 FT ROAD, GANGANAGAR

BANGALORE 160032Tel: 080-3530033-36,3432289

Fax: 080-3431548

Mr Lalit Kumar Pahwa

Managing Director

HARMAN INNOVATIVETECHNOLOGIES LTD

Harman House

482, 80 FT Road

Ganganagar

Bangalore 560 032

Tel: +91-80-3530036 / 37


harmonic filters

Power Linkers

122,Nahar & seth estate

chakala

Mumbai 400099Tel: 022-28325565, 28371902

Fax: 022-28386025


Mr. R. K. Iyer

Vice President

Saha Sprague LimitedNo.805, North Rear Wing, 8th Floor, Manipal

Centre

47, Dickenson Road,

Bangalore 560042

Tel: 080-5595463, 5595266

Fax: 080-5595463

Harmonic measurement and analysisPower Linkers

122,Nahar & seth estate

chakala

Mumbai 400099Tel: 022-28325565, 28371902

Fax: 022-28386025


Harmonic utility Equipments

Mr Parag J Pandya

CE O

Amtech Electronics India ltd

E - 6 GIDC Electronics Zone

Gandhi Nagar

Gandhi Nagar 382 028Tel: 079 - 3225324/3227294/3227304

Fax: 079 - 3224611


Heat exchanger

Mr M SreenivasanChief ExecutiveSUPER ENGINEERING COMPANY

B - 1, Industrial Estate

Ariamangalam

Trichy 620 010

Tel: +91-431-441131

Fax: +91-431-441366

Mr Mohammed Meeran

Proprietor

AASIA RADIATORS

P S C Bose Road

Jawahar Autonagar

Vijayawada 520 007Tel: +91-0866-543881

Fax: +91-0866-545860

Mr Ajit Singh

Chief Executive Officer

AIRFRIGE INDUSTRIES

10/65, Kirti Nagar Industrial AreaNew Delhi 110 015

Tel: +91-11-5931909 / 72, 5162118 / 19Fax: +91-11-5436781


Mr B P Deboo

Managing Partner ALBAJ ENGINEERING CORPORATION

340, Clover Centre

Moledina Road

Pune 411 001

Tel: +91-20-6131511, 6133018, 6121542

Fax: +91-20-6137255


Mr Deepak Singh

Executive Director

BUILDWORTH PVT LTD

G S Road

Dispur

Guwahati 781 005Tel: +91-361-560354

Fax: +91-361-561411


Mr Sucha SinghManaging Director

COIL COMPANY PVT LTD

A - 21/24, Naraina Industrial AreaNew Delhi 110 028

Tel: +91-11-5701967 / 1968 / 9127

Fax: +91-11-5709126


Er Ashok Kumar Gupta

Chairman

CRANE-BEL INTERNATIONALDev - Satya Bhavan

C - 23, Lohia Nagar

Ghaziabad 201 001

Tel: +91-120-4722994, 4716883, 4713281/82

Fax: +91-120-4712709, 4722995


Mr. Dinesh Harjai

Partner

Crupp Metals

Kh. No. 56/1, Mundka,

Rohtak Road,

New Delhi 110041

Tel: 011-5189024, 5474133Fax: 011-5183085

Mr. A. Bhasker Reddy

Managing Partner

Enfab

C-2, Shanthi Nivas,Mettuguda,





Secunderabad 500017

Tel: 040-823073, 830010

Fax: 040-823073, 830010

Email: enfabs @ hd1.vsnl.net.in

Mr B PattabhiramanManaging Director

GB Engineering Enterprises Pvt LtdD - 99, Developed Plots Estate

Thuvakudi

Trichy 620 015

Tel: +91-431-501111 (8 lines)


Mr K C Patel

General Manager

GUJARAT PERFECT ENGINEERING

LTD

301, Shailja Complex II Akota Road

Vadodara 390 020

Tel: +91-265-334861, 645786

Fax: +91-265-646880


Mr C P MaheshwariManaging Director

HC GIDDINGS PVT LTD

3, Chittaranjan Avenue

Kolkata 700 013

Tel: +91-33-272820, 261740Fax: +91-33-2372820, 2361740

Mr A D ParekhGeneral Manager

HDO PROCESS EQUIPMENT AND

SYSTEMS LTD

5/1/2, GIDC Industrial Estate

Vatva

Ahmedabad 382 445

Tel: +91-79-5830591 to 94


Mr B S Adishesh

Wholetime Director


RajamangalamVillivakkamChennai 600 049

Tel: +91-44-655725, 6257783

Fax: +91-44-4451537, 4995762


Mr M K Sen

Managing Director INCORPORATED ENGINEERS LTD

D - 400, Gayatri

MIDC, Uran Phata

Nerul

Navi Mumbai 400 706

Tel: +91-22-7619352, 7619366Fax: +91-22-7619368


Mr Ranjit Puri




A - 4, Sector 24Noida 201 301

Tel: +91-118-4524071 / 72Fax: +91-118-4528630, 4529215, 4542072


Mr P V Rao

Managing Partner INDIRA INDUSTRIAL WORKS

1 - 528, Lankalapalem P O

Visakhapatnam 531 021

Tel: +91-891-29461 / 53

Fax: +91-891-29461

Email:

Mr S V Mehta

Chairman & Director

INDUSTRIAL MACHINERY

MANUFACTURERS PVT LTD

3607 - 3609, GIDC Estate

Phase IV

Vatva Ahmedabad 382 445

Tel: +91-79-5831152 / 1449

Fax: +91-79-5832216

Email:

[email protected]

Mr L Chandrashekar

Managing Partner MYSORE ENGINEERING

ENTERPRISES

No 169, Industrial Suburb

II Stage

P B No 5859, Peenya Post

Bangalore 560 058

Tel: +91-80-8394423


Mr V David Selvaraj

Vice President (Operations)

PARANI STEELS PVT LTD

AL - 84, 4th Street11th Main Road

Anna Nagar

Chennai 600 040

Tel: +91-44-6286285 / 2246 / 2247

Fax: +91-44-6211265

Mr Ramesh Wadhwani

Managing Director UNITOP ENGINEERS PVT LTD

78/1, GIDC Industrial Estate

P O Box No 761

Makarpura

Vadodara 390 010

Tel: +91-265-642161 / 62Fax: +91-265-644698


Mr Chakor L Doshi

Chairman

WALCHANDNAGAR INDUSTRIES LTD

3, Walchand Terraces

Opp Air Conditioned MarketTardeo

Mumbai 400 034Tel: +91-22-4939498, 4934800

Fax: +91-22-4936655

Mr Pashupati Nath Kapoor

Partner KASHI INDUSTRIES

16/80, B 1

Civil Lines

Kanpur 208 001

Tel: +91-512-311395, 319074

Fax: +91-512-319074

Mr Roy Eapen

Proprietor

HEAT TRANSFER DEVELOPMENT

84 - C, Jeevan Complex

5th Cross, 100 Feet Road

Gandhipuram

Coimbatore 641 012Tel: +91-422-858271 / 2

Fax: +91-422-447341

Mr J Peter Arokiam

Managing Director MANIKAM RADIATORS PVT LTD

11/275 - B, Subramaniapalayam

K N G Pundur RoadG N Mills Post

Coimbatore 641 029

Tel: +91-422-843311 / 12

Fax: +91-422-843311


Heat recovery boilers

Mr K G RamachandranChairman & Mg Director

BHARAT HEAVY ELECTRICALS LTD

BHEL House

Siri Fort

New Delhi 110 049

Tel: +91-11-6001010Fax: +91-11-6493021, 6492534

Heat Recovery Wheel (HRW)

Mr. Rajnish Joshi

Exe. Vice President

Arctic India Engineering Pvt. Ltd.

20, Rajpur Road,

New Delhi 110054Tel: 011-2912800

Fax: 011-2915127, 2521754





639

Heat Treatment furnances

Mr R N Bakshi

Managing Director

UNITHERM ENGINEERS LTD

101, Laxmi Market, 1st Floor Vartak Nagar Junction, Pokhran Road No 1

Mumbai 400 606Tel: +91-22-5406131, 5371654, 5371655

Fax: +91-22-5406569


Mr. S. R. Babbar Partner

Wellmake Engineering Company

A-28,Mangolpuri Indl. Area,

Phase-II,

New Delhi 110034

Tel: 011-7018199, 7025409

Fax: 011-7019330

High alumina refractories

Mr V K Gopalakrishnan

Director

VRW INDUSTRIES LTD

No 15, Reddy Street

VirugambakkamChennai 600 092

Tel: +91-44-4838638 / 385

Fax: +91-44-4833153

High Efficiency Electric MotorsMr. Liakat Ali

Proprietor

Premier Electric CompanyPlot No.7,

12/2 Mathura Road,

Faridabad 121002

Tel: 0129-270858, 274311

Fax: 0129-270858

High Efficiency Electric Transformers

Mr. Liakat AliProprietor

Premier Electric Company

Plot No.7,

12/2 Mathura Road,

Faridabad 121002

Tel: 0129-270858, 274311Fax: 0129-270858

Mr. T. V. Joseph

General Manager

Transformers and Electricals Kerela

Ltd.(TELK)

Angamaly P.O. 683573,

Angamaly 683573Tel: 04856-452251

Fax: 04856-452873

High efficiency power distribution &

special Transformers.

Mr. Nitin NayakDirector

El -Tra Equipment Company (India) Pvt. Ltd.

11th Mile, Old Madras Road,

Avalahalli, P.O. Virgonagar,

Bangalore 560049

Tel: 080-8510652, 8472229


High Efficiency Pumps

Sulzer Pumps India Ltd

No.9, MIDC, Thane Belapur Road

Dingha,

Navi Mumbai 400 708Tel: +91 22 790 4321

Fax: +91 22 790 4306


Mr Andre Schmitz

HOC Driers

Managing Director ATLAS COPCO (INDIA) LTD

Mahatma Gandhi Memorial Building

Netaji Subhas Road

Mumbai 400 002

Tel: +91-22-796416 / 17

Fax: +91-22-797928


Mellcon Engineering Pvt Limited

B-297, Okhla Industrial Area

Phase-1

New Delhi 110 020Tel: 011 – 6811727 / 6816103

Fax: 011 – 6816573 / 6819151

MVS Engineering Limited

MVS House, E-24

East of Kailash

New Delhi 110 065

Tel: 011 - 6431908, 6436869

Fax: 011 - 6464994

Email: E-mail: [email protected]

Puriflair India

22, GIDC Estate

P.B 790, Makarpura

Vadora 390 010

Tel: 0265 – 642487 / 645248

Fax: 0265 – 644070

HT capacitors, Furnace duty capacitors

Mr. M.D. Killedar

Manager (Works)

Goa Capacitors Pvt. Ltd.

14, Corlim Industrial Estate,

Corlim, Ilhas,

Panaji 403110Tel: 0832-286176/240

Fax: 0832-286203

Humidifiers

Mr S V Mehta

Chairman & Director

INDUSTRIAL MACHINERY

MANUFACTURERS PVT LTD

3607 - 3609, GIDC Estate

Phase IV

Vatva

Ahmedabad 382 445Tel: +91-79-5831152 / 1449

Fax: +91-79-5832216Email:

[email protected]

HVAC

Mr. Sandeep SaxenaManager

Capital Enterprise

36 Industrial Estate

MLN Regional Engineering College

Allahabad 211002

Tel: 545362

Fax: 461775Email: [email protected]

incinerators

Mr S M Jain

Vice President

ADOR TECHNOLOGIES LTD

Plot No 53, 54 & 55F - II Block, MIDC Area, pimpri

Pune 411 018

Tel: +91-20-7470225, 7476009

Fax: +91-20-7470224 / 7358


Mr U V Rao

Director ALLIED CONSULTING ENGINEERS

PVT LTD

Allied House

Road No 1, chembur

Mumbai 400 071

Tel: +91-22-5284028

Fax: +91-22-5283805


Mr M K Sen

Managing Director

INCORPORATED ENGINEERS LTD

D - 400, Gayatri

MIDC, Uran PhataNerulNavi Mumbai 400 706

Tel: +91-22-7619352, 7619366

Fax: +91-22-7619368


Induction heaters

Inventum engineering companyP O box 9435

Andheri (E)

Mumbai 400093

Tel: 022-26730499/ 590

Fax: 022-26730887






Industrial Ceramics

Mr N Anjiah

Managing Partner

Annapurna Annapurna Technical ceramics21-118

Kakani Nagar Vaisag 534007

Tel: code-507659:


Industrial fans& blowersMr Arindom Mukherjee


ANDREW YULE & CO LTD

Yule House, 8, Dr Rajendra Prasad Sarani

Kolkata 700 001

Tel: +91-33-2422796 / 8210


Industrial furnaces

Mr U V Rao

Director

Allied Consulting Engineers Pvt Ltd

Allied HouseRoad No 1, chembur

Mumbai 400 071

Tel: +91-22-5284028

Fax: +91-22-5283805


Mr Anup Dasgupta

Director FIRE GASES & KILN (INDIA) PVT LTD

156, Jodhpur Park

Kolkata 700 068

Tel: +91-33-4730164 / 1289, 4728391 / 2

Fax: +91-33-4731540

Mr S L Mathur

Managing Director STEIN HEURTEY INDIA PROJECTS

PVT LTD

8/1, Middleton Row

Kolkata 700 071

Tel: +91-33-2260194, 2457484 / 89


Mr N M Sudharshan


ELECTROTECHNIK

“B” Wing, 9th Floor

Parsn Complex

Chennai 600 006Tel: +91-44-8259437

Fax: +91-44-8269617

Mr R K Agrawal


EASTERN EQUIPMENT & ENGINEERSS - 14, Civ il TownshipRourkela 769 004

Tel: +91-61-502508, 503898

Fax: +91-61-503898


Aero therm systems pvt ltd

Plot no 1517 Phase IIIGIDC Vatwa

Aheemedabad 382445Tel: 079-5890158

Fax: 079-5834987


Instrumentation control systemsMr P S Kumar

Managing Director

ABB INSTRUMENTATION LTD

14, Delhi Mathura Road

P O Amarnagar

Faridabad 121 003

Tel: +91-0129-5275592 / 3 / 7, 5276350 / 54 /62 / 67

Fax: +91-0129-5275019 / 466


Mr M L Anand

Chairman

ANAND CONTROL SYSTEMS PVT LTDD - 67/68, Sector VI

Noida 201 301

Tel: +91-118-4537395, 4554627

Fax: +91-118-4533782


Fisher Rosemount (India) Limited

D Wing, 2nd Floor Modern Mills Compound

Mahalaxmi

Mumbai 400 011

Tel: 91 22) 462 0462

Fax: (91 22) 462 0500

Libratherm Instruments

402, Diamond Industrial EstateKetki pada Road

Dahisar East

Mumbai 400068

Tel: 022-28960659

Fax: 022-28963823


Mr. Prem Dua

Director

Puneet Industrial Controls Pvt. Ltd.

45 Community Centre,

East of Kailash,

New Delhi 110065

Tel: 011-6423328, 6419479Fax: 011-6423328

Mr P S Sridharan

Managing Director

MEGATECH CONTROL PVT LTD

Alsha Complex51, 1st Main Road

Gandhi Nagar

Chennai 600 020

Tel: +91-44-4996733 / 5654

Fax: +91-44-4341668, 4996215


Mr A N Sen

Managing Director AN INSTRUMENTS PVT LTD

59 - B, Chowringhee Road

5th Floor

Kolkata 700 020

Tel: +91-33-2402222, 2472509Fax: +91-33-2806684


Insulation

Lloyds Insulation

386, Veer Savarkar Marg

Mumbai 400 025Tel: 022-4340876

Fax: 022-4376858

intermediate controller for compressed

air

Mr Kiran C pande

Manager-Compressed air managementsolutions

Godrej & boyce manufacturing company ltd

Pirojshanagar, Vikhroli

Mumbai-400079

Tel: 022-55962251-56Fax: 022-55961525


Inverter weldingTejas Enterprises

C/5/72

Sahyadri Nagar

Charakop, Kandivili West

Mumbai 200067

Tel: 022-28678692

Fax:Email: [email protected]

Jet Tower-Induced draught without fan

and Fills

Mr Bhagwan Harani

Technical Director Armec group Armec house

Tiny Industrial estate,Kondhwa (B)

Pune-411048

Tel: 020-6930218

Fax: 020-6930537


Kiln furniture systemsMr N G Manoharan

Managing Director

Abref Private ltd

NO 32, Meeran Sahib street

Anna SalaiChennai-600002




641

Tel: 044-28250074

Fax: 044-28233486


kilns

Mr M K SenManaging Director

INCORPORATED ENGINEERS LTDD - 400, Gayatri

MIDC, Uran Phata

Nerul

Navi Mumbai 400 706

Tel: +91-22-7619352, 7619366Fax: +91-22-7619368


Mr Mithu S Malaney


VULCAN ENGINEERS LTD

427, Unique Industrial EstateOff Veer Savarkar Marg

Prabhadevi

Mumbai 400 025

Tel: +91-22-4304529 / 3671

Fax: +91-22-4225814

Email:

[email protected]

Mr Anup Dasgupta

Director

FIRE GASES & KILN (INDIA) PVT LTD

156, Jodhpur ParkKolkata 700 068

Tel: +91-33-4730164 / 1289, 4728391 / 2

Fax: +91-33-4731540Email:

LED based medium intensity aviation

obstruction light

Binay opto electronics Private ltd

44,Armenian street

Calcutta 700001Tel: 033-2429082,2103807

Fax: 033-2421493


LED indicator modules

Binay opto electronics Private ltd44,Armenian streetCalcutta 700001

Tel: 033-2429082,2103807

Fax: 033-2421493


LIGHTING ENERGY SAVER / LIGHTING

TRANSFORMERMr S Raghavan

Manager - Sales & Marketign

Beblec (India) Pvt. Ltd.,

126, Sipcot Indl.Complex

Hosur 635 126

Tel: 91-4344-276358/278658/276958/276959

Fax: 91-4344-276358/59

Email:

Electronics India

No. 438, 4th Main Road

Nagendra BlockBSK First Stage

Bangalore 560 050Tel: 080 – 662 1836

Fax: 080 – 662 1831

Email:

Jindal Electric & Machinery CorpC-57, Focal Point,

Ludhiana 141010

Tel: 670250 / 670250 / 676968

Fax: 0161 – 670252

Email:

low energy consuming Portable

GeneratorsMr. Wasim Javed

Birla Yamaha Limited

A-7, Ring Road,

N. D. S. E. Part - 1,

New Delhi 110049

Tel: 011-4690352 to 54, 4691852Fax: 011-4626188

Email:

Low loss Power & Distribution

TransformersMr. Adrian J D’Souza

Director

Southern Power Equipment Company42, Yumkur Road,

Yeshwanthpur,

Bangalore 560022

Tel: 080-3372996, 3372741

Fax: 080-3372997

Email:

LT Power capacitorsMr. M.D. Killedar

Manager (Works)

Goa Capacitors Pvt. Ltd.


Corlim, Ilhas,

Panaji 403110Tel: 0832-286176/240Fax: 0832-286203

Email:

LUX METER AND HARMONIC

ANALYSER

Mr Dilip Dharmasthal

Managing Director Alacrity Electronics Limited


Valmiki Street

T Nagar

Chennai 600 017

Tel: 044 - 823 6620Fax: 044 - 825 9406

M F induction melting/holding furnace

Mr Mukesh B Bhandari


ELECTROTHERM (INDIA) LTD

Survey No 72Village - Palodia

Via Thaltej Ahmedabad 382 115

Tel: +91-2717-39953 to 57, 39613 to 15

Fax: +91-2717-39616, 91-79-6740923


Maximum Demand Controller

CMS ENERGY Management systems

W 324, Rabale MIDC

Mumbai 400701

Tel: 91-022-27696720,86

Fax: 91-022-27694585

Medium frequency induction meltingand heating systems

Mr D G Sastry

Managing Director

PILLAR INDUCTION INDIA PVT LTD

A/13, 2nd Avenue

Anna Nagar Chennai 600 102

Tel: +91-44-6261703 to 5

Fax: +91-44-6260189


Most energy efficient tube light systems-

T5 Lamps

Mr . Suresh DhingraExecutive Vice President

Asian Electronics

Surya plasa

First follr, K 185/1 Sarai Julena, new friends

colony

New Delhi-110025

Tel: 011-26317232,26929073,26929075


Motors

Mr Saroj Poddar

Chairman

ALSTOM LTD14th Floor, Pragati Devika Tower 6, Nehru Place

New Delhi 110 019

Tel: +91-11-6449906, 6449907, 6449902 / 3

Fax: +91-11-6449447

Email:

Mr S M TrehanManaging Director





CROMPTON GREAVES LTD


Mumbai 400 001

Tel: +91-22-2657937 (Direct)

Fax: +91-22-2653740 (Direct), 2028025,

2625814Email: [email protected]

Mr M V Srisha

General Manager - FA

Fanuc India Limited

NO. 41, Electronic City

KEONICSBangalore 561 229

Tel: 080-8520057 / -0109

Fax: 80-852-0051

Mr. R Vijayraghavan

Managing Director

INTEGRATED ELECTRIC CO (P) LTD.66 A, GROUND FLOOR,

ALSA REGENCY

165,ELDAMS ROAD, ALWARPET,

Chennai 600018

Tel: 080-8362465 / 2047 / 2785 / 2793 / 2465

Multi effect evaporator Praj Industries

Praj house

Bavdhan

Pune 411021

Tel: 020-2951511/2214Fax: 020-2951718/2951515


NEUTRAL COMPENSATORStatic Transformers (P) Ltd

G-4, A/D, Industrial Estate

Polo Ground

Indore 452 015

Tel: 0731 - 420 793, 420 859

Fax: 0731 - 431 968, 420793


Oil coolers

Mr Mohammed Meeran

Proprietor

AASIA RADIATORS

P S C Bose RoadJawahar Autonagar Vijayawada 520 007

Tel: +91-0866-543881

Fax: +91-0866-545860

OIL FIRED THERMOPAC/AQUATHERM

SYSTEM

Thermax LimitedThermal Engg. Division

Chinchwad

Pune 411 019

Tel: 020 - 775 941 to 49

Fax: 020 - 775 907

oil/gas burners,

Mr. Dinesh Harjai

Partner

Crupp Metals

Kh. No. 56/1, Mundka,Rohtak Road,

New Delhi 110041Tel: 011-5189024, 5474133

Fax: 011-5183085

Ovens

Mr N GopinathManaging Director

FLUIDTHERM TECHNOLOGY PVT LTD

SP - 132, III Main Road

Ambattur Industrial Estate

Chennai 600 058

Tel: +91-44-6357390, 6357391


Mr M Gopal

Managing Director

HIGHTEMP FURNACES LTD

I - C, Phase II, P B No 5809

Peenya Industrial AreaBangalore 560 058

Tel: +91-80-8395917 / 4076 / 1446

Fax: +91-80-8397798 / 2661


Mr Mithu S Malaney


VULCAN ENGINEERS LTD427, Unique Industrial Estate

Off Veer Savarkar Marg

Prabhadevi, Mumbai 400 025

Tel: +91-22-4304529 / 3671

Fax: +91-22-4225814

Email:

[email protected]

Plate & spiral heat exchangers,dryers &

evaporators

Mr Satish Tandon

Managing Director

ALFA LAVAL (INDIA) LTD

Mumbai Pune RoadDapodiPune 411 012

Tel: +91-0212-27127721

Fax: +91-02121-2797711


PLC

Mr Madhav P. KamatManaging Director

Electronic Automation Pvt. Ltd.

No. 20, K.H.B Industrial Area,

Yelanhanka

Banglore-560064

Tel: 080-8567561-562,8567161Fax: 080-8567129


Mr Balagopal Karat

Executive Director

SPA ENGINEERING COMPANY LTD

114, 3rd Floor, M G RoadBangalore 560 001

Tel: +91-80-5267981Fax: +91-80-5260818

Pneumatic Tools

Dr Jairam Varadaraj

Managing Director ELGI EQUIPMENT LTD

Elgi Industrial Complex, Trichy Road

Singanallur P O

Coimbatore 641 005

Tel: +91-422-574691 to 5

Fax: +91-422-573697


Portable Engines & Water Pumping Sets

Mr Sanjeev Govil

General Manager-marketing

Honda Siel Power products ltd

5th Floor, Kirthi Mahal Building

19, Rajendra PalaceNew Delhi-110008

Tel: 011-25739103-05

Fax: 011-2572218, 25753652


Portable Gensets,Mr Sanjeev Govil

General Manager-marketing

Honda Siel Power products ltd5th Floor, Kirthi Mahal Building

19, Rajendra Palace

New Delhi-110008

Tel: 011-25739103-05

Fax: 011-2572218, 25753652


Power & control cablesMr Y Kamesh

Managing Director

GEM CABLES & CONDUCTORS LTD

No 1, Badam Sohana Apartments

Raj Bhavan Road

SomajigudaHyderabad 500 082Tel: +91-40-3310486, 3395970

Fax: +91-40-3313486


Power & Distribution Transformers

Mr R R Dhoot

ChairmanIMP POWER LTD

Advent, 7th Floor

12 - A, General J Bhosale Marg

Nariman Point

Mumbai 400 021

Tel: +91-22-2021890 / 886 / 697Fax: +91-22-2026775




643


Mr. S. Dasgupta

Sr. Mktg. Manager

Marson’s Limited

18, Palace Court,

1, Kyd Streeet,Calcutta 700016

Tel: 033-297346, 2264482Fax: 033-2263236

power & energy monitor

Mrs Hema Hattangady

Managing Director Enercon Systems Pvt Ltd.

23, KHB Light Industries Area

P B No.6418, Yelahanka

BangaloreHL

Tel: 080 – 8460666 / 8460555

Fax: 080 – 8460667


Power and control cables

Mr Hiten A Khatau

Chairman & Mg director

CABLE CORPORATION OF INDIA LTD

Laxmi Building, 4th Floor

6, Shoorji Vallabhdas MargBallard Estate

Mumbai 400 001

Tel: +91-22-2666764

Fax: +91-22-2632694

Power capacitors

Mr. M.D. Killedar

Manager (Works)Goa Capacitors Pvt. Ltd.


Corlim, Ilhas,

Panaji 403110

Tel: 0832-286176/240

Fax: 0832-286203

Mr. Shantilal H. KaraniOwner

Malde Capacitors Manufacturing Company

401,Madhav Apt, Jawahar Rd,

Opp. Rly.St, Ghatkopar (E),

Mumbai 400077

Tel: 022-5168283/84Fax: 022-5160758

Power Consultants

Mr D B Arora

Managing Director

Acon Power consultants

45, Satyanand Vihar

Rampur Jabalpur-482008

Tel: 91-0761-2667261, 9826246688

Fax: 91-0761-2664207

Email: acon@sancharnetin

Power control equipments,

Mr A Sarkar

Vice President

SCHNEIDER ELECTRIC INDIA LTD

58, MIDC Area, Satpur Nashik 422 007

Tel: +91-253-350394 / 95 / 96Fax: +91-253-350771


Power factor compensation

Neptune India ltdNeptune house

C 270 SFS Sheikh sarai, Phase I

New Delhi 110017

Tel: 011-6013367-70

Fax: 011-6013371


Power Factor controller CMS ENERGY Management systems

W 324, Rabale MIDC

Mumbai 400701

Tel: 91-022-27696720,86

Fax: 91-022-27694585

Mr. R. K. Iyer

Vice President

Saha Sprague Limited

No.805, North Rear Wing, 8th Floor, Manipal

Centre, 47, Dickenson Road,Bangalore 560042

Tel: 080-5595463, 5595266

Fax: 080-5595463

Power plant & industrial cooling towers

Mr. N. Venkatanarayanan

Managing Director

Enviro Clean Systems Ltd.

Hema Nagar, P.O.Box No.10,

P.O. Uppal,

Hyderabad 500039Tel: 040-7170876/879/881

Fax: 040-7172717/4726

Power plant equipment

Mr Pradeep Mallick

Managing Director WARTSILA INDIA LTD76, Free Press House, Nariman Point

Mumbai 400 021

Tel: +91-22-2815601 / 5598, 28175995 / 5601

Fax: +91-22-2842083


Process control instrumentsMr Sudhir Jalan


BELLS CONTROLS LTD

Bells House, 21, Camac Street

Kolkata 700 016

Tel: +91-33-2475211 / 15Fax: +91-33-2471620


Mr Amod Gujral

Managing Director

Encardio-Rite Electronics Pvt Ltd

A - 7, Industrial Estate, Talkatora Road

Lucknow 226 011Tel: +91-522-416460, 418855


Mr P V Kannan

Managing Director

MICROMAX SYSTEMS LTD104, Salai Road

Sethu Rukmani Complex

Trichy 620 003

Tel: +91-431-760704

Fax: +91-431-762422


Mr K N Balaji


Eurotherm Del India Ltd

152, Developed Plots Estate

Perungudi

Chennai - 600 096

Tel: 044-4961129Fax: 044-4961831


Mr N C Agrawal

Managing Director MEDITRON

SIRTDO Industrial Estate

P O BIT, MesraRanchi 835 215

Tel: +91-651-275875 / 628

Fax: +91-651-275841


[email protected]

Program logic control (PLC)

Mr Laxman R KatratMg Director & CEO

KATLAX ENTERPRISES PVT LTD

507, Golden Triangle

Stadium Road

Ahmedabad 380 014

Tel: +91-79-6461991 / 646, 6854693,6851521Fax: +91-79-6464719 (W), 6853978

Programmable controllers

Mr Ranjan Kumar De

Country Manager



Ghaziabad 201 010

Tel: +91-120-471112 / 0103 / 0105 / 0164

Fax: +91-120-4770822


[email protected]





Pumps

Mr D K Hohenstein


KSB PUMPS LTD

Mumbai Pune RoadP O Pimpri

Pune 411 018Tel: +91-20-7472006, 7473684

Fax: +91-20-7476120


Mr K C DhingraManaging Director

WESTERN INDIA MACHINERY CO PVT

LTD

Park Plaza

North Block, 6E, 6th Floor

71, Park Street

Kolkata 700 016Tel: +91-33-2468913 / 9674

Fax: +91-33-2468914

radiant heater

Mr. Ashok Tanna

Managing Director

Vinosha Boilers Pvt. Ltd. And Taurus HeatSystems

Baarat House, Ist Floor,

104, Apollo Street, Fort,

Mumbai 400001

Tel: 022-2674590, 2676447Fax: 022-2611515

RADIANT TUBE RECUPERATIVEHEATERMr U V Rao

Director

ALLIED CONSULTING ENGINEERS

PVT LTD

Allied House

Road No 1, chembur

Mumbai 400 071Tel: +91-22-5284028

Fax: +91-22-5283805


Thermax Limited

Thermal Engg. DivisionChinchwadPune 411 019

Tel: 020 - 775 941 to 49

Fax: 020 - 775 907

Reactive compensator

Emco Electronics

106, Industrial areaSion (East)

Mumbai 400022

Tel: 022-24096731/782

Fax: 022-24096039

Reactive power compensation

equipment and systems

Mr. S. M. Subba Rao

Adviser

Meher Capacitors (P) Ltd.

52/1, Basappa Road,Shantinagar,

Bangalore 560027Tel: 080-2236879, 2241272

Fax: 080-2225325

Reactors

Mr Ranjit PuriChairman & Mg Director



A - 4, Sector 24

Noida 201 301

Tel: +91-118-4524071 / 72

Fax: +91-118-4528630, 4529215, 4542072Email: [email protected]

Reciprocating & centrifugal pumps

Mr Hemant Didwania

Director

INDIAN COMPRESSORS LTD

33, Okhla Industrial EstateNew Delhi 110 020

Tel: +91-11-6839440 / 9, 635030

Fax: +91-11-6840020

RecuperatorsMr R K Agrawal


EASTERN EQUIPMENT & ENGINEERSS - 14, Civ il Township

Rourkela 769 004

Tel: +91-61-502508, 503898

Fax: +91-61-503898


Refractoreis

Mr.R.RajagopalanDy.General Manager

Carborundum Universal Limited-Super

Refractories

Plot Nos.102&103,Sipcot Industrial Complex

Phase II

Ranipet-632403Tel: 04172-244197,244951,244582Fax: 04172-244982


Mr N anjiah

Managing Partner

Annapurna Annapurna Technical ceramics

21-118Kakani Nagar

Vaisag 534007


Mr I C Sinha

Managing Director

BURN STANDARD CO LTD

10 - C, Hungerford Street

Kolkata 700 017

Tel: +91-33-2471772 / 067 / 762Fax: +91-33-2471788


Mr Kantilal Gugalia

Chief Executive

KATNI TILE WORKS

P B No 62Katni 483 501

Tel: +91-7622-52682, 53212, 50894

Fax: +91-7622-52733

Mr M L Chand

Executive Director

OCL INDIA LTDRajgangpur,

Dist. Sundergarh 770 017

Tel: +91-6624-220121 (4 lines)

Fax: +91-6624-220933 / 133 / 733


Mr Arun BhalotiaManaging Director

TATANAGAR REFRACTORIES &

MINERALS CO LTD

Chamber Bhawan

Bistupur Jamshedpur 831 001

Tel: +91-657-427187, 435039, 428044

Fax: +91-657-428044

Mr K S Swaminathan

Mg Director & Vice Chairman

TATA REFRACTORIES LTD

P O Belapur

Jharsuguda 768 218

Tel: +91-6645-50260

Fax: +91-6645-50243

Daka Monolitics Pvt. Ltd.

32-B, Samachar Marg

Opp. Allahabad Bank

Mumbai 400 023

Tel: 044 - 265 4837

Refrigeration Dryers.

Mr. Rajnish Joshi

Exe. Vice President

Delair India Pvt. Ltd.

20, Rajpur Road,

New Delhi 110054

Tel: 011-2912800Fax: 011-2915127, 2521754





645

Rotary kilns

Mr Madhukar Sinha

Managing Director

Associated Plates & Vessels Pvt Ltd 1/A -

14, 15 & C - 17, Industrial Area

Bokaro Steel City, Bokaro 827 104Tel: +91-6542-51034, 51434

Fax: +91-6542-51334Email: [email protected],

[email protected]

Rotometers

AQUAMEAS (Danfoss)Commerce avenue, 3rd floor,

Mahaganesh SOC., Paud Road

Pune 411 038

Tel: +020 544 9767, 544 9757

Fax: +020 542 0401


EUREKA INDUSTRIAL EQUIPMENTS

PVT. LTD.

Royal Chambers, Paud Road,

Pune 411038

Tel: 91 20 5443079 / 4004535/ 4004554

Fax: 91 20 5441323

Fitzer Instruments (India) Pvt. Ltd.

Near Ambivli Station (W)

P.O. Mohone

Thane 421 102

Tel: 0251 – 2271321Fax: 0251 – 2271336


SCADA System for Energy managementMr. Shashank Kalkar

Director Marketing

RMS Automation Systems Pvt. Ltd.

W-218, M.I.D.C.,

Ambad,

Nasik 422010

Tel: 0253-383261, 384604Fax: 0253-383261, 384604

Screw compressors

Mr Jasmohan Singh

Managing Director

FRICK INDIA LTD21.5 KM, Main Mathura RoadFaridabad 121 003

Tel: +91-129-5275691 (4 lines), 5270546

Fax: +91-129-5275695


Sections & blocks for thermal insulation

Mr Shreyas C ShethManaging Director

AMOL DICALITE LTD

301, Akshay

53, Shrimali Society,’Navrangpura

Ahmedabad 380 009

Tel: +91-79-6443331, 6560458Fax: +91-79-6569103

Separator and other oil & gas

processing equipments

Mr A D Parekh

General Manager

HDO PROCESS EQUIPMENT AND

SYSTEMS LTD5/1/2, GIDC Industrial Estate

Vatva Ahmedabad 382 445

Tel: +91-79-5830591 to 94

Fax: +91-79-5833286


Servo voltage stabiliser

Green Dot electric corporation

G 9, Hem Kunt Tower

98, Nehru Place,

New delhi 100019

Tel: 011-26416395


Slip Power Recovery Systems

Mr A M Naik

Mg Director & CEO

LARSEN & TOUBRO LTD

L & T HouseBallard Estate

Mumbai 400 001

Tel: +91-22-2618181

Fax: +91-22-2620223, 2610396, 2622285


Mr J Schubert

Managing Director SIEMENS LTD

130, Padurang Budhkar Marg

Worli

Mumbai 400 018

Tel: +91-22-4931350 / 60

Fax: +91-22-4950552

Email:

Smart demand controller

Mrs Hema Hattangady

Managing Director

Enercon Systems Pvt Ltd.


P B No.6418, YelahankaBangaloreHLTel: 080 – 8460666 / 8460555

Fax: 080 – 8460667


Soft starter

Excellent Industrial Instruments

1/63, Type ESidco Nagar

Villivakkam

Chennai 600049

Tel: 044-6172977

Fax: 044-6172531

Mr. K. W. Kekane

Director Sales

Minilec Marketing Services Pvt. Ltd.

S.No. 1073/1-2-3, At. Post. Pirancoot,

Tal. Mulshi,

Pune 412111Tel: 02139-22162, 22354 to 57

Fax: 02139-22134, 22180

Mr Ranjan Kumar De

Country Manager



Ghaziabad 201 010

Tel: +91-120-471112 / 0103 / 0105 / 0164

Fax: +91-120-4770822


[email protected]

Crompton Greaves Limited

Electronics Technology Div.

71 / 72, MIDC, Satpur

Nashik 422 007

Tel: 0253 - 351 069

Fax: 0253 - 351 492

Email:

Mr. Sudhir Naik



B -117 & 118, GIDC,Electronics Zone, Sector-25

Gandhi Nagar 382044

Tel: 02712-21636, 22531Fax: 02712-24698

Project & Supply

A - 605, Sunswept

okhandawala Complex

Swami Samarth Nagar, 4, Bungalow,

Andheri (West)

Mumbai 400 050Tel: 022 - 626 6584

Vrushali Services

5, Swapna Nagar, Hanuman Nagar,Near

DNC High School

Nandivli Road, Dombivli (East)-Mumbai- 421 201Tel: 0251 – 472 426

Fax: 0251 – 431 151

Software for promoting energy

conservation

Mr. Rahul S. Walawalkar

Product Manager - Eco Lumen & Manager Tata Infotech Ltd.

Manish Commercial Centre,

216-A, Dr. Annie Besant Rd., Worli,

Mumbai 400025

Tel: 91 22 8291261

Fax: 91 22 8290214





Software to measure the efficiency of

motors

Mr Narayana Sharma

Director

V B India

# 1032, 14th main, 7th crossBTM lay out

1st stage, 1st crossBangalore 560029

Tel: +91 (80) 6781315

Fax: 91-080-6687798


Soot Blower with Industrial Boilers

Mr. R. Rajshekhar

Managing Director

R R Techno Mechanicals (P) Ltd.

94, Thiru Vi Ka Industrial Estate,

Guindy,

Chennai 600032Tel: 044-2346693

Fax: 044-4918183, 2333204

Email:

Sound proof gensets

Mr R N Khanna

Managing Director CONTROLS & SWITCHGEAR CO LTD

222, Okhla Industtrial Estate

New Delhi 110 020

Tel: +91-11-6918834 to 37, 6836170 / 020

Fax: +91-11-6848241 / 7342 / 8245Email: [email protected]

Speciality Refrigerants/PropellantsK.Ganesh

Marketing Manager(South Asia)Regional

Segment Manager

Dupont Flurochemicals E.I.DuPont India Ltd

Arihant Nitco Park,^th Floor

90,Dr.Radha Krishnan Road

Mylapore

chennai 600004Tel: 044-8472800,8473752(D)

Fax: 044-8473800


split air conditioner

Mr Brij Raj PunjChairmanLLOYD ELECTRIC & ENGINEERING

LTD

M - 13A, Punj House

Connaught Place

New Delhi 110 001

Tel: +91-11-3329091 to 98


star -delta-star converter

Mr M Vijayasarathy

Managing Director

VIJAY ENERGY PRODUCTS PVT LTD

S P - 75, Ambattur Industrial Estate

Chennai 600 058Tel: +91-44-6254326, 6256883


Ambetronics

4B Pushotam

GirgaonNear Dream Land Cinema

Mumbai 400004

Tel: 022-28371143

Excellent Industrial Instruments

1/63, Type E, Sidco Nagar

VillivakkamChennai 600049

Tel: 044-6172977

Fax: 044-6172531

Steam jet ejectors

Forbes Marshall

PB No 29, Mumbai-Pune roadKasarwadi

Pune 411034

Tel: 91-0212-21279445

Fax: 91-0212-797413

MAZDA CONTROLS LTD

MAZDA HOUSE

ANCHWATI 2ND LANE, AMBAWADI AHMEDABAD 380006

Tel: 79 6431151

Fax: 79 6565605

STEAM TRAP MONITOR

Spirax Marshall Limited

P B No.29, Mumbai-Pune Road

Kasarwadi,Pune 411 034Tel: 020 - 794 495

Fax: 020 - 797 593/ 413

Steel tubes for boilers

Tube Products of India

Post Box No. 4, AvadiChennai 600 054Tel: 91 44 6384040

Fax: 91 44 6384051


Superheater & Economiser

Mr Ranjit Puri

Chairman & Mg Director INDIAN SUGAR & GENERAL


A - 4, Sector 24

Noida 201 301

Tel: +91-118-4524071 / 72

Fax: +91-118-4528630, 4529215, 4542072Email: [email protected]

SYNTHETIC FLAT BELTS

Elgi Ultra Industries Ltd.

‘Elgi House’, Trichy Road

Ramanathapuram

Coimbatore 641 045

Tel: 0422 – 304141Fax: 0422 - 311 740

Habasit Iakoka Pvt. Ltd.

C - 207, Kailas Esplanade

Opp. Shreyas Cinema

L B S Marg, Ghatkopar

Mumbai 400 086Tel: 022 - 500 2464

Fax: 022 - 500 2466

NTB group

NTB House, A-302

Road No.32, Wagle Estate,

Thane 400 604Tel: (091)-22-5822118,5821582

Fax: 58100565823778

NTB International ltd

A 302, Road no 32

Wagle estate

Thane 400604Tel: 022-25821582, 25822118

Fax: 022-25810056


Systems engineering for captive power generation

Mr D R Dhingra

Managing Director CONTINENTAL GENERATORS PVT LTD

3869, Behind Primary School, G B Road

Delhi 110 006

Tel: +91-11-7535566 to 68, 525632, 522983,

528510

Fax: +91-11-7516598, 528510

TEMPERATURE INDICATORCONTROLLER (TIC)

Ensave Systems Private Limited

3, Anand Shopping Center

Second Floor, Bhattha, Paldi

Ahmedabad 380 007

Tel: . 079 – 662 1116Fax: 079 – 663 7907

Thermal power equipment including

steam turbines

Mr K G Ramachandran


BHARAT HEAVY ELECTRICALS LTD

BHEL HouseSiri Fort

New Delhi 110 049

Tel: +91-11-6001010

Fax: +91-11-6493021, 6492534




647

Thermic filud heaters

Aero therm systems pvt ltd

Plot no 1517 Phase III

GIDC Vatwa

Aheemedabad 382445

Tel: 079-5890158Fax: 079-5834987


Thyristorised Power factor Controller

Mr. Shashank Kalkar

Director Marketing

RMS Automation Systems Pvt. Ltd.W-218, M.I.D.C., Ambad,

Nasik 422010

Tel: 0253-383261, 384604

Fax: 0253-383261, 384604

Transformer

Mr Saroj Poddar Chairman

ALSTOM LTD


6, Nehru Place

New Delhi 110 019

Tel: +91-11-6449906, 6449907, 6449902

Fax: +91-11-6449447

Mr G V Rao

CMD

Rowsons Marketing Pvt Ltd

4, 7 th Street GopalapuramMadras 600 086

Tel: 044 - 28110196/28112958

Fax: 044 - 2815741/28114021Email: [email protected]

Mr N J Danani

Vice Chairman & Mg Director

BHARAT BIJLEE LTD

Central Marketing Office (Motor)

P O Box 100, Kalwe, Thane Belapur Road

Mumbai 400 601Tel: +91-215-7691656

Fax: +91-215-7691401 / 2

Mr Rahul N Amin


JYOTI LTDIndustrial Area, P O Chemical IndustriesVadodara 390 003

Tel: +91-265-380633, 380627

Fax: +91-265-380671, 381871


Mr Sylvester P Moorthy

General Manager MEASUREMENT SYSTEMS PVT LTD

66, 4th Main Road

Industrial Town

Rajajinagar

Bangalore 560 044

Tel: +91-80-3300347 / 494 / 522Fax: +91-80-3303141

TRANSVECTOR NOZZLES

General Imsubs Pvt. Ltd.

3711/A, GIDC

Phase IV, Vatva

Ahmedabad 382 445

Tel: 079 - 584 0845/ 2503Fax: 079 - 584 1846


S J United

300/ 1-B, 16th Cross

Upper Palace Orchards

Bangalore 560 080

Trivector monitor

Mrs Hema Hattangady

Managing Director



P B No.6418, YelahankaBangaloreHL

Tel: 080 – 8460666 / 8460555

Fax: 080 – 8460667


universal power & energy meter

Mrs Hema HattangadyManaging Director



P B No.6418, Yelahanka

BangaloreHLTel: 080 – 8460666 / 8460555

Fax: 080 – 8460667


Vaccum Pumps

Kakati Karshak Industries Pvt. Ltd

Nacharam Industrial Area

Hyderabad 500 076

Tel: 91-40-7153104/05

Fax: 91-040-7171980


Nash vaccum pumps

67 UPS, Kaggadaspura Extension

Guru Layout

Bangalore

Tel: (+91) 80 - 521 49 38Fax: (+91) 80 - 528 43 37Email: [email protected]

PPI PUMPS PVT LTD

4/2 PHASE 1 G I D C VATWA

AHMEDABAD 382445

Tel: 079-5832273/4 / 5835698

Fax: 079-5830578

Variable Drives,

Mr. Liakat Ali

Proprietor

Premier Electric Company

Plot No.7,

12/2 Mathura Road,Faridabad 121002

Tel: 0129-270858, 274311Fax: 0129-270858

Variable fluid couplings

Mr Praveen Sachdev

Mg Director & CEOGREAVES LTD


P O Box 91

Mumbai 400 001

Tel: +91-22-2671524 / 4913

Fax: +91-22-2677850, 2652853

Email:

Variable Frequency Drive

Mr Ramnath S Mani

Managing Director

CONTROL TECHNIQUES INDIA

LIMITED

117/B, Developed PlotIndustrial Estate

Perungudi

Chennai 600 096

Tel: 044-4961123 / 1130 / 1083

Mr. Balagopal

Managing Director

Dynaspede Integrated Systems (P) Limited136-A Sipcot Industrial Complex

Hosur 635126

Tel: 91-4344 - 276915, 276813

Fax: 91-4344 - 276841

Dr M T Sant

President

TB Wood’s (India) Pvt Ltd27A, II Cross, Electronics City

Hosur Road

Banglore 561229

Tel: 080 8520123

Fax: 080 8520124






Mr Ranjan Kumar De

Country Manager


C - 11, Industrial Area

Site IV,shahiabadGhaziabad 201 010

Tel: +91-120-471112 / 0103 / 0105 / 0164Fax: +91-120-4770822


[email protected]

Asea Brown Boveri ltd

Plot No 5 & 6, II Phase

Peenya Industrial AreaP B no 5806, Peenya

Bangalore 560058

Tel: 080-8370416 / 8394734 extn 2322 /

6691375

Fax: 080-8399178 / 8396537

Mr S M Trehan

Managing Director

CROMPTON GREAVES LTD


Mumbai 400 001Tel: +91-22-2657937 (Direct)

Fax: +91-22-2653740 (Direct), 2028025,

2625814Email: [email protected]

Mr. Sudhir Naik



B -117 & 118, GIDC,

Electronics Zone, Sector-25Gandhi Nagar 382044

Tel: 02712-21636, 22531

Fax: 02712-24698

Email:

[email protected]

Mr. K. W. KekaneDirector Sales

Minilec Marketing Services Pvt. Ltd.

S.No. 1073/1-2-3, At. Post. Pirancoot,

Tal. Mulshi,

Pune 412111

Tel: 02139-22162, 22354 to 57

Fax: 02139-22134, 22180

Mr Debashish Ghosh

Manager -commercial marketing products

Rockwell Automation

C II, Site IV,

Sahibabad Industrial AreaGhaziabad dist-201010

Tel: code-4895247-252

Fax: 4895225-227


Mr J Schubert

Managing Director SIEMENS LTD

130, Padurang Budhkar MargWorli

Mumbai 400 018

Tel: +91-22-4931350 / 60

Fax: +91-22-4950552

Email:

Waste Heat Recovery

Mr U V Rao

Director ALLIED CONSULTING ENGINEERS

PVT LTD

Allied House

Road No 1, chembur

Mumbai 400 071

Tel: +91-22-5284028


Mr Robert A Childs

Managing Director

DEUTSCHE BABCOCK POWERSYSTEMS LTD

18 / 2A, Sennerkuppam

By - Pass RoadPoonamallee

Chennai 600 056

Tel: +91-44-4985949 / 1250

Fax: +91-44-4992221


Kuppuraju K

President-TechnicalCetharVessels Pvt ltd

4,Dindigul road,

tiruchirappilly

Tel: 0431-482452/53

Fax: 0431-481079


Waste Heat Recovery Recuperators

Mr R P Sood

Managing Director


14/6, Mathura Road

Faridabad 121 003

Tel: +91-129-274408, 275307 / 607Fax: +91-129-276448:

Waste Heat Recovery system

Mr K C Rana

Managing Director

AVU ENGINEERING PVT LTD A - 15, APIE

Balanagar

Hyderabad 500 037

Tel: +91-40-3773235 / 2343

Fax: +91-40-3772343 / 3235


Cristopia Energy systems

303, Kothari Manor NO 10, Diamon colony

New Palasia

Indore 452001

Tel: 91-0731-2433644, 2536624

Fax: 91-0731-2533766Email:

Ensys Technologies (I) Pvt. Ltd.

B/69-A, Seventh Avenue

Ashok Nagar Chennai 600 083

Tel: 044 - 3711259/ 297

Fax: 044 – 4897752

Mr C E Fernandes

Chairman & Mg Director GEI HAMON INDUSTRIES LTD

26 - A, Industrial Area

Govindpura

Bhopal 462 023

Tel: +91-755-586692, 586922, 587147Fax: +91-755-587678, 586619


Mr B S Adishesh

Wholetime Director


Rajamangalam

Villivakkam

Chennai 600 049

Tel: +91-44-655725, 6257783Fax: +91-44-4451537, 4995762


Megatherm Engineers & Consultants Pvt.

Ltd.

10, Kodambakkam High RoadChennai 600 034Tel: 044 - 823 3528/ 3707

Fax: 044 - 825 8559

Mr. M. M. Narang

Proprietor

Membrane India

347, Udyog Vihar, Ph.-II,Gurgaon 122016

Tel: 0124-341159

Fax: 0124-342717




649

WHR boilers

Mr P V Raju

Managing Director

Thermal Systems (Hyd) Pvt. Ltd.Plot No.1, Apuroopa Township

IDA, JeedimetlaHyderabad 500 055

Tel: 040 - 309 8272/ 8273

Fax: 040 - 309 7433






1 Confederation of Indian Industry ALL TYPES

Energy Management Cell

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





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





DCM Shriram Consolidated Ltd.

5th flr. Kanchenjunga Bldg.,18 Barakhamba

RoadNew Delhi - 110 001

Telephone : (011) 331-6801

Fax : (011) 331-8072


Contact Person : Dr. G.C. Datta Roy, Chief

Executive Officer

INTESCO Asia Ltd.

Oakland,114 Ulsoor Road Cross

Bangalore - 560 042

Telephone : (080) 558-3726

Fax : (080) 559-6036Email : [email protected]

Contact Person : Mr. R. Vasu, President & CEO

Saha Sprague Limited

266,Dr. Annie Besant Road,1st flr.

Opp. Passport Office,Worli

Mumbai - 400 025

Telephone :(022) 421-0234

Fax : (022) 430-1969


Contact Person : Mr. Manoj Saha, Director

Saket Projects Ltd.

Saket House,Pancheel,Usmanpura

Ahmedabad - 380 013

Telephone : (079) 755-1817

Fax : (079) 755-0452


Contact Person : Mr. Kamal Khokhani, Director

See Tech solutions Pvt.Ltd.

H-001,Sanchayani Prestige,Swavalambi Nagar Nagpur - 440 022

Telephone : (071) 226-4433

Fax : (071) 226-5816Email : [email protected]

Contact Person : Mr. Millind Chittawar, Chief

Consultant

Thermax Energy Performance Services Limited

Sai Chambers,15,Mumbai Pune Road

WakadewadiPune - 411 003Telephone : (020) 551-1010

Fax : (020) 551-1144

Contact Person : Mr. Shishir Joshipura, Chief

Executive Officer

Sudnya Industrial Services Pvt. Ltd.

5 Raj Apartments,28 Pushpak Park,Aundh

Pune - 411 007Telephone : (020) 5888-5601

Fax : (020) 5898-6290


Contact Person : Mr. Shishir Athale, Director

Shri Shakti Alternative Energy Limited

Venus Plaza Begumpet

Hyderabad - 500 016

Telephone : (040) 790-7979

Fax : (040) 790-8989Contact Person : Mr. D.V. Satya Kumar, Managing

Director

Basera Environmental & Energy Management

Group

Kewra Dam Road

Bhopal

Telephone : (075) 523-4731Fax : (075) 586-8382


Contact Person : Mr. Rahul Saxena, CEO

Agni Energy Services Pvt. Ltd.

1-A/1 kautilya 6-3-652 Somajiguda

Hyderabad - 500 082

Telephone : (040) 606-2172

Fax : (040) 339-4529


Contact Person : Mr. G.S. Varma, President

Asian Electronics LimitedD-11 Road No.28 Wagle Industrial Area

Thane - 400 064

Telephone : (022) 583-5504

Fax : (022) 582-7636


Contact Person : Mr. Suresh Shah, Chairman &

Managing Director

List of Indian Energy Service Companies (ESCOs)

List of Energy Service Companies




655

Financial Mechanism




656Financial Mechanism

ENERGY CONSERVATION AND 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: [email protected]




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





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, theproject 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 ‘EnergyEfficiency’ 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, moresuch 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: [email protected]; [email protected]





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:[email protected]; [email protected]




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.





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.







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

Efficiency & Energy

Conservation projects

Cost of carrying out

Energy Audit and for

Preparation of Bankable

Detailed Project Report

for availing Term Loan

Rs.10.00 Lakhs per

project or 2% of the loan

directly availed from

IREDA, whichever is less

Fund Utilisation

certificate in the format

prescribed by IREDA

shall be required to be

submitted


Energy Audit and for

Preparation of Bankable

Detailed Project Report

for availing Term Loan

Rs.10.00 Lakhs per


directly availed from

IREDA, whichever is less

--do--Utility DSM Projects

For Setting up a DSM

Cell in the utility

Rs.10.00 Lakhs (provided

loan of minimum 100

Lakhs is availed.

--do--


Energy Audit by ESCO

and Preparation of

Bankable Detailed

Project Report

Rs.10.00 Lakhs per


availed from IREDA,

whichever is less

--do--

Cost of preparation of

Performance Contract

for the Project

Rs.4.00 Lakhs per project

or 1% of the loan availed

from IREDA, whichever is

less

--do--

Cost of Collaboration/Experience Sharing/

Technology Transfer

Rs.4.00 Lakhs per projector 1% of the loan availed


less

--do--

ESCO Promoted

Projects (with

performance

guarantee/ shared

saving)

Cost of Promotional/

Outreach Efforts by the

ESCO

Rs.2.00 Lakhs per project

or ½% of the loan availed


less

--do--

curity for IREDA’s Loan:

OPTION PROJECT FINANCING EQUIPMENT FINANCING

SET 1 Bank Guarantee/Pledge of FDRfrom Scheduled CommercialBank

Bank Guarantee/Pledge of FDR fromScheduled Commercial Bank

SET 2 State Government Guarantee State Government GuaranteeSET 3 Unconditional and irrevocable

guarantee of All India PublicFinancial Institution with “AAA”or equivalent rating.

Unconditional and irrevocable guaranteeof All India Public Financial Institutionwith “AAA” or equivalent rating.

SET 4 § Equitable Mortgage(Mortgage by deposit of titledeeds) of all immovable

properties§ Hypothecation of movable

§ Demand Promissory Note for theamount of loan

§ Exclusive charge by way of

hypothecation of all movable assetsacquired/ to be acquired out of





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 locatedeither 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.

assets, both existing andfuture, subject to prior charge of Banks on specifiedcurrent assets

§ Guarantees by promoters/promoter directors andpromoter companies

§ Deposit of post datedcheques in accordance withrepayment schedule of principal loan amount andinterest.

IREDA’s loan and Borrowers’ ownfunds under the project, both existingand future

§ Guarantees by promoters/ promoter directors and promoter companies

§ Deposit of post dated cheques inaccordance with repayment scheduleof principal loan amount and interest.



MINISTRY OF LAW, JUSTICE AND COMPANY AFFAIRS(Legislative Department)

New Delhi, the 1 st October, 2001/ Asvina 9, 1923 (Saka)

The following Act of Parliament received the assent of the President on the29th September, 2001, and is hereby published for general information:--

THE ENERGY CONSERVATION ACT, 2001

No 52 OF 2001[29

thSeptember 2001]

An Act to provide for efficient use of energy and its conservation and for matters connected therewith or incidental thereto.

BE it enacted by Parliament in the Fifty second Year of the Republic of India as

follows:—

CHAPTER I

PRELIMINARY

1. (1) This Act may be called the Energy Conservation Act, 2001.

(2) It extends to the whole of India except the state of Jammu and Kashmir

(3) It shall come into force on such dates as the Central Government may, by notification

in the Official Gazette, appoint; and different dates may be appointed for different

provisions of this Act and any reference in any such provision to the commencementof this Act shall be construed as a reference to the coming into force of that provision.

Short title, extentand commencement

667667



Definitions 2. In this Act, unless the context otherwise requires: —

(a) “accredited energy auditor” means an auditor possessing qualifications specified under

clause (p) of sub-section (2) of section 13;

(b) “ Appellate Tribunal” means Appellate Tribunal for Energy Conservation establishedunder 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 aconnected 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 energyincluding submission of technical report containing recommendations for improving

energy efficiency with cost benefit analysis and an action plan to reduce energyconsumption;

(j) “energy conservation building codes” means the norms and standards of energy

consumption expressed in terms of per square meter of the area wherein energy is

used and includes the location of the building;

(k) “energy consumption standards” means the norms for process and energy consumption

standards specified under clause (a) of section 14;

(l) “Energy Management Centre” means the Energy Management Centre set up under the

Resolution of the Government of India in the erstwhile Ministry of Energy,

Department of Power No. 7(2)/87-EP (Vol. IV), dated the 5th July, 1989 and registered

under the Societies Registration Act, 1860; 21 of 1860

(m) “energy manager” means any individual possessing the qualifications prescribed under

clause (m) of section 14;

(n) “ Governing Council” means the Governing Council referred to in section 4;

(o) “member” means the member of the Governing Council and includes the Chairperson;

(p) “notification” means a notification in the Gazette of India or, as the case may be, the

Official Gazette of a State;

(q) “prescribed” means prescribed by rules made under this Act;

(r) “regulations” means regulations made by the Bureau under this Act;

(s) “schedule” means the Schedule of this Act;

(t) “State Commission” means the State Electricity Regulatory Commission established

under sub-section (l) of section 17 of the Electricity Regulatory Commissions Act,1998;

14 of 1998

668



9 of 194054 of 1948

14 of 1998

(u) words and expression used and not defined in this Act but defined in the IndianElectricity Act, 1910 or the Electricity (Supply) Act, 1948 or the Electricity

Regulatory Commissions Act, 1998 shall have meanings respectively assigned to them

in those Acts.

CHAPTER II

BUREAU OF ENERGY EFFICIENCY

3. (1) With effect from such date as the Central Government may, by notification,appoint, there shall be established, for the purposes of this Act, a Bureau to be

called the Bureau of Energy Efficiency

Establishment and

incorporation of Bureau of Energy

Efficiency

(2) The Bureau shall be a body corporate by the name aforesaid having perpetual

succession and a common seal, with power subject to the provisions of this Act, to

acquire, hold and dispose of property, both movable and immovable, and to contract,

and shall, by the said name, sue or be sued.

(3) The head office of the Bureau shall be at Delhi.

(4) The Bureau may establish offices at other places in India.

4. (1) The general superintendence, direction and management of the affairs of the Bureau

shall vest in the Governing Council which shall consists of not less than twenty, but

not exceeding twenty-six members to be appointed by the Central Government.

Management of Bureau

(2) The Governing Council shall consist of the following members, namely:-

(a) the Minister in charge of the Ministry or Department

of the Central Government dealing with the Power

ex offi cio

Chairperson;

(b) the Secretary to the Government of India, in charge of the Ministry or Department of the Central

Government dealing with the Power

ex offi cio member;

(c) the Secretary to the Government of India, in charge of

the Ministry or Department of the Central

Government dealing with the Petroleum and Natural

Gas

ex offi cio member;

(d) the Secretary to the Government of India, in charge of


Government dealing with the Coal

ex offi cio member;

(e) the Secretary to the Government of India, in charge of


Government dealing with the Non-conventional

Energy Sources

ex offi cio member;

(f) the Secretary to the Government of India, in charge of


Government dealing with the Atomic Energy

ex offi cio member;

(g) the Secretary to the Government of India, in charge of


Government dealing with the Consumer Affairs

ex offi cio member;

54 of 1948

(h) Chairman of the Central Electricity Authority

established under the Electricity (Supply) Act, 1948

ex offi cio member;

Karnataka Act

17 of 1960

(i) Director-General of the Central Power Research

Institute registered under the Karnataka SocietiesAct, 1960

ex offi cio member;

XXI of 1860

(j) Executive Director of the Petroleum Conservation

Research Association, a society registered under the

Societies Registration Act, 1860

ex offi cio member;

1 of 1956

(k) Chairman-cum-Managing Director of the Central

Mine Planning and Design Institute Limited, a

company incorporated under the Companies Act,

1956

ex offi cio member;

669



(l) Director-General of the Bureau of Indian Standards

established under the Bureau of Indian Standards

Act, 1986

ex offi cio member;

63 of 1986

(m) Director-General of the National Test House,

Department of Supply, Ministry of Commerce and

Industry, Kolkata

ex offi cio member;

(n) Managing Director of the Indian Renewable Energy

Development Agency Limited, a company

incorporated under the Companies act, 1956

ex offi cio member;

1 of 1956

(o) one member each from five power regionsrepresenting the States of the region to be appointed

by the Central Government

members;

(p) such number of persons, not exceeding four as may be

prescribed, to be appointed by the Central

Government as members from amongst persons who

are in the opinion of the Central Government capable

of representing industry, equipment and appliance

manufacturers, architects and consumers

members;

(q) such number of persons, not exceeding two as may be

nominated by the Governing Council as members

members;

(r) Director-General of Bureau ex offi cio 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 maybe prescribed.

Meetings of Governing

Council

5. (1) The Governing Council shall meet at such times and places, and shall observe such

rules of procedure in regard to the transaction of business as its meetings (including

quorum of such meetings) as may be provided by regulations.

Meetings of GoverningCouncil

(2) The Chairperson or, if for any reason, he is unable to attend a meeting of theGoverning Council, any other member chosen by the members present from amongst

themselves at the meeting shall preside at the meeting.

(3) All questions which come up before any meeting of the Governing Council shall be

decided by a majority vote of the members present and voting, and in the event of an

equality of votes, the Chairperson or his absence, the person presiding, shall have

second or casting vote.

6. No act or proceeding of the Bureau or the Governing Council or any Committee shall beinvalid merely by reason of -

Vacancies etc.,

not to invalidate proceedings of Bureau,

GoverningCouncil or Committee

(a) any vacancy in, or any defect in the constitution of, the Bureau or the Governing

Council or the Committee; or

(b) any defect in the appointment of a person acting as a Director -General or Secretary of the Bureau or a member of the Governing Council or the Committee; or

(c) any irregularity in the procedure of the Bureau or the Governing Council or the

Committee not affecting the merits of the case.

Removal of member from

office

7. The Central Government shall remove a member referred to in clause (o), (p) and (q) of sub-section (2) of section 4 from office if he —

(a) is, or at any time has been, adjudicated as insolvent;

670



(b) is of unsound mind and stands so declared by a competent court;

(c) has been convicted of an offence which, in the opinion of the Central

Government, involves a moral turpitude;

(d) has, in the opinion of the Central Government, so abused his position as to

render his continuation in office detrimental to the public interest:

Provided that no member shall be removed under this clause unless he

has been given a reasonable opportunity of being heard in the matter.

8. (1) Subject to any regulations made in this behalf, the Bureau shall, within six months

from the date of commencement of this Act, constitute Advisory Committees for the

efficient discharge of its functions.

Constitution of

AdvisoryCommittees andother committees

(2) Each Advisory Committee shall consist of a Chairperson and such other members as

may be determined by regulations.

(3) Without prejudice to the powers contained in sub-section (1), the Bureau may

constitute, such number of technical committees of experts for the formulation of

energy consumption standards or norms in respect of equipment or processes, as it

considers necessary.

9. (1) The Central Government shall, by notification, appoint a Director -General from

amongst persons of ability and standing, having adequate knowledge and experiencein dealing with the matters relating to energy production, supply and energy

management standarisation and efficient use of energy and its conservation

Director-General of

Bureau

(2) The Central Government shall, by notification appoint any person not below the rank

of Deputy Secretary to the Government of India as Secretary of the Bureau

(3) The Director-General shall hold office for a term of three years from the date on

which he enters upon his office or until he attains the age of sixty years, whichever is

earlier

(4) The salary and allowances payable to the Director-General and other terms and

conditions of his service and other terms and conditions of service of the Secretary of

the Bureau shall be such as may be prescribed(5) Subject to general superintendence, direction and management of the affairs by the

Governing Council, the Director-General of the Bureau shall be the Chief ExecutiveAuthority of the Bureau

(6) The Director-General of the Bureau shall exercise and discharge such powers and

duties of the Bureau as may be determined by regulations

10. (1) The Central Government may appoint such other officers and employees in the

Bureau as it considers necessary for the efficient discharge of its functions under thisAct.

Officers andemployees of

Bureau

(2) The terms and conditions of service of officers and other employees of the Bureau

appointed under sub-section (1) shall be such as may be prescribed.

11. All orders and decisions of the Bureau shall be authenticated by the signature of the

Director-General or any other officer of the Bureau authorised by the Director-General in

this behalf.

Authentication of orders and decisions

of Bureau

CHAPTER III

TRANSFER OF ASSETS, LIABILITIES ETC, OF ENERGY MANAGEMENT CENTRE TO BUREAU

12. (1) On and from the date of establishment of the Bureau -

(a) any reference to the Energy Management Centre in any law other than this Act or

in any contract or other instrument shall be deemed as a reference to the Bureau;

(b) all properties and assets, movable and immovable of, or belonging to, the Energy

Management Centre shall vest in the Bureau;

Transfer of assets,liabilities andemployees of

Energy

Management Centre

(c) all the rights and liabilities of the Energy Management Centre shall be transferred

to, and be the right and liabilities of, the Bureau;

671



(d) without prejudice to the provisions of clause (c), all debts, obligations and

liabilities incurred, all contracts entered into and all matters and things engagedto be done by, with or for the Energy Management Centre immediately before

that date for or in connection with the purposes of the said Centre shall be

deemed to have been incurred, entered into, or engaged to be done by, with or

for, the Bureau;

(e) all sums of money due to the Energy Management Centre immediately before

that date shall be deemed to be due to the Bureau;

(f) all suits and other legal proceedings instituted or which could have been

instituted by or against the Energy Management Centre immediately before thatdate 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 monthsfrom the date if such employee opts not to be the employee of the Bureau withinsuch period.

(2) Not withstanding anything contained in the Industrial Disputes Act, 1947 or inany other law for the time being in force, the absorption of any employees by the Bureau

in its regular service under this section s hall not entitle such employees to any

compensation under that Act or other law and no such claim shall be entertained by any

court, tribunal or other authority.

14 of 1947

CHAPTER IV

POWERS AND FUNCTIONS OF BUREAU

Powers andfunctions of

Bureau

13. (1) The Bureau shall, effectively co-ordinate with designated consumers, designatedagencies 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 beassigned 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 energyconsumption 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;

672



(m) give financial assistance to institutions for promoting efficient use of energy and

its conservation;

(n) levy fee, as may be determined by regulations, for services provided for

promoting efficient use of energy and its conservation;

(o) maintain a list of accredited energy auditors as may be specified by regulations;

(p) specify, by regulations, qualifications for the accredited energy auditors;

(q) specify, by regulations, the manner and intervals of time in which the energy

audit shall be conducted ;

(r) specify, by regulations, certification procedures for energy managers to bedesignated 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 andcoordinate with them for inclusion of such curriculum in their syllabus;

(t) implement international co-operation programmes relating to efficient use of energy and its conservation as may be assigned to it by the Central Government;

(u) perform such other functions as may be prescribed.

CHAPTER V

POWER OF CENTRAL GOVERNMENT TO FACILITATE AND ENFORCE EFFICIENT

USE OF ENERGY AND ITS CONSERVATION

14. The Central Government may, by notification, in consultation with the Bureau, —

(a) specify the norms for processes and energy consumption standards for any equipment,

appliances which consumes, generates, transmits or supplies energy;

(b) specify equipment or appliance or class of equipments or appliances, as the case may be, for the purposes of this Act;

(c) prohibit manufacture or sale or purchase or import of equipment or appliance specified

under clause (b) unless such equipment or appliances conforms to energy consumption

standards;

Power of Central

Government toenforce efficient

use of energy andits conservation

Provided that no notification prohibiting manufacture or sale or purchase or

import or equipment or appliance shall be issued within two years from the date of

notification issued under clause (a) of this section;(d) direct display of such particulars on label on equipment or on appliance specified under

clause (b) and in such manner as may be specified by regulations;

(e) specify, having regarding to the intensity or quantity of energy consumed and the

amount of investment required for switching over to energy efficient equipments and

capacity or industry to invest in it and availability of the energy efficient machinery and

equipment required by the industry, any user or class of users of energy as a designatedconsumer 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 designatedconsumers 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;

673



(i) direct, if considered necessary for efficient use of energy and its conservation, anydesignated 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 energyauditor;

(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 economicviability 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 itsconservation in the building or building complex;

(q) amend the energy conservation building codes to suit the regional and local climaticconditions;

(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 intervalsof 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 efficientuse of energy and its conservation;

(v) take steps to encourage preferential treatment for use of energy efficient equipment or

appliances:

Provided that the powers under clauses (p) and (s) shall be exercised in

consultation with the concerned State.

CHAPTER VI

POWER OF STATE GOVERNMENT TO FACILITATE AND ENFORCE EFFICIENT USE

OF ENERGY AND ITS CONSERVATION

15. The State Government may, by notification, in consultation with the Bureau -Power of State

Government toenforce certain

provisions for

efficient use of energy and its

conservation

(a) amend the energy conservation building codes to suit the regional and local climatic

conditions and may, by rules made by it, specify and notify energy conservation

building codes with respect to use of energy in the buildings;

674



(b) direct every owner or occupier of a building or building complex being a designatedconsumer to comply with the provisions of the energy conservation building codes;

(c) direct, if considered necessary for efficient use of energy and its conservation, anydesignated 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

Conservation Fund for the purposes of promotion of efficient use of energy and its

conservation within the State.

(2) To the Fund shall be credited all grants and loans that may be made by the StateGovernment or, Central Government or any other organization or individual for the

purposes of this Act.

Establishment of Fund by State

Government

(3) The Fund shall be applied for meeting the expenses incurred for implementing the

provisions of this Act.

(4) The Fund created under sub-section (l) shall be administered by such persons or any

authority and in such manner as may be specified in the rules made by the State

Government.

17. (1) The designated agency may appoint, after the expiry of five years from the date of

commencement of this Act, as many inspecting officers as may be necessary for the

purpose of ensuring compliance with energy consumption standard specified under

clause (a) of section 14 or ensure display of particulars on label on equipment or appliances specified under clause (b) of section 14 or for the purpose of performing

such other functions as may be assigned to them.

Power of

inspection

(2) Subject to any rules made under this Act, an inspecting officer shall have power to -

(a) inspect any operation carried on or in connection with the equipment or appliancespecified 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 activityand 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;

675



(ii) to make an inventory of stock of any equipment or appliance checked or

verified by him;

(iii) to record the statement of any person which may be useful for, or relevant to,

for efficient use of energy and its conservation under this Act.

(3) An inspecting officer may enter any place of designated consumer -

(a) where any activity with the help of energy is carried on; and

(b) where any equipment or appliance notified under clause (b) of section 14 has been

kept,

during the hours at which such places is open for production or conduct of businessconnected therewith.

(4) An inspecting officer acting under this section shall, on no account, remove or cause to

be removed from the place wherein he has entered, any equipment or appliance or books of accounts or other documents.

18. The Central Government or the State Government may, in the exercise of its powers and performance of its functions under this Act and for efficient use of energy and its

conservation, issue such directions in writing as it deems fit for the purposes of thi s Act to

any person, officer, authority or any designated consumer and such person, officer or

authority or any designated consumer shall be bound to comply with such directions.

Explanation – For the avoidance of doubts, it is hereby declared that the power to issue

directions under this section includes the power to direct –

Power of CentralGovernmentor State

Governmentto issuedirections

(a) regulation of norms for process and energy consumption standards in any

industry or building or building complex; or

(b) regulation of the energy consumption standards for equipment and appliances.

CHAPTER VII

FINANCE, ACCOUNT S AND AUDIT OF BUREAU

Grants and loans by Central

Government

19. The Central Government may, after due appropriation made by Parliament by law in this

behalf, make to the Bureau or to the State Government grants and loans of such sums or

money as the Central Government may consider necessary.

20. (1) There shall be constituted a Fund to be called as the Central Energy Conservation Fund

and there shall be credited thereto -

Establishment of

Fund by CentralGovernment

(a) any grants and loans made to the Bureau by the Central Government under section

19;

(b) all fees received by the Bureau under this Act;

(c) all sums received by the Bureau from such other sources as may be decided upon

by the Central Government.

(2) The Fund shall be applied for meeting -

(a) the salary, allowances and other remuneration of Director-General, Secretary

officers and other employees of the Bureau,

(b) expenses of the Bureau in the discharge of its functions under section 13;

(c) fee and allowances to be paid to the members of the Governing Council under sub-

section (5) or section 4;

(d) expenses on objects and for purposes authorised by this Act

Borrowing

powers of Bureau

21. (1) The Bureau may, with the consent of the Central Government or in accordance with the

terms of any general or special authority given to it by the Central Government borrow

money from any source as it may deem fit for discharging all or any of its functionsunder 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).

676



22. The Bureau shall prepare, in such form and at such time in each financial year as may be

prescribed, its budget for the next financial year, showing the estimated receipts andexpenditure of the Bureau and forward the same to the Central Government.

Budget

23. The Bureau shall prepare, in such form and at such time in each financial year as may be

prescribed, its annual report, giving full account of its activities during the previous financial

year, and submit a copy thereof to the Central Government.

Annual report

24. The Central Government shall cause the annual report referred to in section 23 to be laid, as

soon as may be after it is received, before each House of Parliament.

Annual report tobe

laid beforeParliament

25. (1) The Bureau shall maintain proper accounts and other relevant records and prepare an

annual statement of accounts in such form as may be prescribed by the Central

Government in consultation with the Comptroller and Auditor -General of India.

Accounts and

Audit

(2) The accounts of the Bureau shall be audited by the Comptroller and Auditor-General of

India at such intervals as may be specified by him and any expenditure incurred in

connection with such audit shall be payable by the Bureau to the Comptroller andAuditor-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 rightsand privileges and authority in connection with such audit as the Comptroller and

Auditor-General generally has in connection with the audit of the Government accounts

and in particular, shall have the right to demand the production of books, accounts,

connected vouchers and other documents and papers and to inspect any of the offices of

the Bureau.

(4) The accounts of the Bureau as certified by the Comptroller and Auditor-General of

India or any other person appointed by him in this behalf together with the audit report

thereon shall forward annually to the Central Government and that Government shall

cause the same to be laid before each House of Parliament.

CHAPTER VIII

PENALTIES AND ADJUDICATION

26. (1) If any person fails to comply with the provision of clause (c) or the clause (d) or clause

(h) or clause (i) or clause (k) or clause (l) or clause (n) or clause (r) or clause (s) of section 14 or clause (b) or clause (c) or clause (h) of section 15, he shall be liable to a

penalty which shall not exceed ten thousand rupees for each such failures and, in the

case of continuing failures, with an additional penalty which may extend t o one

thousand rupees for every day during which such failures continues:

Penalty

Provided that no person shall be liable to pay penalty within five years from the

date of commencement of this Act.

(2) Any amount payable under this section, if not paid, may be recovered as if it were an

arrear of land revenue.

27. (1) For the purpose of adjudging section 26, the State Commission shall appoint any of its

members to be an adjudicating officer for holding an inquiry in such manner as may be

prescribed by the Central Government, after giving any person concerned a reasonableopportunity 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 adjudicatingofficer, 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 hethinks fit in accordance with the provi sions of any of those clauses of that section:

Power to

adjudicate

677



Provided that where a State Commission has not been established in a State, theGovernment of that State shall appoint any of its officer not below the rank equivalent

to a Secretary dealing with legal affairs in that State to be an adjudicating officer for the purposes of this section and such officer shall cease to be an adjudicating officer

immediately on the appointment of an adjudicating officer by the State Commission on

its establishment in that State:

Provided further that where an adjudicating officer appointed by a State Government

ceased to be an adjudicating officer, he shall transfer to the adjudicating officer

appointed by the State Commission all matters being adjudicated by him and thereafter the adjudicating officer appointed by the State Commission shall adjudicate the

penalties on such matters.

28. While adjudicating the quantum of penalty under section 26, the adjudicating officer shallhave due regard to the following factors, namely:-

Factors to be

taken intoaccount by

adjudicatingofficer

(a) the amount of disproportionate gain or unfair advantage, wherever quantifiable, made as

a result of the default;

(b) the repetitive nature of the default.

Civil court not

to have

jurisdiction

29. No civil court shall have jurisdiction to entertain any suit or proceeding in respect of any

matter which an adjudicating officer appointed under this Act or the Appellate Tribunal is

empowered by or under this Act to determine and no injunction shall be granted by anycourt or other authority in respect of any action taken or to be taken in pursuance of any

power conferred by or under this Act.

CHAPTER IX

APPELLATE TRIBUNAL FOR ENERGY CONSERVATION

Establishment

of Appellate

Tribunal

30. The Central Government shall, by notification, establish an Appellate Tribunal to be known

as the Appellate Tribunal for Energy Conservation to hear appeals against the orders of theadjudicating officer or the Central Government or the State Government or any other

authority under this Act.

Appeal toAppellate

Tribunal

31. (1) Any person aggrieved, by an order made by an adjudicating officer or the Central

Government or the State Government or any other authority under this Act, may prefer

an appeal to the Appellate Tribunal for Energy Conservation:

Provided that any person appealing against the order of the adjudicating officer

levying any penalty, shall while filing the appeal, deposit the amount of such penalty:

Provided further that where in any particular case, the Appellate Tribunal is of the

opinion that the deposit of such penalty would cause undue hardship to such person, theAppellate 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 CentralGovernment 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 notfiling 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 thereon 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.

678



(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 theappeal 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 onehundred and eighty days, the Appellate Tribunal shall record its reasons in writing for

not disposing of the appeal within the said period.

(6) The Appellate Tribunal may, for the purpose of examining the legality, propriety or

correctness of any order made by the adjudicating officer or the Central Government or

the State Government or any other authority under this Act, as the case may be in

relation to any proceeding, on its own motion or otherwise, call for the records of such proceedings and make such order in the case as it thinks fit.

32. (1) The Appellate Tribunal shall consist of a Chairperson and such number of Members not

exceeding four, as the Central Government may deem fit.

(2) Subject to the provisions of this Act, -

Composition of Appellate Tribunal

(a) the jurisdiction of the Appellate Tribunal maybe exercised by Benches thereof;

(b) a Bench may be constituted by the Chairperson of the Appellate Tribunal with twoor more Members of the Appellate Tribunal as the Chairperson of the Appellate

Tribunal may deem fit:

Provided that every Bench constituted under this clause shall include at least

one Judicial Member and one Technical Member;(c) The Benches of the Appellate Tribunal shall ordinarily sit a t Delhi and such other

places as the Central Government may, in consultation with the Chairperson of the

Appellate Tribunal, notify;

(d) The Central Government shall notify the areas in relation to which each Bench of the Appellate Tribunal may exercise jurisdiction,

(3) Notwithstanding anything contained in sub-section (2), the Chairperson of the Appellate

Tribunal may transfer a Member of the Appellate Tribunal from one Bench to another

Bench

Explanation – For the purposes of this Chapter, –

(i) “Judicial Member” means a Member of the Appellate Tribunal appointed as such

under item (i) or item (ii) or clause (b) of sub-section (1) of section 33, and includes

the Chairperson of the Appellate Tribunal;

(ii) “Technical Member” means a Member of the Appellate Tribunal appointed as such

under item (iii) or item (iv) or item (v) or item (vi) of clause (b) of sub-section (l) of

section 33

33. (1) A person shall not be qualified for appointment as the Chairperson of the Appellate

Tribunal or a Member of the Appellate Tribunal unless he -

(a) in the case of Chairperson of the Appellate Tribunal, is or has been, a judge of

the Supreme Court or the Chief Justice of a High Court; and

(b) in the case of a Member of the Appellate Tribunal,-

(i) is, or has been, or is qualified to be, a Judge of a High Court; or

Qualifications for

appointment of Chairperson andMembers of

Appellate Tribunal

(ii) is, or has been, a Member of the Indian Legal Service and has held a post

in Grade I in that service for atleast three years; or

(iii) is, or has been, a Secretary for at least one year in Ministry or Department

or the Central Government dealing with the Power, or Coal, or Petroleum

and Natural Gas, or Atomic Energy; or

(iv) is, or has been Chairman of the Central Electricity Autho rity for at least

one year; or

(v) is, or has been, Director-General of Bureau or Director-General of the

Central Power Research Institute or Bureau of Indian Standards for atleast

three years or has held any equivalent post for atleast three years; or

679



(vi) is, or has been, a qualified technical person of ability and standing having

adequate knowledge and experience in dealing with the matters relating toenergy production and supply, energy management, standardisation and

efficient use of energy and its conservation, and has shown capacity in

dealing with problems relating to engineering, finance, commerce,

economics, law or management

Term of office 34. The Chairperson of the Appellate Tribunal and every Member of the Appellate Tribunal

shall hold office as such for a term of five years from the date on which he enters upon his

office:Provided that no Chairperson of the Appellate Tribunal or Mem ber of the

Appellate Tribunal shall hold office as such after he has attained, –

(a) in the case of the Chairperson of the Appellate Tribunal, the age of seventy

years;

(b) in the case of any Member of the Appellate Tribunal, the age of sixty-five

years.

Terms and

conditions of

service

35. The salary and allowances payable to and the other terms and conditions of service of the

Chairperson of the Appellate Tribunal, Members of the Appellate Tribunal shall be such as

may be prescribed:

Provided that neither the salary and allowances nor the other terms and conditions of

service of the Chairperson of the Appellate Tribunal or a Member of the Appellate Tribunal

shall be varied to his disadvantage after appointment.

Vacancies 36. If for reason other than temporary absence any vacancy occurs in the office of the

Chairperson of the Appellate Tribunal or the Member of the Appellate Tribunal, the Central

Government shall appoint another person in accordance with the provisions of this Act to fill

the vacancy and the proceedings may be continued before the Appellate Tribunal from the

stage at which the vacancy is filled.

Registrationand removal

37. (1) The Chairperson or a Member of the Appellate Tribunal may, by notice in writing under his hand addressed to the Central Government, resign his office:

Provided that the Chairperson of the Appellate Tribunal or a Member of the Appellate

Tribunal shall, unless he is permitted by the Central Government to relinquish his officesooner, 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 asthe 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.

680



38. (1) In the event of the occurrence of vacancy in the office of the Chairperson of theAppellate Tribunal by reason of his death, resignation or otherwise, the senior-most

member of the Appellate Tribunal shall act as the Chairperson of the Appellate Tribunal

until the date on which a new Chairperson appointed in accordance with the provisions

of this Act to fill such vacancy enters upon his office.

Member to act asChairperson in

certain

circumstances

(2) When the Chairperson of the Appellate Tribunal is unable to discharge his functions

owing to his absence, illness or any other cause, the senior most Member of the

Appellate Tribunal shall discharge the functions of the Chairperson of the Appellate

Tribunal until the date on which the Chairperson of the Appellate Tribunal resumes hisduties.

39. (1) The Central Government shall provide the Appellate Tribunal with such officers and

employees as it may deem fit.

(2) The officers and employees of the Appellate Tribunal shall discharge their functions

under the general superintendence of the Chairperson of the Appellate Tribunal as the

case may be.

Staff of Appellate

Tribunal

(3) The salaries and allowances and other conditions of service of the officers andemployees of the Appellate Tribunal shall be such as may be prescribed.

5 of 190840. (1) The Appellate Tribunal shall not be bound by the procedure laid down by the Code of

civil Procedure, 1908 but shall be guided by the principles of natural justice and subjectto the other provisions of this Act, the Appellate Tribunal shall have powers to regulateit own procedure.

Procedure and powers of

Appellate Tribunal

5 of 1908

(2) The Appellate Tribunal shall have, for the purposes of discharging its functions under

this Act, the same powers as are vested in the civil court under the Code of C ivil

Procedure 1908, while trying to suit in respect of the following matters, namely:-

(a) summoning and enforcing the attendance of any person and examining him on oath;

(b) requiring the discovery and production of documents;

(c) receiving evidence of affidavits;

1 of 1872(d) subject to the provisions of section 123 and 124 of the Indian Evidence Act, 1872,

requisitioning any public record or document or copy of such record or document

from any office

(e) issuing commissions for the examination of witnesses or documents;

(f) reviewing its decisions;

(g) dismissing a representation of default or deciding it, ex parte;

(h) setting aside any order of dismissal or any representation for default or any order

passed by it, ex parte;

(i) any other matter which may be prescribed by the Central Government.

(3) An order made by the Appellate Tribunal under this Act shall 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 maytransmit any order made by it to a civil court having local jurisdiction and such civil

court shall execute the order as if it were a decree made by the that court.

45 of 1860

2 of 1974

(5) All proceedings before the Appellate Tribunal shall be deemed to be judicial

proceedings within the meaning of sections 193 and 228 of the Indian Penal Code and

the Appellate Tribunal shall be deemed to be civil court for the purposes of section 345

and 346 of the Code of Criminal Procedure, 1973.

681



Distribution of

business amongst

Benches.

41. Where Benches are constituted, the Chairperson of the Appellate Tribunal may, from time totime, by notification, make provisions as to the distribution of the business of the Appellate

Tribunal amongst the Benches and also provide for the matters which ma y be dealt with by

each Bench.

Power of

Chairpersont totransfer cases

42. On the application of any of the parties and after notice to the parties, and after hearing such

of them as he may desire to be heard, or on his own motion without such notice, the

Chairperson of the Appellate Tribunal may transfer any case pending before one Bench for

disposal, to any other Bench.

Decision to be by

majority43. If the Members of the Appellate Tribunal of a Bench consisting of two Members differ in

opinion on any point, they shall state the point or points on which they differ, and make areference to the Chairperson of the Appellate Tribunal who shall either hear the point or

points himself or refer the case for hearing on such point or points b y one or more of the

other Members of the Appellate Tribunal and such point or points shall be decided

according to the opinion of the majority of the Members of the Appellate Tribunal who have

heard the case, including those who first heard it.

Right to

appellant to takeassistance of legal practitioner

or accredited

auditor and of Government to

appoint presentingofficers

44. (1) A person preferring an appeal to the Appellate Tribunal under this Act may either

appear in person or take assistance of a legal practitioner or an accredited energy

auditor of his choice to present his case before the Appellate Tribunal, as the case may

be.

(2) The Central Government or the State Government may authorise one or more legal

practitioners or any of its officers to act as presenting officers and every person so

authorised may present the case with respect to any appeal before the Appellate

Tribunal as the case may be.Appeal toSupreme Court

45. Any person aggrieved by any decision or order of the Appellate Tribunal may, file an appeal

to the Supreme court within sixty days from the date of communication of the decision or order of the Appellate Tribunal to him, on any one or more of the ground specified in

section 100 of the Code of Civil Procedure, 1908:

Provided that the Supreme Court may, if it is satisfied that the appellant was prevented

by the sufficient cause from the filing the appeal within the said period, allow it to be filedwithin a further period of not exceeding sixty days.

5 of 1908

CHAPTER X

MISCELLANEOUS

46. (1) Without prejudice to the foregoing provisions of this Act, the Bureau shall, in exercise

of its powers or the performance of its functions under this Act, be bound by such

directions on questions of policy as the Central Government may give in writing to itfrom time to time:

Provided that the Bureau shall, as far as practicable, be given an opportunity toexpress his views before any direction is given under this sub-section.

Power of

Central

Government toissue directionsto Bureau

(2) The decision of the Central Government, whether a question is one of policy or not,shall be final.

47. (1) If at any time the Central Government is of opinion -Power of CentralGovernment to

supersede

Bureau

(a) that on account of grave emergency, the Bureau is unable to discharge the functions

and duties imposed on it by or under the provisions of this Act; or

682



(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 functionsand 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 4shall, 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 theBureau 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 fullreport of any action taken under this section and the circumstances leading to such

action to be laid before each House of Parliament at the earliest.

48. (1) Where a company makes a default in complying with the provisions of clause (c) or

clause (d) or clause (h) or clause (i) or clause (k) or clause (l) or clause (n) or clause (r) or clause (s) of section 14 or clause (b) or clause (c) or clause (h) of section 15, every

person who at the time of such contravention was incharge of, and was responsible to

the company for the conduct of the business of the company, as well as the company,shall be deemed to have acted in contravention of the said provisions and shall be liable

to be proceeded against and imposed penalty under section 26 accordingly:

Provided that nothing contained in this sub -section shall render any such person

liable for penalty provided in this Act if he proves that the contravention of the

aforesaid provisions was committed without his knowledge or that he exercised all due

diligence to prevent the contravention of the aforesaid provision.

Default by

companies

(2) Notwithstanding anything contained in sub-section (l), where any contravention of the

provisions of clause (c) or clause (d) or clause (h) or clause (i) or clause (k) or clause (l)

or clause (n) or clause (r) or clause (s) of section 14 or clause (b) or clause (c) or clause

(h) of section 15 has been committed with the consent or connivance of, or in

attributable to, any neglect on the part of , any director, manager, secretary or other

officer of the company, such director, manager, secretary or other officer shall also bedeemed 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 andincludes a firm or other association of individuals.

43 of 1961 49. Notwithstanding anything contained in the Income -tax Act, 1961 or any other enactment for

the time being in force relating to tax on income, profits or gains -

(a) the Bureau;

Exemption from

tax on income

(b) the existing Energy Management Centre from the date of its constitution to the date of

establishment of the Bureau,

683



shall not be liable to pay any income tax or any tax in respect of their income, profits or

gains derived.

Protection of

action taken ingood faith

50. No suit, prosecution or other legal proceedings shall lie against the Central Government or Director-General or Secretary or State Government or any officer of those Governments or

State Commission or its members or any member or officer or other employee of the Bureau

for anything which is in good faith done or intended to be done under this Act or the rules or

regulations made thereunder.

Delegation 51. The Bureau may, by general or special order in writing, delegate to any member, member of the committee, officer of the Bureau or any other person subject to such conditions, if any,

as may be specified in the order, such of its powers and functions under this Act (except the

powers under section (58) as it may deem necessary

Power to obtain

information52. Every designated consumer or manufacturer of equipment or appliances specified under

clause (b) of section 14 shall supply the Bureau with such information, and with such

samples of any material or substance used in relation to any equipment or appliance, as theBureau may require.

Power toexempt

53. If the Central Government or the Stat e Government is of the opinion that it is necessary or

expedient so to do in the public interest, it may, by notification and subject to suchconditions as may be specified in the notification, exempt any designated consumer or class

of designated consumers from application of all or any of the provisions of this Act:Provided that the Central Government or the State Government, as the case may be, shall

not grant exemption to any designated consumer or class of designated consumers for the

period exceeding five years:

Provided further that the Central Government or State Government, as the case may be

shall consult the Bureau of Energy Efficiency before granting such exemption.

Chairperson,

Members,officers and

employees of the AppellateTribunal,

Members of

StateCommission,

Director-General,Secretary,

members,officers andemployees to be

public servants.

54. The Chairperson of the Appellate Tribunal or the Members of the Appellate Tribunal or

officers or employees of the Appellate Tribunal or the members of the State Commission or

the members, Director-General, Secretary, officers and other employees of the Bureau shall be deemed, when acting or purporting to act in pursuance of any of the provisions of theAct, to be public servants within the meaning of section 21 of the Indian Penal Code. 45 0f 1860

Power of

CentralGovernment toissue directions.

55. The Central Government may give directions to a State Government or the Bureau as to

carrying out into execution of this Act in the State

Power of Central

Government tomake rules.

56. (1) The Central Government may, by notification, make rules for carrying out the

provisions of this Act.

(2) In particular, and without prejudice to the generality of the foregoing power, such rulesmay 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;

684



(d) the terms and conditions of service of officer and other employees of the Bureau

under sub-section (2) of section 10;

(e) performing such other functions by the Bureau, as may be prescribed, under

clause(u) of sub-section (2) or section 13;

(f) the energy consumption norms and standards for designated consumers under clause (g) of section 14;

(g) prescribing the different norms and standards for different designated consumers

under the proviso to clause (g) of section 14;

(h) the form and manner and the time within which information with regard to energyconsumed 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 reportunder 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 provisionsof this Act and not inconsistent with the rules, if any, made by the Central Government.

Power of State

Government tomake 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.

685



Power of

Bureau to make

regulations

58. (1) The Bureau may, with the previous approval of the Central Government and subject to

the condition of previous publication, by notification, make regulations not inconsistentwith 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 andregulations to

be laid before

Parliament andState

Legislature

59. (1) Every rule made by the Central Government and every regulation made under this Act

shall be laid, as soon as may be after it is made, before each House of Parliament while

it is in session, for a total period of thirty days which may be comprised in one sessionor in two or more successive session, and if, before the expiry of the sessionimmediately following the session or the successive sessions aforesaid, both Houses

agree in making any modification in the rule or regulation, or both Houses agree that

the rule or regulation should not be made, the rule or regulation shall thereafter have

effect only in such modified form or be of no effect, as the case may be; so however that any such modification or annulment shall be without prejudice to the validity of

anything previously done under that rule or regulation.

(2) Every rule made by the State Government shall be laid, as soon as may be after it is

made, before each House of the State Legislature where it consists of two Houses, or where such Legislature consists of one House, before that House.

Application of

other laws not barred.

60. The provisions of this Act shall be in addition to, and not in derogation of, the provisions of

any other law for the time being in force.

686



61. The provisions of this Act shall not apply to the Ministry or Department of the CentralGovernment dealing with Defence, Atomic Energy or such other similar Ministries or

Departments undertakings or Boards or institutions under the control of such Ministries or

Departments as may be notified by the Central Government.

Provisions of Actnot to apply in

certain cases

62. (1) If any difficulty arises in giving effect to the provisions of this Act, the Central

Government may, by order, published in the Official Gazette, make such provisions not

inconsistent with the provisions of this Act as may appear to be necessary for removing

the difficulty:Provided that no such order shall be made under this section after the expiry of two

years from the date of commencement of this Act.

(2) Every order made under this section shall be laid, as soon as may be after it is made,

before each House of Parliament.

Power to removedifficulty.

687



THE SCHEDULE

[See section 2 (s)]

List of Energy Intensive Industries and other establishments specifiedas 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

688




689

References




690References

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 & StatisticsMinistry of power - www.powermin.nic.in

Central Electricity Authority (CEA), India - www.cea.org

CMIE – www.cmie.com

Indian Statistics – www.indiastat.com

India info line – www.indiainfoline.com

Cement Manufacturers Association (CMA) – www.cma.com

Sugar – www.sugaronline.com

Paper - www.Kakaz.com

Fertilizer

Database - www.Eco-web.com

Petroleum Conservation & Research Association - www.pcra.org

Alkali Manufacturers Association - www.amaionline.org

Ministry of Chemicals - www.chemicals.nic.in

Chemical Manufacturers Association - www.icmaindia.com

Chemical Technology - www.chemicals-technology.com

Gujarat Alkalies - www.gujaratalkalies.com

Equipment Suppliers

Bharat Heavy Electricals Limited – www.bhel.com

Thermax – www.thermax.com

Asea Brown Boveri – www.abb.com

Siemens www.siemens.com

Financial InstitutionsIndian Renewable Energy Development Agency www.iredaltd.com

World Bank – www.worldbank.org

The Energy & Resources Institute – www.teriin.org

USAID – www.usaid.gov




692References

Resource person consulted /organisation visitedThe Associated Cement 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 madeFinancial 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, KondappalliJK 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, ChennaiLarsen & 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





694Conclusion

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

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

industriesThe 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

Documents

Indian Industry - Investor Manual for Energy Efficiency