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Knowledge Exchange PlatformPromoting Energy Effi ciency through Best Practices in Industries covered under the

Perform Achieve & Trade (PAT) SchemeNEWSLETTER ISSUE-9, OCTOBER 2018

INSIDEINSIDE Message of Director General, Bureau of

Energy Efficiency

Green Supply Chain- A Model for

Sustainable Textile Production

Best Practice Case Studies

• JKWhiteCementWorks,Gotan

(AdivisionofJKCementLtd)

• M/s.WinsomeYarnsLimited

RDFProductionforCementPlants

DaKShaTA-DatabaseforKnowledge

Sharing on Technological

Advancements

KnowledgeExchangePlatform

Update

Message

Mr. Abhay BakreDirector GeneralBureau of Energy Effi ciency

The award winning paintings of children who participated in National Level Painting Competition-2013 organised by Bureau of Energy Effi ciency, Ministry of Power, Government of India, are presented here. Paintings of Arushi Aggarwal (Haryana), Snigdha Bhattacharjee (Tripura), Priyam Das (Delhi), Anuja Anil Khilari (Maharashtra), Lopa Mudra De (Tripura), Vani Gupta (Uttar Pradesh), Modak Verma (Himachal Pradesh), Deeksha Moolya (Karnataka), Swostishree Mohanty (Odisha) appear below in the same order.

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Warm greeting to industry friends and colleagues!

ThepastfewyearshavebeenquitesignificantaspartofourjourneyunderPerformAchieveandTrade(PAT)scheme,withthefirstcyclefarexceedingtheexpectationsandnextthreecyclescurrentlyrunningconcurrentlywithchallengingtargets.WithinitiativeslikePAT,Indiahasnotonlybeenabletoreaffirmitsgloballeadershipinmitigatingtheimpactstacklingclimatechange,butalsodemonstratedthatwearewillingtochallengeourownsuccessandtestnewlimits.Forrealisingthisvision,wearecurrentlyleadingaconsultativeefforttorevisitthestrategiesandinitiativesunderthenewmissionROSHANEE(RoadMapofSustainableandHolisticApproachtoNationalEnergyEfficiency).

Iwish to encourage the industry leaders to join handswith BEE in realising thisroadmap, wherein we recognise the importance of efforts being made at theindividual industry level and are committed to support and addmomentum totheseeffortsthroughforumlikeKnowledgeExchangePlatform(KEP)initiative.

As Industry braces itself to achieve the targets under the rolling cycles of PAT there willbeaneedtobring inknowledgeandenhanceaccesstonewand innovativetechnologies and services that can take them on a continuous energy savingtrajectory. To realise this potential, we have initiated the process of developingtechnologyroadmapfordifferentsectorsandmappingofbestavailableinternationaltechnologies under KEP. To compliment this process we have also created aDatabase for Knowledge Sharing on Technological Advancements– DaKShaTA,whichisamobilebasedapplicationtohelpguideindustrytolatesttechnologicaladvancements, theircostbenefitanalysis,CO2mitigationpotentialandaccesstotechnologysuppliers.

This issue of newsletter covers case studies, which have been selected fromAluminium and Cement sectors. I will encourage the industry associations andopinion leaders to provide their inputs and suggestions in making KEP moreinteractiveandvibrant.

Abhay Bakre

NEWSLETTER ISSUE-9, OCTOBER 20182 For circulation within the KEP network only

– Ms. Ritu Bharadwaj & Mr. Somnath Bhattacharjee,Institute for Industrial Productivity India

Green Supply Chain- A Model for Sustainable Textile Production

TheimportanceofthetextilesectorfortheSouth Asia region cannot be overstated as itprovidesdirectemploymenttomorethan55millionpeopleandindirectemploymenttonearly90millionpeople.Theimportanceof the sector to the region is also refl ected from the share of the sector in globalexports. SouthAsia‘s share inglobal tradeis around 4.4 percent,while generating anexport volume of over US$ 37 billion . Atthe national level, it constitutes around 80 per cent of total exports of Bangladesh providing direct employment to 3 millionpeople;45percentinSriLankaemployingmore than 1.8 million; 55 per cent inPakistan employing more than 15 millionandaround12percentinIndiaemployingmorethan38million.Butallthesepositiveaspects of the sector is overshadowedby the range of environmental and socialimpacts associated with its operations,impairing sustainability of very inputs on

which this sector thrives. The main issueslinked to textile sector are typically thoseassociated with discharge of untreatedeffluents leading to water pollution, highenergy and chemical use, GHG emissionsand associated issues ofworkplace safety.Resource effi ciency along the supply chain of textile sector is an effective approachto tackle these issues. The following casestudy provides details of various resource efficiencymeasuresundertakenbydifferentactors along the supply chain of textile, the impactsachievedandreplicationpotential.ThecasestudyinbasedonajointinitiativeofIIPandIKEAundertakeninIndia.

Indian Textile Sector: An OverviewIndia is the world’s third largest producerof cotton, after China and the USA and the secondlargestcottonconsumerafterChina.

It contributes about 14 percent of industrial production, 4 per cent to GDP, 20 per cent to the foreign exchange earnings and providesdirectemploymenttomorethan38million ,makingthissectorthesecondlargest provider of jobs after agriculture.The sector also creates a large volume ofindirect employment, both in traditionalindustries (like production of cotton andother natural fibers) aswell as inmodernindustries(liketextiledesignandfashions).

The Textile and Apparel Supply Chain comprises raw material producersessentially covering farmers, ginningfacilities, spinning processes, processing sector,weavingandknitting factoriesandgarment manufacturing facilities. Thissupply chain is perhaps one of the mostdiverseintermsoftherawmaterialsused,technologiesdeployed andendproducts.Cotton remains the most significant rawmaterialfortheIndiantextileindustrywithaproductionof5billionkgmakingupfor

Environmental Issues associated with Textile industryWater: The textile industry uses high volumes ofwater throughout its operations,fromcultivationtobleaching,dyeingandwashingoffinishedproducts.Onanaverage,approximately200litresofwaterarerequiredtoproducelkgoftextiles.

Energy: Highenergyconsumption(oil,gas&coal)andconsequentGHGemissionsindifferentstagesof textileproductionparticularlywetprocessing,withsignificantenergysavingpossibility.

Chemicals:Thecottonproductionprocessinvolvesextensiveuseoffertilizersinfarmlandsthatcausessoildepletionaswellascontaminationofsurfaceandgroundwaterresources. Similarly thewet process of textilemanufacture specifically the dyeing,printingandfinishinginvolvesextensiveuseofchemicals,whicharemostlyhazardous.

Air Pollution: ApartfromGHGemissionsduetofossilfuelburning,variousprocesseslikedyeing,printing,fabricpreparationetc.alsoresultsinemissionsofhydrocarbons,formaldehyde and other volatile compounds, which are hazardous to health andenvironment.

Solid Waste: Solidwasteincludesscrapsoffabricandyarn,off-specificationyarnandfabricandpackagingwaste.Therearealsowastesassociatedwith the storageandproductionofyarnsandtextiles,suchaschemicalstoragedrums,cardboardreelsforstoringfabricandconesusedtoholdyarnsfordyeingandknitting.

Facts about Cotton• 2.5%oftheworldscultivatedlandis

usedtogrowcotton• Cotton accounts for up to 10% of

global pesticide use• Cotton is grown in around 80

countriesaroundtheworld• The largest producers are China,

India, USA, Pakistan, Brazil andUzbekistan

• Morethan300millionpeopleworkin the cotton industry

• On average, 10,000 litres of wateris used to grow one kilogram ofcotton, but it can require threetimesasmuch if farmingpracticesare poor

• Nearlyhalfofalltextileproductionis based on cotton

NEWSLETTER ISSUE-9, OCTOBER 2018 3

22percentofworldsharenextonly to30percent of China. Cotton grows mostlyin western and central India and cottoncultivation provides direct livelihood to 6 millionfarmers.

However, Indian cotton production relieson extensive use of hazardous pesticides and chemical fertilizers. Data reveals thatCottoncultivationinIndiaconsumes44.5%ofthetotalpesticidesusedinthecountry.Inaddition,cottonisawaterintensivecropandaround6%ofthewaterforirrigationinIndia is used for cotton cultivation (Figures fromwww.indiastat.com).

It isestimatedthatthereareabout65,000garment units in the organized sector, ofwhich about 88 per cent are for wovenclothwhiletheremainingareforknits.Theweavingandknitssectorliesattheheartofthe industry.Weaving, usingpowerlooms,was traditionally done by compositemills that combined it with spinning andprocessing operations. Over the years,government incentives and demand forlow cost, high volume, standard productsmoved the production towards powerloomfactories.

Supply Chain InterventionIndian textile industry has suffered frominefficiency and low productivity atbothendsof thesupplychain– low farmyields affecting cotton production andinefficiency in garment sector leading tohighenvironmentalandsocialexternalities.The case study focuses on how resourceefficiency has been brought through lowcost intervention along the entire supply chainofIKEA.

The supply chain intervention, as showninfigure1,coversbothresourceefficiency

issues at the level of farmers producingcotton as well as the production facilitiesor textile mills. At the farm level, theemphasis was on reducing water andpesticide use, while the focus at themanufacturing facilities was to enhanceefficiency of the production process. Forease of understanding, the interventions havebeenpresentedintwosections–oneatthelevelofcottonproducersi.e.farmersand the other covering aspects of fabric production.

Enhancing resource effi ciency for cotton growersThe IKEA initiative in India targeted theAurangabadregionofMaharashtra,wheremajor factors responsible for low cottonyieldhavebeen inadequacyofwater andpestattack.Farmerstypicallyresorttooverexploitation of available water resourcesand indiscriminate use of pesticides andfertilizers that have resulted in severe degradation of surface and groundwaterreservoirs, soil erosion and bio-diversity loss.

Approach adopted

Theprojectadoptedparticipatoryapproachto address these issues. Awarenesscampaignsandinteractionswereorganizedto motivate farmers to adopt sustainableapproaches to cultivation that could (i)reduce the use of pesticides, fertilizers and water, (ii) enhance productivity and (iii)reducetheenvironmental&socialimpacts.The skills and capacities on better cropmanagement practices was developedat the local level through FarmerTrainingand Farmer Field Schools (FFS),where thefarmers were provided practical handson training on sustainable irrigation, cultivationandpest controlpractices.Thefarmers producing cotton by adoptingsuchapproacheswerefurthersupportedtoget their cottoncertifiedas‘BetterCottonInitiative’ product that provided themaccesstobettermarket.

The result of the pilot project was veryencouraging and inspired other farmers

to join the initiative. More than 6000farmersjoinedthisprojectinAurangabad,Maharashtra.Thishappenedasaresultof,

• Campaignstocreateawarenessamongfarmers about the Better CottonInitiative(BCI)anditsbenefits.

• Organisaion of farmers in to‘LearningGroups’to provide practical hands ontraining.

• Initiation of Farmers Field Schools toenhance the skills of the farmers onsustainablecropmanagementpractices

• Guidance of expert agronomists atevery stage

• Continuous monitoring and timelyfeedbacktofarmersbytheexperts

• Training to farmers on usage andhandlingofplantprotectionchemicals

• Facilitation to link the farmers tobankingchannels

• Street plays and awareness campaignson child labour, health and safety, and employmentconditionsetc.wasdonetopromoteawarenessaboutsocialissues

Impact of BCI

AnimpactassessmentcarriedoutbyWWFfortheprojectshowsthat:

Details of BCI

BCI exists to make global cottonproductionbetter for thepeoplewhoproduceit,betterfortheenvironmentit grows in andbetter for the sector’sfuture. Itworkswithadverse rangeofstakeholders to promote measurableand continuing improvementsfor the environment, farmingcommunities and the economies ofcotton-producing areas. BCI aims totransform cotton production worldwidebydevelopingBetterCottonasasustainablemainstreamcommodity.

Figure 1: Supply chain of textile sector

Newsletter Issue-9, OctOber 20184

• Farmers now use 38% less pesticidesreducing environment damage andharmful effect on the health of thefarmershandlingit.

• Efficient irrigation practices havehelpedthefarmersuse24%lesswaterreducing the strain on the already scare surfaceandgroundwaterresources.

• Farmers now use 29% less fertilizershelping preserve soil health and preventingchemicalpollution.

• Farmersbenefitedfromreducedcostoffarminputsandincreasedcropyields.

• Certification of cotton through BCIhelpedfarmersgetbetterpricefortheirproduce.

The success of Aurangabad provides an effective model for scale up sustainableproduction of cotton in India as well asothercountriesinSouthAsiafacingsimilarissues. IKEA, which currently uses around0.6% oft he world’s cotton productioneveryyeariskeengraduallyswitchingoverto sourcing 100 percent BCI cotton in its supplychain.

Promoting resource efficiency in Textile ProductionTocomplement theeffortsunderBCI, thesustainability effort was extended up inthe supply chain – i.e. textile production.

Figure 2: Process flow diagram of the pilot unit

Figure 3: Electricity use by different departments (KWh, %)

Detailed investigation and technical backstopping support was provided byIIP to increase resource use efficiency in a textile production unit in Erode district of Tamil Nadu, which is one of the mostimportant textile producing clusters inIndia. The vendor targeted under thisinitiative is one of the largest suppliers of IKEA in India andhouse all the importantstagesoftextileproduction.Theyproducetextile for various IKEA products andsource 100 percent of their raw materialrequirement from farmers producingcotton under ‘Better Cotton Initiative’ inAurangabad.

Amajordrawbackwiththetextileindustryin Erode is that there has been very little investment for technology up gradationand modernization. In general, themachineries installed are obsolete andoutmoded,resultinginlowefficiency,highenergy consumption and excessive wateruse. Another significant challenge for thetextile industry in Erode proper effluent management. Erode is in a dry, water-scarce region, and the rapid expansion of the textile industry has taken place in anunplanned manner with no associateddevelopment of supporting infrastructureorinstitutionalcapacity.Thishasledtothedepletion of groundwater reserves anda serious deterioration in environmentalqualityofbothsurfaceandgroundwater.Alargequantityofsaltisusedinthedyeingprocess and the wastewater from thisprocessishighlysalineandiscontaminatedwith a variety of chemicals. As there ishardly any source of fresh water nearby,waterisbroughtinbytrucksfromgroundwatersourcesasfaras50Kmsawayatanenormouscost.Typicalwaterconsumptionin Erode is around 200 to 400 litres/kgof finished product, compared with theinternationalnormof120to150 litres/kg.Most of the bleaching and dyeing units in Erode are located in clusters along the banksof theRiverCauveri&Bhavani, intowhich they discharge effluent. Industrialeffluents stagnate in the riverbeds and percolateintothegroundwater.Asaresult,thegroundwaterqualityaroundthecluster

of bleaching and dyeing units is getting polluted.Thebleachinganddyeingprocessare the main causes of pollutants whichinclude caustic soda, hydrochloric acid, sodium hydro sulphate, hypochlorite andperoxides.Thisdeterioratingwaterqualityhasinturnpollutedthesoil,withthecropproductivity falling drastically in the nearby agriculturalbelt.Thoughcurrentlyonlythedecline in crop productivity is observed, it would not be long before the pollutantspercolate into the soil and ground watercausing an irreversible environmentaldamage.

The approach to resource efficiency in the next stage of textile supply chain in Erode was therefore to focus on minimisationof water & energy footprint along withreductioninwasteandeffluentdischarge.The unit chosen for pilot intervention is a medium sized wet processing mill,manufacturing a wide range of cottonand blended home textile products. Theactivities of the mill include sizing andwarpingofyarn,weaving,wetprocessing,printingandspecializedfinishing.Theunitcaters to both own production aswell asjobordersandneedsofglobalcustomerssuch as IKEA.The productsmanufacturedinclude bleached, dyed, printed fabrics and bleachedanddyedyarns.

Figure 2 depicts the process flow chartalong with the input and output at eachstage.Largeamountsofenergy isused intheunit alongwaterbothdirectly aswellas in the form of steam for different wetprocessingstagesofthisunit.

Energy:Electricity,firewoodanddieselarethevariousenergytypesusedintheplant.Electricityisusedtopowerequipmentandmachinery for drying, pumping, lighting,

Fabric processing M/cs, 333 kWh, 46%

Boiler – 2 No, 72.9

kWh, 10%

Yarn Dyeing M/c, 125 kWh, 17%

E.T.P, 112.5 kWh, 15%

Soft Flow, 35 kWh, 5%

Lighting & A/C, 54,kW

h, 7%

Newsletter Issue-9, OctOber 2018 5

andofficeequipment(Figure3).Firewoodisusedasafuelforboilerstogeneratesteamandforthermicfluidheaters.DieselisusedasafuelforDieselGeneratorsetswhichareusedasastandbypowersource.Theformsof energy, description and source in the plantaresummarizedinTable1.

Electricity and firewood are the primaryenergysourcesused in themill.Theplantuses around 4 million units of electricityand18000tonnesofwoodannually.

Water:Sincetheplantisawetprocessingmill, large quantities of water is used atalmost every stage of the productionprocess. Excessive water use lowers thewatertableanddepleteswatersourcesforfutureproductionandcommunityuse.Themainsourceofwaterfortheplantisopenwell.Asperthezerodischargeregulationsapplicable to textile industry, the plant’streatedeffluenthastobedivertedbacktothe well for recharging. The recharging isfacilitatedwithROsystemandonlymake-upwater is drawn to replenish thewater

loss. Table 2 shows section/ equipmentwisewaterconsumptionintheplant.

The amount of water consumed varieswidelydependingonthefollowingfactors:

• Typeof fabricbeingprocessed-waterconsumptionintextileoperationsvarybetween processing different fabrictypes.Waterusedinprocessingwovenfabricaverages50-100m3ofwaterpertonne of production depending upon theoperatingsequences.

• Management and work practices -improper management and workpractices also contribute to excessive water consumption. About 5-10%savings in water consumption canbe achieved by applying good housekeepingmeasures and adoptinggoodpractices.

• Typeofprocess-waterconsumptionintextileoperationsvarywidelybetweenthe different unit equipment for thesame process. Some dyeing methodsconsume largequantitiesofwater (i.e.

jiggers) while others have very lowwaterconsumption(i.e.pad-batch).

• Machine type - water consumption indifferent textile processing machinesdependsonbathor liquor ratio (weightofbathwaterdividedbyweightoffabric).

• Process control - lack of adequateprocess controls (e.g. flow and levelcontrols)also leads toavoidablewaterloss.

Waste & Effluent discharge. Almost allchemicals and dyes are carried over intowastewater except chemicals picked-upbyfabricandyarn.Wastewatergeneratedfrom the various pretreatment washingand dyeing operations contain substantial pollution loads characterized by a high biological load suspended solids (e.g.fibersandgrease),dissolvedsolids,colours(i.e. dyes), high temperature and strongalkalinity.

The plant generated Biological Oxygen Demand (BOD) levels in the effluentvaries between 1500-4000ppm andTotalDissolved Solids (TDS) from 7000 ppm tomore than 10000 ppm. In addition somechemicals released into the wastewaterare highly toxic and hazardous and pose a threattohumanhealthandaquaticlife.Allthewastewatersfromtheplantiscollectedin tanks and sent to primary clarifier.Aeration tank takes care of BOD andChemical Oxygen Demand (COD). In thetertiary clarifier, turbidity is removed.Thisis followed by ultra-filtration and reverseOsmosis (RO) plant. TDS gets removedand permeate is collected from all threestages of RO. Final reject from RO is sentto evaporator and the resulting salt slurry is stored in a shed.The solidwastearisingfromtheprimaryclarifierisseparatedfromliquid in a filter press.The sludge is driedinopenbedandpackedandstoredunderclosedroof.Thesludgearisingfromprimarytreatmentisabout480kg/day.

Towards resource efficient and cleaner production

In order todealwith the existing resourceinefficiency and environmental issues,

Table 1: Different forms of energy & water used in the Plant

Energy&Waterform Description of use

ProcessSteam(Directsteam)

Steamisdistributedthroughpipelinestothefabric/bathsduringsomewetprocessingstagessuchaschemicaldesizing,scouring,bleaching,mercerizing,andsteamfixationofdyesandprints.

HeatingSteam(Indirectsteam)

Steamdistributedthroughpipelinesandindirectlyappliedto process and used for heating purposes such as drying cylinders,kiers,softflowdyeingM/cs,yarndyeing,andcausticevaporatorplant.

Thermicfluid(Oil) Usedinstenters,printersforindirectlyheatingairwhichinturnisusedfordryingorheatsetting.

LPG Directflameuseforsingeing

Table 2: Water Consumption in the plant

Equipment or Section Total Water Consumption, KLD

Kiers 126

Jiggers 288

Padding Mangle 7.4

Rotary screen Printing 183.15

Printwasher 80

Yarndyeing 303

Mercerizing 25

Softflowdyeing 279

TOTAL 1291.55

NEWSLETTER ISSUE-9, OCTOBER 20186

a thorough resource audit was carriedout in the unit followed by developmentof a ‘greening’ action plan detailing themeasures that need to be undertaken bythe unit. This action plan was presentedto the unit and a through a consultative process involving the plant personnel and seniormanagement,aprioritizationexercisewas carried out. The financial assessment

in terms of investment needed for variousinterventions and payback period helpedthePlantManagementintakinginvestmentdecision. The Management also felt thatsuch investments would help them inenvironmental&regulatorycompliance.Theplant was further provided with technicalbackstopping support to implementthe recommended measures. An impact

assessmentwassubsequentlycarriedouttogaugetheimpactsofinterventionsalreadyimplemented by the unit, those underprogressandproposedinnearfuture.

Energy Saving measures: Details of impact of some of the short term energysaving initiatives already implemented bytheunitareasfollows:

Annualreductioninfirewoodconsumption=134TonsAnnualsavings=Rs.0.415MillionInvestment=Rs.0.028MillionSimplepayback=1monthAnnualGHGreduction=100TonsofCO2

AnnualElectricitycon.reduction=20130kWhAnnualsavings=Rs.0.141millionAnnualInvestment=Rs.0.18MillionSimplepayback=16monthsAnnualGHGreduction=16.9TonsofCO2

Insulation of Boiler Feed water tank Variable Frequency Drive (INVERTER) for Calendaring

Annualthermalenergysavings=16.5GcalAnnualelectricitysavings=7015kWhAnnualsavings=Rs.1.36MillionAnnualInvestment=Rs.2.06MillionSimplepaybackperiod=18monthsAnnualGHGreduction=6TonsofCO2

Annualelectricitysavings=108098kWhAnnualsavings=Rs.0.594MillionAnnualInvestment=Rs.2.1MillionSimplepaybackperiod=42monthsAnnualGHGreduction=101TonsofCO2

Single Shot Dyeing and Printing Replacement of Surface Aerator with Diff used Aerator

Annualwatersavings=3.95MillionLitresAnnualelectricitysavings=23040kWhAnnualsavings=Rs.0.161MillionInvestment=Rs.0.025MillionSimplepayback=2monthsAnnualGHGreduction=10.4TonsofCO2

Annualwatersavings=5.49MillionLitresAnnualelectricitysavings=32105kWhAnnualsavings=Rs.0.224MillionInvestment=Rs.0.05MillionSimplepayback=3monthsAnnualGHGreduction=26.9TonsofCO2

Recycling of Wash Water in Rotary Screen Printing Recovery of cooling water from Hydraulic Jiggers

Some other energy saving measures likeuse of acrylic sheets for natural lighting in plants,powersavingmeasures inworker’squarters, reducing AC load, insulation ofbare steam pipes yielded payback in lessthan7monthswithhighelectricityandfuelwoodsavingsalongwithGHGmitigation.

Water & Energy saving measures: Short terminitiativeswithwater,energyandGHGmitigation potential implemented by theplantareasfollows:

Besides water and energy savings, theintervention also contributed towards

Cooling Water and Condensate Recovery from Pre-shrinking RangeAnnualwatersavings=0.86MillionLitresAnnualsavingsinwatercost=Rs.0.11MillionAnnualsavingsinelectricityconsumption=5005kWhAnnualGHGreduction=4Tons of CO2

Netannualsavings=Rs.0.146MillionInvestment=Rs.0.05MilllionSimplepayback=4months

Before implementati on Aft er implementati on


Optimizing Well Water Pumping Energy

Annualreductioninwaterconsumption=30.5millionLitresAnnualelectricitysavings=2857kWhAnnualsavings=Rs.0.19MillionAnnualInvestment=Rs.0.325MillionSimplepaybackperiod=21monthsAnnualGHGemissionreduction=2TonsofCO2

Improvements in Yarn Dyeing SectionAnnualreductioninpowerconsumption=16331kWhAnnualreductioninwater(RO)consumption=1.83Million LitresAnnualcostsavings=Rs.0.35MillionInvestment=Rs.0.18MillionSimplepaybackperiod=7monthsAnnualGHGreduction=8.9Tons of CO2

Before:EffluentpumpedtoETPalongwithcondensate

After:EffluenttoETPbygravity and condensate recycled in yarn dyeing as hotwater

effective compliance of environmentalstandards(zeroeffluentdischargefromtheunit), improved workplace environment,improved safety in the work place andreduced negative health impacts for theworkers through better ventilation ofwork places, reduction in contaminationof drinking water sources,and reducedemissions.

Scaling up Resource Conservation MeasuresThe supply chain greening approach in textile sector represents a win-winsituation.FortheSMEvendorandfarmersinvolved in cotton growing, it meansimproved resource productivity, reducedwastages and higher profit margins. Forsocially and environmentally conscious

corporate like IKEA, it means reducedcarbon footprint for its operations. Theadditionalco-benefitsbywayofsocialandenvironmentalimpactsareabonus.

The successful demonstration hasencouraged IKEA to internalise thisapproach with all its vendors in IndiaandSouthAsiaregion. IKEAhasalreadyset sustainability targets for its vendors on energy, water and rawmaterial useas well as increasing use of renewableenergy. In order to motivate othervendors in India, IKEA organised a‘Sustainability’ workshop in whichall major IKEA vendors in India wereencouragedtofollowasimilarapproachby showcasing the benefits beingachievedbytheparticipatingunit.

Following the success of supply chaingreeningmodelinIndia,IIPmadeefforttopromote similar approach in Bangladeshin partnership with other leading brandslikeH&M,RawstarG,C&AandIKEAundera South-South cooperation approach throughexposurevisitstoIndia,awarenessgeneration, energy/ resource audit inrepresentative units (participating vendors supplying textile products to international brands) and workshops to showcaseimpacts achieved by participatingvendors. The results of the project wasquite successful as Bangladesh GarmentManufacturers Exporters Association (BGMEA), which is the biggest and mostimportant textile industry association inBangladesh, has agreed to scale up this modelamongtheirmembers.

Thesupplychaingreeningefforts in Indiaand Bangladesh helped in demonstratinghowCorporatePolicyofglobalbuyerscanhelp in stimulating sustainability alongtheir supply chain. However, successfulscale up of such models will need theinvolvement and support of not just thefarmers and textile industry but otherstakeholders,specifically,thepolicymakersthat incentivize adoption of energy/resource efficient technologies, enable access to finance, facilitate certificationamong other. This will be particularlyimportantforovercomingthebarriersthatenergy/resource efficient technologiesand sustainable approaches will face inreplacing conventional and deep rooted processesandmethods.Experienceshowsthat scaling up of such technologies willrequire both ‘supply side’ push throughtechnology assistance, capacity building andgovernmentpolicies that incentivizesadoption of such technologies as well as‘demand side’ pull through favourableCorporate and public procurement policythatpromotessourcingofresourceefficientproducts.

Indian experience with the supply chaingreening provides a lot of learning that canhelp in shapingofeffective strategiesand policies in other South Asian countries, particularly those dealing with the


Table 3: Greening action plan under implementation and associated benefit streams

Greening measure implemented

Investment (INR)

Annual Savings

(INR)

Pay-back period

(month)

Annual Fuel (thermal energy)

Savings (Gcal)

Annual Electricity

Savings(‘000 KW)

Annual Water Saving

(ML)

Annual CO2 emission reduction (tonnes)

Medium-termprojects

IndirectsteamuseinJiggers(undertrial)

525000 355074 18 309 - - 86

VFD for ID fan of boiler (under investigation)

50000 108864 6 - 25.92 - 22

Insulation of drying cylinders (undertrial)

100000 195920 6 169 - - 47

Avoiding horizontal yarn dryer andmaximizinguseofverticaldryer

100000 567000 24 - 130.2 - 109

Replacementofsurfaceaeratorwithdiffusedaerator

2100000 594541 42 - 108.098 - 101

Long-termprojects

VFDforIDfanofthermicfluidheater

35000 66528 6 15.84 - 16

Maximizingcondensaterecovery 100000 219450 5 160.65 - - 43

AFBCboilerwithmulti-fuelcapability in place of exisiting firewoodfired-boiler

1500000 7269500 >24 5500 - - 1700

Wasteheatrecoveryfromyarndyeingmachine

1400000 666500 24 - - - 156

VFD for Stenter exhaust fan 70000 26612 31 - 6.336 - 5

Centralizedcompressedairsys-teminplaceofdistributedsystemwithpipingsizemodification

900000 445560 24 - 111.39 - 94

VFDforthermicfluidcirculationpump

50000 43788 14 - 10.426 - 9

Adopting Continous Scouring and Bleaching Range and phasing outpost-mercerizedactivitiesinjiggers

25000000 12500000 24 5.9 1453 ↓ 10 -15 Litres/kg

1221

Rainwaterharvestingplan(pro-posed)

350000 1070550 - - - 8.235

implementation challenges that are quitesimilartoIndia,andopenupopportunitiesfor knowledge transfer to other countriesalong the lines of technology/ expertisetransfertoBangladesh.

1. UN-COMTRADEdatabase,WorldIntegratedSolutions(WITS)

2. DerivedfromPlanningCommission‘sEmploy-mentestimates

3. PotentialSupplyChainsInTheTextilesAndClothing Sector In South Asia An Exploratory Study, United Nations Conference on Trade andDevelopment(UNCTAD)

4. Devaraja.,T.S,IndianTextileandGarmentIndustry-AnOverview,DepartmentofCom-merce,PostGraduateCentre,UniversityofMysore,Hassan,India

5. ChandraPankaj.,TheTextileandApparelIndustry in India, Indian Institute of Manage-ment,Ahmedabad,April,2006


JK White Cement Works, Gotan (A division of JK Cement Ltd)

– Mr. Gajendra Panwar & Mr. V. S. Rathore , JK White Cement Works, Gotan

IntroductionJKWhiteCementisthefirstWhiteCementfactory in India, which manufacturedWhite Cement through dry processtechnology. The Gotan plant wascommissioned in 1984 with an initialproductioncapacityof50,000tons.ItusestechnicalexpertisefromF.L.Smidth&Co.ofDenmarkandstate-of-the-arttechnologywith continuous on-line quality controlby microprocessors and X-rays, ensuringthepurestwhite cement.Over theyears,continuous process improvements andmodifications have increased the plant’sproduction capacity to 610,000 tons per annum.OwingtoitsconstantR&DeffortsandupdatedtechnologyJ.K.WallPutty,anew, value-added productwas launchedin2002.

Raw Mill-1 Specification and IntroductionRawmill 1 is 3.2mdiameter and5.25mlength with drying chamber and single

chamber mill. There is dryer for materialdryingbeforeenteringinmill.Twoparallelair separator formaterial separation.Millfeed size is 6mmby two impact crusherwhich is in parallel and vibrating screeninstalledaftertwoimpactcrushers.

Methodology AdoptedThe talented in-house team usedbrainstorming sessions, departmentalmeetings and a root cause analysis toolto analyze the problem scientifically. Afishbonediagram(Figure 1)waspreparedto understand the root cause of the problems.Adetailedimplementationplanwas prepared by the team (Figure 2) tocarryoutthetaskasperaschedule.

Reason for low output and higher energy consumption of mill:• Milloutletresiduewashighupto49%

on 90 micron because of inadequatemedia pattern ofmill which results inhighercirculating loadofmill and thisresults in decrement the efficiency oftheseparator.

• Claynib’sformationinmillsbecauseofnon-chargingoflargesize(70mm&80mm)grindingmediainmill.

• Grinding media filling level is low inmill. Grinding media filling level was

Best Practices Case Study

Action Jul-13 Jul-13 Aug-13 Dec-13 May-14 Mar-15

1 Grindingmediapatternchanged

2 Grindingmediafillinglevelincreased

3 Dryerfanmotorreplacedfrom60Kw(DC)to110kw(AC)Installed VFD in dryer fan

4 Screeninletbeltspeedincreasedfrom46rpmto60rpmbychangegearbox

5 Hopperfillingconveyorbeltmotorkwincreasedfrom22kwto30Kw

6 Air Blaster installed in clay crusher

7 Pneumatichammerinstalledforseparator-2 air slide for proper distributionofmaterial

8 Nib’sseparatorinstalledatmilloutletfornibs separation

9 Dryer&millinletRALreplacedwithgravityflap.

10 Observation&monitoring’s

Figure 1: Fishbone diagram for identifying the root cause of increase in power consumption of raw mill 1

Figure 2: Implementation plan to increase the capacity and to reduce the specific power consumption of raw mill 1


25%inmillwithdifferentsizesofballs.Optimumfillinglevelofmediawasnotdone.

• Dryeroutlettempwasbelow55degreecentigrade because we were unableto increase the rpm of the fan whichresults in frequent tripping of fan andthis results in lower kW of the motorofthefan.Earlier fanofmotorwasDCthereforefrequentloadfluctuationwashappened.Becauseofaboveproblemsof mill we were unable to get therequired mill outlet temperature (>85degreecentigrade)

• Material flow distribution was notproper in separator no. 2 (351SR2).All Material from mill outlet elevatorwas going into separator -1 throughair slide, Air slide of separator -2 wasfrequentlyjammed.

• When both raw mill 1 & raw mill 2were run combined then hoppers oflimestone&claywasnotmaintainedbythe operator because tunnel to hopper belt (311 BC2) was tripped frequentlybecause of lower size capacity motor(22kw).

• Screen inletbelt (331BC8)was trippedfrequently even after increasing thefeed of raw mill 1 because of lowerspeedofscreeninletbelt(331BC8).

• Jamming of clay crusher due toexistenceofmoistureinbothclay(clay1& clay2) around7%and this results infrequent tripping of clay crusher inletbelt (331BC4)which leads to feedcutofmill&createsprocessdisturbance.

• Frequent Jamming of mill diaphragmduetoformationofclaynibsandwear&tearofgrindingmediawhichresultsin increased outlet draught& increaseof material filling level of mill andcombination of above factors finallyresultsinreductionoffeed.

• Frequent tripping of dryer inlet(331SU1) & Mill inlet Rotary Air Lock(331SU1) because of oversize claylumps passed through clay crusher &under capacity motors of both rotaryairlockswhichresultsinfeedcutofmillandcreatesprocessdisturbance.

Grinding Media Pattern Before

60mm 50mm 40mm 30mm 25mm 20mm 19mm

8.82 2.84 7.58 3.73 2.01 7.67 12.14

Grinding Media Filling Level Before

h r Filling% Charge(ton)

60 154 25.84 44.69

Grinding Media Filling Level After

h r Filling% Charge(ton)

49 154 29.70 52.36

Grinding Media Pattern After

80mm 70mm 60mm 40mm 25mm 20mm 19mm

1.0 2.0 14.10 14.3 6.65 16.13 12.14

Separator efficiency before optimisation

residue on 90 microns 100 minus Circulating Load (CL)

Circulating factor (CF)

Efficiency (η %)

Separator No.

feed product rejects feed product rejects

50.32 12.56 69.16 49.68 87.44 30.84 2.00 3.00 58.59 separator-1

50.32 13.12 68.45 49.68 86.88 31.55 2.05 3.05 57.30 separator-2

Separator efficiency after optimisation

residue on 90 microns 100 minus Circulating Load (CL)

Circulating factor (CF)

Efficiency (η %)

Separator No.

feed product rejects feed product rejects

40.12 11.54 68.12 59.88 88.46 31.88 1.02 2.02 73.11 separator-1

40.12 13.05 67.48 59.88 86.95 32.52 0.99 1.99 72.99 separator-2

Improvements carried out:

• Grinding media pattern changed.Earlier grinding media optimizationwasnotdone.Followingactionstakento optimize the size and quantity ofgrindingmedia-

a)Wehaveincreasedthequantityof20mmgrindingmediafrom9.67tonneto17.13tonne

b)Wehaveincreasedthequantityof25mmgrindingmediafrom2.01tonneto6.65tonne

c) Quantity of 30mm grindingmediawasaddedto40mmandthisresultsin increasedqty.of40mmgrindingmedia (from 8.58 tonne to 14.3tonne)

d)Quantity of 50mm grindingmediawasaddedto60mmandthisresultsin increasedqty.of60mmgrindingmedia (from 9.82 tonne to 14.35tonne)

e) 70mm(2tonne)&80mm(1.0tonne)grindingmediawas charged in the

mill to avoid the formation of claynibsinthemill.

• Increase grinding media filling level-Grindingmediafilling levelwas low inmill. Grinding media filling level was25%inmillwithdifferentsizesofballs.Optimumfillinglevelofmediawasnotdone.Mediafilling levelwas increasedfrom25%to29.70%.

• Separator louvers & separator rotorrpm adjusted to take different sampletoachievemaximumefficiencyofbothseparator.

• DryerfanDCmotor(60kw)wasreplacedwithACmotorwithVFD(110kw)to–a) Achievetherequiredflow,b)AvoidtheRPMfluctuation.c) Avoidthefantripping.d) Increasethedryeroutlettemperature.e) Achieve the optimum mill outlet

temperature which also results inincreasing the grinding efficiency of mill&separator.

(f )Increaseaveragetphofrawmill1.


LocationDiameter(mm) Pdy,mmwcPstat,mmwc Drybulbtemp.(deg.C)Damperposition Densityatzerodeg.(kg/m3) Density(kg/m3) PitotconstantVelocity(m/sec) Vol.flowrate(m3/Hr.)

• We have replaced the gear box ofscreeninletbelt(331BC8)whichresultsinincreasingofbeltspeedfrom46rpmto60rpmandthisresults inachievingtherequiredTPHofthemillandhurdlefreeoperation.

• After increase speed of screen inletbelt we are able to achieve followingbenefits-

a) Reduction in breakdown frequencyofmillrelatedtooverloadingofbelt.

b)Mill Feed was increased up torequiredTPH.

c) Smoothoperation.

• We have replaced the motor of belt(311 BC2) from 22 kW to 30 kW to

maintainthefilling levelofhoppersofrawmillandthisresultsinachievingtherequiredTPHofthemill.

• Afterreplacingthemotorfrom22KWto30KW,weareabletoachievefollowingbenefits-a) Hopper level maintained of both

mills.b)Breakdown reduced related to

hopperempty.c) Increasedaveragetphofrawmill1.

• Material flow distribution was notproper in separator no. 2 (351SR2).All Material from mill outlet elevatorwas going into separator -1 throughair slide, Air slide of separator -2 wasfrequently jammed. A pneumatichammerwasinstalledatseparator-2airslidetoovercomefromthisproblem

• Afterinstallationofpneumatichammerwe are able to achieve following

Dryer inlet flow before and after modification

Location Diameter(mm)

Pdy, mmwc

Pstat, mmwc

Dry bulb temp.(deg.C)

Damperposition

Density at zerodeg.(kg/m3)

Density (kg/m3)

Pitot constant

Velocity(m/sec)

Vol.flowrate(m3/

Hr.)

dryer inlet 1385 5.96 3.04 198 100 1.41 0.77 0.869 10.76 58350

After

Location Diameter(mm)

Pdy, mmwc

Pstat, mmwc

Dry bulb temp.(deg.C)

Damperposition

Density at zerodeg.(kg/m3)

Density (kg/m3)

Pitot constant

Velocity(m/sec)

Vol.flowrate(m3/

Hr.)

dryer inlet 1385 7.81 4.6 230 100 1.41 0.66 0.869 13.20 71584

benefits-a) Proper distribution of material in

bothseparator.b)Separatorefficiencyimproved.c) Increasedaveragetphofrawmill1.d)Circulatingloadinrange.

• Pneumatic air blaster installed in claycrusher for prevent jamming of claycrusher and avoid tripping of clay crusherinletbelt(331BC4).

• After installation of air blaster in claycrusherweareabletoachievefollowingbenefits-

a) Reduction in breakdown frequencyduetojammingofclaycrusher

b)Increasedaveragetphofrawmill1.

c) Smoothoperation.

• Nib’s separator installed at mill outletforpreventjammingofmilldiaphragmbyworngrindingmedia&claynibs.


Mr. Rajeev Sharma Unit Head, J.K. White Cement Works, Gotan (Rajasthan)

Thisisanexcellentexampleofhowasystematicproblemsolvingapproachandhighleveloftechnicalskillcanproducemagicalresults.Asincere&committedcontributionfromallrelevantdepartmentsresultsinachievingthereductioninspecificspecificenergyconsumptionandincreaseinTPHof themill.

• After installed Nib’s separator at milloutlet:

a) Efficiencyofmillincreased.

b)Solved problem regardingdiaphragmjamming.

c) Increasedaveragetphofrawmill1.

d)Breakdownreduced.

e) Separatorefficiencyimproved.

f ) Milloutletdraughtmaintained.

• Mill inletanddryer inletrotaryair lock(RAL) replaced with gravity flap forpreventfrequentlytrippingofrotaryairlock.

• AfterreplacedRALwithgravityflapweareabletoachievefollowingbenefits-

a) Reduction in breakdown frequencyduetotrippingofRAL.

b)Smoothoperation.

c) Increasedaveragetphofrawmill1.

d)Directsavingofpower.

Impacts and Benefits• EnergySavings:Planthadreducedraw

mill1specificenergyconsumptionfrom13.16 to 12.35 in first year which wasfurtherreducedto11.41in2014-15.

• Financial implications: Total cost incurred for carrying above improvementswas16Lacs(Approx.)

• Paybackperiod:Thepaybackperiodisshort, at 1 year, as the plant increased theproductionafterimplementationofthisproject.

82.0

89.0

9391

93

70.0

75.0

80.0

85.0

90.0

95.0

100.0

2012-13 2013-14 2014-15 2015-16 2016-17

(TPH

)

YEAR

RAW MILL-1 (TPH)

13.1612.35

11.4111.97 11.67

5.00

7.00

9.00

11.00

13.00

15.00

17.00

19.00

2012-13 2013-14 2014-15 2015-16 2016-17

KW

H/T

on o

f mat

eria

l

YEAR

RAW MILL-1 (KWH/Ton of Material)

Figure 3: Raw Mill TPH (year 12-13 to year 16-17)

Figure 4: Raw Mill- kWh/ton of raw mix (year 12-13 to year 16-17)

Box 1: Impact of the optimization on the overall performance of the plant

• Using a step-by-step approach to solve the problem increased the team’sconfidenceandsetanexampleofteamworkintheplant.

• ISO50001EnergyManagementSystemcertificationimplementationprocessintheearly2014-15alsohelpedtheteamtoemphasisonscientificanalysisoftherootcauseoftheproblem

• Theprojectwas instrumental inmotivatingotherdepartments to reduce theirenergyconsumption.

• Operational optimization of raw mill 1 section sets as an example for otherOperation departments to run the section at optimum output to reduce theenergyconsumptionthroughoperationalexcellence.

• Projecthelped in reducingplant’senergycostandachieving theTarget inPATcycle-1.


M/s. Winsome Yarns Limited

– Mr. Pradeep Dhingra, PSG Energy & Services Pvt. Ltd.

Best Practices Case Study

About the PlantM/s. Winsome Yarns Limited, Derabassi,Punjab,isapartoftheWinsomeGroupofIndustries engaged in spinning, knitting,and hydropower.WinsomeYarns Limitedwas the first textile unit to producecottonmelangeyarninIndia.Progressingcontinuously, its production capacity has nowreached110,000spindles.WinsomeYarnsLimitedhasaproductprofilewhichincludes speciality yarns such as slub yarns, nippyyarns, streaky yarns, blendedyarns (cotton blend with nylon, modal,wool,silk,soya,bamboo,etc.).

PGS Energy Services Pvt. Ltd., identifiedenergy conservation opportunities after a PAT audit. Energy conservations schemesworth Rs 160 lacs were implemented indifferentpartsoftheplantdescribedbelow.

Energy ConsumptionInnovative Project: Compressed AirSystem Optimization & Total Reductionin Electricity Consumption: 1221 MWh/Annum (approximate reduction in kW/CFM:15%)

Compressed air is a major energyconsuming utility in textile units,accounting for about 7% of the powerconsumed. The cost of compressed airis one of the largest components of atextile utility’s cost. Air compressorsare considered the lifeline of textile units, because most of the machinery ispneumatically operated. In theWinsomeYarnsLtd.,DerabassiUnit,thecompressedairnetworkhasthreemainunits.

Problems necessitating innovation

• The system’s efficiencywas low in thecentralizedcompressedairsystem.

• The specific power consumptionwas 0.20 kW per CFM, which wasconsiderablyhigh.

• The centrifugal compressor dryer wasrunning inefficiently (demand higherthancapacity)becauseofair leakagesinmachines.

• Spares and maintenance costs wereconsequentlyhigh.

Specification Unit 2014-15 2015-16 2016-17

Overall Production Tonne 9330.03 13068 10690

ElectricalEnergyConsumption LakhkWh 599 685 625.7

• Lossesinproductivityandqualitywereobserved.

• Air leakage audits found leakagesamountingto800CFM.

• Analysissuggestedthatthecompressedairsystemcouldbemademoreenergyefficient if air leakages were arrestedand maintenance carried out in therecommendedtimeframe.

Compressed Air Consumption Comparison

Process Before Implementation

After Implementation

Compressed Air Consumption

(CFM)

Compressed Air Consumption

(CFM)

% of Compressed Air used in

different sections

1 Winding 43560 31,680 60

2 Spinning 18150 13200 25

3 BlowRoom&Carding 7260 5280 10

4 Preparatory Machine 3630 2640 5

Images before and after optimization of the Compressed Air SystemBefore Implementation After Implementation


Mr. B.S. Sharma Plant Head Winsome Yarns Ltd Derabassi, Mohali, Punjab

ItisamatterofpridethatourteamatWinsomeYarnsLtd.hasputtremendouseffortsforsustainabilityandenergyconservation.WehaveastrongbeliveinenvironmentconservationandourmanufacturingprocessareincoherencewithEcosystem.WepracticeEcofriendlymeansforenergygenerationfromrenewableresourcesadopt,rainwaterharvesting,zerowastegeneration&producing&promotingresponsiblefashionwhichhelptosaveenvironment.KudostoourengineeringheadMr.D.S.Pandey&Energysavingteam.

Replacement of T8 Tube (42 Watt) with LED Tube (15 watt)

Plant no Unit 1 Unit2 Unit 3 Colonies Total

NumberofT8lamps 1897 1704 2741 1000 7342

Powerconsumption(LkWh/annum) 6.94 6.24 10.03 3.66 26.86

NumberofLEDTubeLamps 1897 1704 2741 1000 7342

Powerconsumptionpermonthafterinstallation

2.48 2.23 3.58 1.31 9.59

Powersaving(LkWh/annum) 4.46 4.01 6.45 2.35 17.27

Investment(inRs.Lac) 12.33 11.08 17.82 6.5 47.72

MonetarySaving(Rs.Lac/annum) 33.47 30.06 48.36 17.64 129.53

PayBack(inmonths) 5 5 5 5 5

Images showing energy conservation measures in lighting before and after implementation.

Before Implementation After Implementation

Initiatives Taken1. Meetings were conducted with the

plant’smanagementtoapprisethemofairleakagesinplantandtakeapprovalforthefollowing:

Replacement of T8 lamps with LED lamps•TotalReductioninElectricityConsumption:1727MWh/annum

o Formingadedicated team to arrestairleakages

o Stoppingproductiontillairleakageswererectified

o Fundstoarrangesparepartsrequiredtoarresttheleakages.

2. Formationofadedicatedteamwiththemission,’Savepower,arrestairleakage’.

3. Dailymonitoring of air leakages in themachines,followedbyrectificationwork.

4. FormationofaseparateteamforM&V(measurement & verification) whichwouldhelptoquantifyenergysavings.

After arresting air leakages the specificpowerconsumptionwasreducedto0.173kW per CFM, from 0.20 kW per CFM,asavingof14%.

Energy Savings in terms of MTOEAftermodificationtheusageofelectricityhasbeenreducedtoaround0.275MWh/tonofyarn.

The environmental impact ofimplementing the ENCON measuresresultsintermsofsavingsofMTOE

MTOE savings

Savings in production process= 0.253MTOEb

Team behind the initiative


RDF Production for Cement Plants

Further to the earlier article ‘IncreasingEnergy Efficiency in Indian CementManufacturing’ published in KEP issue8 2017; this articlewill outline a state ofthe art, patented and UK Governmentproven technology for production of high quality, Solid Refined Fuel (SRF) fractionfor producing alternative fuels (AF)from Municipal Solid Waste (MSW) andCommercialandIndustrialwastestreams.

Increasinguseofwaste-derivedalternativefuels(AF)incementplantshasbeenamajorglobalsuccessstoryofthepastfewdecades.With substitution rates of 70% or higher,millions of tonnes of waste have beendiverted from landfilland likewisemillionsof tonnes of fossil fuels saved from beingburnt,providingbenefittotheenvironment.Furthermore, the global cement industryhas seen significant financial benefits asAFwillgenerallybeavailableat lowercostthan fossil fuels.However, this global bestpractise has proven slow in spreading tosomepartsoftheworld.

For an existing cement plant to useAF it is true that capital investment isrequired, which in some cases can bea barrier to entry. In particular, new ormodified fuel handling systems andburners will generally be required, duetothepropertiesoftheAFdifferingfromcoal. Use ofmultiple burners at differentlocations in the cement kiln is alsobecoming increasingly the standard toenableuseofmultipledifferentfuelsandthemost energy efficient heating of theraw material. Modification of the plantemissionscontrolequipmentmayalsobe

required.Shuttingdowntheplanttomaketherequiredchangesisliabletointerruptthe continuous production that is of keyimportance, particularly to individuallyowned cement plants. However thisshould be considered part of the long-term plant investment strategy and canbe incorporated into the existing plant maintenance/upgrade schedule. For allnew-build cement plants it should nowbeconsideredstandard&bestpractisetodesign foruseofAFtosupplement fossilfuelsfromdayone.

The state-of-the-art AF handling and burner systems developed to date aregenerally flexible and can handle a varietyofmaterials(includingfossilfuels),however for best performance they canbeoptimisedforspecifictypesofAF.ThetypeofAFavailableisakeyconsiderationbecause a vast array of such fuels have beenused,with significantdifferences inCVandhandlingproperties.Transportingthe AF long distances can compromisethe financial and environmental benefitssignificantly,soitisimportanttoconsiderlocal sources of AF whenever possible.FurthermorenotallAFarecreatedequal,and there may be competition for thebest. For example used rubber tyres areanexcellentAF,with lowermoisture andash contents and a significantly higherCV than coal. Nowadays in Europe thereis a seller’smarket in such tyreswithnotenoughsupplytomeetthedemand.Someearly adopters have even been priced outofthemarket– long-termsecurityofsupplymustbeconsideredaspartoftheAF selection!

There is one particular AF that is available in almost limitless quantities and inpracticallyeverylocation–refusederivedfuel (RDF). Sometimes also referredto as solid recovered fuel (SRF), as itsname suggests this fuel is obtained byprocessing refuse obtained from a greatvariety of sources, including domestichouseholds and commercial premises,typically supermarkets, offices, hotelsand so forth. As such it can also beunderstood that in the long-term RDFshould be considered a secure supply of AF-theincreasingpopulationandwealthof developing nations resulting in ever-increasing production of such refuse, the majority of which is currently not beingsafelytreatedoroptimallydisposedof.

Inadditiontothevarietybetweendifferenttypes of AF, there can also be significantvariationinthepropertiesofRDF.InEurope,a technical standard EN 15359:2011 hasbeen introduced to assess the qualityof RDF which if sufficiently high can becertifiedasSRF.ThevariationinRDFqualityislargelyattributabletotwofactors:

1. TheRDFproductionprocess

2. Thecompositionoftherefusefeedintothe process

For example, paper/card and plasticswill generally make a very good RDFwhereas waste food and glass will not.Inthis respectthebestandmostreliableRDF production must be considered asa combination of obtaining the mostsuitable refuse available and having the right process. Similar to the AF handlingsystemsforcementplants,agreatdealofinvestmentoftimeandmoneyworldwidehas by now established state-of-the-artRDF production technology which isgenerally ready to be used worldwide,however it will require some adaptationtobestsuitthelocaleconomicfactorsandrefusesector.

Mr. Richard Woosnam ProjectsManager, Fairport Engineering Limited

Mr. Dr. Richard Maslen ProjectsManager, Fairport Engineering Limited


RDF production facilities can include a wide variety of process operations,typicallyincluding:

1. Policing of incomingwaste to removebulkyand/orhazardousobjects.Thisisnormallycarriedoutmanually.

2. Removaloforganicmaterials,generallyby screening. The removed organicmaterial will normally be suitable foranaerobicdigestionoranimalfeed.

3. Removal of ferrous and non-ferrousmetals. In Europe these are typicallyremovedbymagnetsandeddycurrentseparators respectively but hand-picking may be preferred. These non-fuelmaterialscanprovideasignificantadditional revenue stream for theRDFproductionfacility.

4. Removal of glass, ceramics and otherdense materials. The most commonmethodsinvolveuseoflowpressureairsystemswhichwilldivertthelighterfuelmaterials. Dependent on the availablemarketsthismaybesuitableforuseasarecycledaggregate.

5. Shredding of the RDF to the correctspecification for the cement plant.The basic form of RDF is generally ashredded‘floc’materialaround25mm-50mmnominalsize.

In the case of more advanced RDFproduction, additional process operationsmaybeinvolved,suchas:

6. Thermal treatment to reduce themoisture content of the RDF. Thiswill have a major benefit to the RDFquality and the performance of theAF handling systems at the cementplant.Thismaybeespeciallyimportantduringmonsoonseasondependingonhowtherefuseiscollectedandstored.As part of integrated facilities, it maybe possible to use waste heat fromthe cement plant and/or bio-methanegeneratedfromtheorganicfraction.

7. In somemarkets, itmay be financiallyviable to removecertainplasticsusinganopticalsorter,oraswiththemetalshand-pickingmaybepreferredinIndia.

Although this will tend to reduce theCV of the RDF, the plastics can achieve agoodpriceintherecyclingmarket.

8. Forming the RDF, for example intopellets, briquettes, or bales. Thiscan make the RDF more suitable fortransportation and handling in somecementplants. ItcanalsoopenuptheRDF for use in other markets such asadvancedconversiontechnologies likegasificationorpyrolysis.

In terms of assessing the quality of theRDF/SRF,thekeyparametersaregenerallyasfollows:

1. Calorific Value (CV) – often the singleheadline figure that grabs attention.The energy density of RDF/SRF (CV/bulk density) is generally significantlylower than coal so will require largervolumetricfeedratestosupplythekilnenergydemand.Thiswillinturnhaveaknock-on effect on the size of storageand conveying systems as well as theburneritself.

2. MoistureContent–aswellasaffectingtheCV, themoisturecontentwillhaveamajor effect on the reliability of thehandlingequipmentaswellasmoisturecontrol within the mill and emissionstreatment systems. Wet, sticky, low-quality RDF with poor particle sizecontrolisparticularlypronetostickingandbridging.

3. AshContent– in cementplants this isnot generally as significant as someother applications, since the ash can normally be safely contained in theclinker without compromising quality.However it is still generally wise toavoidfuelswithexcessiveashcontent.

4. Sulphur Content – the sulphurcontent of RDF/SRF will generally besignificantly lower than coal. This canhave a beneficial effect on flue gasdesulphurisation systems and theemissionofoxidesofSulphur.

5. Nitrogen Content –the nitrogencontent of RDF/SRF will generally beslightlylowerthancoal.Thiscanhavea

beneficial effectonSCR/SNCR systemsandNOxemissions.

6. Chlorine Content –the chlorinecontent of RDF/SRF will generally besignificantlyhigher than coal.This canhave a negative effect on corrosionanddioxinformationwithinthekilnsogenerally requires monitoring. This iscurrently a topic of some attention inthe RDF/SRF production industrywithstudies of the origin of the chlorine and how it can be controlled. At presentmuchworkisfocussingonPVC(whichcanberemovedbyoptical sorter)andsodium chloride (salt) in the organicfractionoftherefuse.

7. HeavyMetalContent–theheavymetalcontentofRDF/SRFvaries significantlybutisgenerallyslightlyhigherthancoal.As with the chlorine there is currentinvestigation on how to reduce heavymetalcontentwhichismovingtowardsfeed policing, in particular removalof waste electronics and electricalequipment (WEEE),andefficientmetalremovalbyoverbandmagnets,opticalsorters and more modern technologysuch as induction sorters, X-Ray andlasertechnology.

In addition to the average values of the above parameters it is important toconsiderthevariation.Successfulcementkiln operation requires a consistent fuel,which can be an issue with some RDF,particularly from lower end processes.Blending of RDF/SRF with coal will alsohelpimproveconsistency.

As can be inferred from the abovediscussion, higher end production technologywillgenerallyproduceamoreconsistent, cleaner, higher CV fuel, albeit at


ahigher investment.Howeverconverselyit will generally reduce the investmentrequiredinthecementplantfuelhandlingsystems, burners and emissions controlsystems. To optimise the overall balanceof benefits to expenditure for RDFproduction for cement plants in Indiait will be necessary to carry out a localaudit of the available refuse, locations, markets and transport networks, as wellas the cement plants themselves. Thisexpertise is typically best provided by a single consultant company that hasknowledge of all aspects of the RDFprocess, from collection and processingtofinaluseinthecementplant.Theywillbe able to ensure that the entire process from RDF production, transport to andstorage at the cement plant, handlingand introductionto the cement kilns isintegrated and considered holistically.Likewise, when considering all that hasbeen discussed above, an integrated RDF production facility,potentially including an anaerobic digestion facility, nearby to thecementplantcanbeseenasanidealscenario. Although this would require asignificantinvestmentitwillmaximisethebenefitsandthesecurityofproduction.

Orchid Environmentalwas established in2003 by Fairport Engineering to developRDF production technology, as part of thecompetitionby theUKGovernment’sDepartment of the Environment, Food,andRuralAffairs (DEFRA).TheirRecyclingand Recovery Centre (RRC) at Liverpool,UK successfully produced RDF for usein cement plants for several years. Withsteady plant operation and qualitycontrol the RDF achieved the necessary standardandconsistency tobeclassifiedasthehigherqualitySRFaccordingtotheEuropeanStandard.KeytothissuccesswastheparentcompanyFairportEngineeringhavingover30yearsofexperienceinthebulkmaterialshandlingindustryincludingspecific experience working on the AFhandling systems at a number of UKcementplants.

The Orchid process includes all of the processing stages described in the

previous section and as such represents a state-of-the-art SRF production facility.The mass balance (based on UK waste)from theOrchidprocess is shownbelow.With60%recoveryofSRF,22%evaporatedmoisture, and in total 13.4% of value-added products (metals, plastic andaggregate), only 4.5% of the incomingrefuse remained as residual materialrequiringdisposaltolandfill.

One key aspect of the Orchid technologyis the patented thermal process drum,as shown in the photo below.Whilst themajority of the process equipment isrelativelystandardandcanbesourcedfromavarietyofreputablesuppliers,thethermalprocessingisuniquetotheOrchidprocess.AlthoughsomesimilarequipmenthasbeenusedinRDFproduction,themajorityofRDFproductionfacilitiesdonotemploythermalprocessing. This means that the RDF andvalue-added products are generally lowerquality.Asmentionedpreviously,moisturecontent of the RDF in particular can lead to handlingproblemsatthecementplantandwillcertainlyresultinalowerCV.

The low carbon fuel produced by theOrchidprocessisshowninthephotobelow.With moisture content typically around16.5% it is suitable for mechanical andpneumatic conveying, and consistentlysized to avoid burner blockages. Withlow organic, metals, glass and ceramicscontent, abrasion and corrosion are significantlyreduced.ExperienceintheUKhas demonstrated that compromises onRDFqualitywill almost inevitably lead toproblems at the cement plant. By takingdirectcontrolofRDFproduction,cementcompanies can ensure that they get thequalityfuelthattheyneed.

In conclusion, RDF/SRF is not the onlyAF available but in the long-term maybe the most easy to obtain in sufficientquantities to make a major impact onthe considerable energy requirements ofthe Indiancement industry.Furthermore,the benefits of diversion of refuse fromlandfillandburningmustbefactoredintothe overall impact assessment. Cementplants should incorporate introduction of AFintotheiroperationalandmaintenancestrategy at the earliest opportunity and could also benefit from taking controlfurtherbackdowntheAFsupplychaintoimprove fuelsecurityandqualitycontrol.Grants from the World Business Councilfor Sustainable Development may beavailable to contribute towards the upfront costs of AF implementation, andfurthermore the Perform Achieve andTradeschemewillrecompensebusinessesthat successfully substitute fossil fuels with AF, on their future fuel bills and onan ongoing basis. The equipment andknowhow required to implement allstages of this process is well-establishedand ready to bring to India, however aresponsible consultant, (such as Fairport Engineering Ltd) should be broughton board to consider all relevant local factors before deciding on the specifictechnology tobe introduced. In thiswayIndiancementplantscanensurethattheyimplement the solution that is best forthemandmaximisetheprovenbenefitsoffossilfuelsubstitutionforAF.


DaKShaTA- Database for Knowledge Sharing on Technological Advancements

Institute for IndustrialProductivity (IIP))amobile application DaKShaTA- Databasefor Knowledge Sharing on TechnologicalAdvancements, which is a one stoprepository of all the information needsof the industry such as technological advancements in different processesand applications, their performance ondifferent parameters and other relevantinformation such as benchmarks,internationalstandardsetc.

Mr. Abhay Bakre, Director General,Bureau of Energy Efficiency, released the mobile application DaKShaTA on8th March, 2018 at the 2nd ‘NationalWorkshopcumTechnologyExhibition forPromoting Energy Efficient and CleanerProduction’.DaKSHaTAisanappthataimsto help industry identify technologies and measures for enhancing energyefficiency, improving productivity andreducing CO2 emissions, while assessingthecost-effectivenessofenergyefficiencyinvestmentoptions.

It is estimated that energy efficiency inthe industrial sector can be improvedtremendouslythroughadoptionofprovenand commercially available technologies.However,industryleadersoftencite(i)thelackofinformationonrelevantoptionsandbenchmarks,and(ii)difficultiesinbuildinga clear-cut financial case for energyefficiency investments, as the two mainbarriers to adoption of energy efficiency technologiesandmeasures.Thisdatabaseaims to help decisionmakers realise thispotential by providing comprehensiveand easily accessible information thatcan help in overcoming information andfinancialbarriers.

DaKShaTA app provides a dashboardapproach to guide the industry to the right technology, data, information andexpertsfortheirneeds.Theappcurrentlycovers informationonthecementsector,

(i) Technologies & Resources

(a) Cement Technologies

Technologies cover technical and/oroperational practices that can be used to improve productivity and reduce energyconsumptionandemissions.Awiderangeofoptionsareincludedsuchas:

• Operational practices, that can beimplemented without any majorchanges in the physical setting of the plant;

• Retrofit components or systems referto technical elements that are addedto the existing plant infrastructure to enableanimprovement;

• New equipment or system refers tosubstitutionofoneormoreequipmentusedwithinaprocess

• Materialsubstitutionincludespartialorcomplete substitution of conventionalinputs with better performingalternatives

• New processes includes a new set oftechnologies/activities the output ofwhich is either the same as, or canbe a substitute to, the output of an incumbentprocess.

For each technology/measure, thefollowingtypesofinformationisprovided:

Technology/Measures Description

This is a description of the key anddistinct characteristics of the technology ormeasure thatcanhelp reduceenergyconsumption and CO2 emissions. Co-benefits or non-energy benefits, suchas enhanced productivity, reduced maintenance costs, improved productquality, and reduced environmentalimpact offered by the technologyor measure are also included in thedescription,wheneverpossible.

which has been primarily compiled fromawidearrayofpubliclyavailable sourcesand published literature. In some cases,this information is supplemented by theknowledge and opinions of IIP’s expertnetwork.

The app contains sector-specificinformation, which includes anintroduction to the most relevantcharacteristics of the sector including its size, its importanceintermsof itsenergyconsumption and GHG emissions, aswell as estimated potential for technicalimprovements for improved energy andcarbon efficiency. A typical flowdiagramwith the main production processes isdesigned to allow users quickly accesssome of the information, as well asunderstandmajorindustrialprocessesfornon-technicalexperts.

Theinformationundertheappisclassifiedundersixkeytabsasfollowing:


Energy Savings

Informationisprovidedonthereductionsin different forms of energy use (e.g.electricity,heat,fuel)thatcanbeenabledbythetechnologyormeasure.Thesevaluesareprimarily extracted from literatre andareoftenreported in the formofspecificenergy savings – such as GJ/t-clinker orkWh/t-hot metal. In some cases, savingpotentialsarealsoreportedascumulativeannualsavingsachievedinaplantwithaparticular size or as the total saving that can be achieved with the application ofthis technology at different scales (e.g.national or global). In order to maintainconsistency and allow comparisons, unitconversionsareperformedon thevaluesreportedintheliterature.

CO2 Reductions

Inthissectioninformationonthepotentialreductions in CO2 emissions that can beachieved with the implementation ofthe technology or measure is provided.In the majority of the cases, these arefigureshavebeenextracted fromvariousliterature sources. In a limited numberof cases, CO2 reduction potentials are calculated based on the energy saving

potentialsandcountryandsectorspecificemission factors are reported. As theCO2 emissions may differ depending onthecontext specific factors– suchas thecharacteristicsofdominant rawmaterialsand fuels and prevailing electricity supply systemchacteristics–wheneverpossible,the country for which the CO2 saving potentials are realized/estimated is alsoreported.

Costs

In this section, available information ontheimplementationandoperationalcostsofthetechnologyormeasureisreported.Wheneverpossible,additionalinformationoncostsavings,paybacktimes,andotherfinancial indicators such as internal rateof return (IRR) or Return on Investment(RoI) are also included. In the majorityof the cases, these figures are reportedas they appear in literature, without anyfurther processing (other than basic unit conversion).

It should be noted that technology/measure specific information is offeredasguidance.Gainsandcosts that canberealized in individual sites will requiresite-specific assessments. It should also

be noted that a large majority of thetechnologies/measures included in thedatabase will also enable facilities torealize additional co-benefits or non-energybenefitssuchasimprovedproductquality, enhanced productivity, reducedinput and maintenance costs. Thesebenefitsarenotquantified in thecurrentversion of the database but instead mentionedqualitatively.

(b) Processes

Processes are a distinct set of activities necessary for the production of an intermediate or final product, or inputsintoanotherprocess.Abriefdescriptionofthemainprocessescommonlyusedinthesectorisprovided.

(c) Products, Publications and Tools

A wide range of resources that providefurther information on the technology/measureisprovidedinthedatabase.Theseinclude reports, guidelines, standards, reference documents, peer reviewedpublications, websites, presentations,animations, case studies and companyexperiences.


(ii) Key Data Detailed data is presented on areas such as trends and current levels of production, thesector’spositionintheoverallindustrialenergy use and CO2 emissions, energysavingsandGHGmitigationpotential,andkeycountriesand/orplayersinthesector.

(iii)Benchmarks

Benchmarks include information onbest performance levels reported in theliterature, broken to the level of mainprocessesemployedwithinasector.

(iv) OrganizationsIn the organizations section, informationis provided on the main organizations,whose work and/or objectives focus

on improving energy efficiency and

productivity in the sectors and areas

coveredinthisdatabase.Herebothglobal

andnationalorganizationsandprograms

are included

(v) Programs

In the programs section, major global

programsandschemeswiththeobjective

of improving energy efficiency and

productivity in the sectors have been

covered.

(vi) Service Providers

This section provides the list of service

providers listed with Bureau of Energy

Efficiency for the Sector

Currentlythedatabasecoversinformationonthecementsectorbutweshortlyplanto includeother sectors.The informationcontained in the database is primarilycompiled from a wide array of publiclyavailablesourcesandpublishedliterature.

This database is an initial step towardscreating a platform for easy accessto relevant and reliable information.Currently this app is available on android operatingsystemandhasbeendevelopedfortheCementsector,butthereisaplanto extend it for other industry sectors and iOSplatforminduecourse.

The App can be downloaded fromGoogle Play store by following the link:https://play.google.com/store/apps/details?id=com.iipnet


KNOWLEDGE ExCHANGE PLATFORMHighlights of the 2nd National Workshop cum Technology Workshop

The 2nd ‘National Workshop cumTechnology Exhibition for PromotingEnergy Efficient and Cleaner Production for Sustainable Industrial Growth’ wasorganized by Knowledge ExchangePlatform (KEP) initiative on 8th and 9thMarch, 2018 at India Habitat Centre, NewDelhi. This workshop is second in seriesto be organized under the KnowledgeExchange Platform (KEP) initiative (http://knowledgeplatform.in/events/cross-sectoral-workshop-cum-exhibition/),for promoting cross-sectoral exchangeof best practices, technologies and approaches on energy efficiency in the industries coveredunder thePAT scheme.This event was organized with a focuson creating awareness, building capacityand to facilitate access of the industry to reliable and efficient technologies, service providers and financing opportunities forenhancing energy efficiency in the industry and the building sectors. The theme andobjectiveofthisworkshopcumtechnologyexhibition was particularly important forthe industries covered under the 2nd and 3rdPATcycleaswellasthoseproposedtobe covered in future PAT cycles with thefollowingspecificobjectives:

• Catalyse cross sectoral exchange of best practices, tools, techniques and experiences in energy managementpractices/approachesalongwith theirimpact that have high possibility ofreplicationacrosssectors.

• Create exposure to nationally andinternationally available innovative

and cutting edge technologies and practices that can support industry in meeting the future energy efficiencytargets.

• Facilitate Technology transfer and B2B interaction with technologysuppliers to assess their applicability, cost and performance parameters intheIndiancontext.

• Creating awareness on the provisions of PATtohelptheindustryinmeetingtherequirementsunderthescheme.

• Creating awareness about the new financing and business models for promotingenergyefficiency.

The workshop was inaugurated by Mr. Abhay Bakre, Director General, Bureau of Energy Efficiency. In his inauguraladdress,hementionedthatheisenthusedwith the proactive participation of theindustry in the event and also felt that an initiative like KEP can help the industryimprovetheirperformanceonacontinuousbasis which was particularly importantundertherollingcycleofPAT.HesaidthatitwasgoodtonotethatKEPhasbeenableto catalyse the transfer of best practices and technologies within and across theindustry sector. Cross-sectoral knowledgetransfer and peer-to-peer learning has beenhighonBEE’sagendaandhehopedthat KEP would continue to leverage theplatform to promote exchange of bestpractices and enhance access of Indian industrytonationalaswellasinternationalbest practices and technologies. He

mentionedthatBEEiscurrentlyorganizingtechnicalcommitteemeetingsfordifferentPAT sectors and he would encourage theindustry participants to provide their input toBEEsothatthecommitteecancomeupwith robust target setting, nomalisationandM&Vparameters.

Mr. Abhay Bakre, Director General, Bureau of Energy Efficiency, also released the mobile application DaKShaTA, whichis a Database for Knowledge Sharing onTechnologicalAdvancements.DaKSHaTAisanapp(availableongoogleplaystore)thataimstohelpindustryidentifytechnologiesand measures for enhancing energyefficiency, improving productivity andreducing CO2 emissions, while assessingthecost-effectivenessofenergyefficiencyinvestment options. Currently this app isavailableonandroidoperatingsystemandhasbeendevelopedfortheCementsector,but there is a plan to extend it for other industry sectors and iOS platform in duecourse.

Welcome address and introduction totheworkshopwasgivenbyMr. Somnath Bhattacharjee, Director, Institute for Industrial Productivity. He mentionedthat KEP has always endeavored tocome up with new and innovativesolutions and technology features to remain responsive to industry’s needsparticularly as new challenges and issuesare emerging under the rolling cycle ofPAT.Mr. Harish Chatterjee, Vice President (Manufacturing), Raymond Limited, delivered the Special Address at the

Mr. Abhay Bakre, Director General, Bureau of Energy Efficiency delivering his inaugural address

Hon’ble Chief Guest, Mr. Abhay Bakre, Director General, Bureau of Energy Efficiency and other dignitaries inaugurating the Technology & Poster Exhibition


inaugural ceremony. He mentioned thatwith an increasing role of Indian Industryintheglobalmarket,itwasimportantthatthe industries adopted the best available global technologies and standards to enhancetheircompetivenessandplatformlike KEP can help industries achieve this.Mr. S.K. Wali, Whole Time Director, J K Lakshmi Cement Limited, delivered the SpecialAddressattheinauguralceremony.Hementioned that the onlyway forwardfortheIndianIndustrywastoadoptamoreenergy efficient and sustainable pathwaytoremaincompetitiveintheglobalmarket.Healsosaidthatthere isnosuchconceptasrockbottomwhenitcomestoimprovingenergy performance in an industry andcorroborated his statement by givingexampleoftheCementindustrywherehementionedthatadecadeago,thecurrentlevel of energy performance (SEC) of thecement industrywasunthinkable,but theindustry made it happen. He mentionedthat the Industry needs to continue with

this drive and explore new options forenhancing their energy productivity and resourceconservation.

Special address was delivered by Ms. Sandy Sheard, Counsellor for Energy, Climate & Growth Unit, British High Commission (BHC). She mentioned thatthe UK Government supports IndianGovernment’sactionsforenhancingenergyefficiency through initiatives like PAT andfeel that knowledge sharing andUK-Indiatechnology/bestpracticetransfercanplayamajorroleinpromotingthisagenda.Shementioned that the UK Government haslaunched industrial de-carbonization and energy efficiency action plans setting out Government and Industry commitmentsto reduce GHG emissions and improveenergy efficiency. The action plans underthisinitiativearetheresultofjointworkingbetween Government and Industry toidentify voluntary commitments from allpartiestoenabledifferentindustrysectors

decarbonizetill2050.ShementionedthatBHCwouldcontinuetoworkalongsideBEEto enhance energy efficiency of the Indian Industry in line with their mandate forpromotingenergysecurity.

The Technology and Poster Exhibition was inaugurated by the Hon’ble Chief Guest, Mr. Abhay Bakre, Director General, Bureau of Energy Efficiency.Thetechnology exhibition had participation fromARMECCoolingTowerPrivateLimited,Arvind Envisol Private Limited, ArvindLimited,AtlasCopco(India)Limited,BristolBlueGreen Ltd, Delta Power Solutions(India) Pvt Ltd., Energy Efficiency ServicesLimited, IKN Engineering India Pvt Ltd,InvotechSolutionsandSystems,JKLakshmiCement Limited, Mechwell Industries Ltd,Power Star, Raymond Limited and SEaBEnergy.ThePosterexhibitionshowcased40posters that represented the best practice examplesandtechnologies.Thisexhibitionprovided an exposure to the participants

Dr. Anupam Agnihotri with the panelists of first technical session

Mr. K K Chakarvarti with the panelists of third technical session

Mr. Paul Silcock with the panelists of second technical session

Mr. K N Rao with the panelists of fourth technical session (Part 1)


onthenewtechnologiesandpracticesandtheirimpactsintheformofpayback,energysavings,resourceconservationbenefitsetc.

The inaugural event was followed bythreetechnicalsessions.Thefirsttechnicalsession was chaired by Dr. Anupam Agnihotri, Director, Jawaharlal Nehru Aluminium Research Development and Design Centre.Thediscussion in thesession focused on achievements andlearnings from PAT Cycle 1 and creatingopportunity for energy efficient industrial growth under the 2nd and 3rd PAT cycle.Dr Ashok Kumar, Director, Bureau of Energy Efficiency, in his presentation mentioned about India’s commitmentunderNDCsistoreduceemissionintensityby33-35%by2030comparedto2005levelandPATschemeisexpectedtocontributea substantial proportion of this target.While explaining, why it is important forIndian Industries to adopt energy efficient practices/technologies, he also presented

the benefits and the impact achievedunder the1st PATCycle.Thepresentationby Ms. Ritu Bharadwaj, Chief of Program, Institute for Industrial Productivity, focusedontheactions takenso farunderKEP and plans for enhancing the scopeandeffectivenessofKEP tobecomemoreresponsive to industry needs particularly as theyaremovingintosubsequentcyclesofPAT.

Thesecond technical sessionwas focusedon Scope of International Technology Transfer to facilitate Industry in achieving PAT Targets, which was chaired by Mr. Paul Silcock, Chief Technical Officer, Bristol BlueGreen Limited. This sessionwas planned in amanner that it broughttogether the international technology providers and industry representatives with a view to promote interactionsbetween the two stakeholder groupsthat can help in facilitating adoption of cleaner technologies. The session had

presentations on technologies available for variousoperatingareasviz.electricalsavingthrough voltage management, solutionsto improve upon energy efficiency incompressed air system by Atlas Copco,Flexibuster™ technology that turns organic wasteintoenergyexactlyatthepointwherethe waste is produced and the energy isrequiredbySEaBEnergyLimited,enhancedWaste Heat Recovery (WHR) generationfrom IKNCooler by IKN Engineering IndiaPrivateLimitedandopportunitiesofsavingenergy via Automatic voltage controller/optimisationsystembyPowerStar.

ThethirdtechnicalsessionwasfocusedonSmallGroupActivity(SGA),whichisanin-house approach to achieving Continuous EnergyEfficiencyImprovement,whichwaschaired by Mr. K. K. Chakarvarti, Expert Consultant & Senior Advisor- KEP. Theindustries that shared their experience in this session included JK Lakshmi CementLimited, Sirohi&Durg plant, Vedanta

Mr. K N Rao with the panelists of fourth technical session (Part 2)

Dr. Ashwani Pahuja with the panelists of fifth technical session (Part2)

Mr. Harish Chatterjee with the panelists of fifth technical session (Part 1)

Mr. S. P. Garnaik with the panelists of sixth technical session (Part 1)


Limited,ArvindLimited,RaymondLimited,My Home Industries Private Limited andDalmiaCement(Bharat)Limited.

The secondday of theworkshop focusedon exchanging the best practices adopted to enhance the energy efficiency index in electrical and thermal utilities andtechnology solutions to enhance the energy efficiency index by technology suppliers. The fourth technical sessionwas focused on sharing of best practicesin energy efficiency in electrical utilities.ThissessionwaschairedbyMr. K. N. Rao, Director (Energy & Environment), ACC Limited andhadpresentationsfromEnergyEfficiency Services Limited, UltraTechCement Limited Unit - Rawan CementWorks,ACCLimited,ArvindLimited,NabhaPower Limited, Raymond Limited andBhushanSteelLimited

The fifth technical session (Part 1) wasfocused on technology Solutions to enhance the energy efficiency index in process and thermal utility, was chairedby Mr. Harish Chatterjee, Vice President (Manufacturing), Raymond Limited.The session had presentations on technologies available for various process areas viz.applications of ComputationalFluid Dynamics (CFD) and heat pumpsin industries by Mechwell IndustriesLimited, energy efficient cooling systembyArmecCoolingTowers,energyefficientevaporation technology by Arvind Envisol Limited, energy savings that canbe achieved through false air reduction by Invotech Solutions and Systems and

enhancing the power quality by DeltaPower Solutions (India) Private Limited.The Part 2 of this sessionwas chaired byDr. Ashwani Pahuja,Executive Director, Dalmia Cement (Bharat) Limited. Thissession had presentations on electrifying power generation solutions by GE Power,efficient steam utilization systems in Pulp& Paperindustry by Central Pulp & PaperResearch Institute (CPPRI) and Spent PotLiner (SPL) utilization in cement & steelindustrybyVedantaLimited.

The sixth technical session was focusedon best practices in energy efficiency in thermal utilities, process & crosssectoral application, was chairedby Mr. S.P. Garnaik, Chief General Manager, Energy Efficiency Services Limited. The session had presentationson Technological interventions in lowtemperature heating and cooling by SEE-TechSolutions,benchmarkingtoaccelerateenergy efficiency in cement, thermalpower plant and pulp & paper industryby Confederation of Indian Industry (CII)and energy efficiency opportunities in dairy industry by Umang Dairies Limited,best practices pertaining to cross –sectorapplication by Seshasayee Paper and Boards Limited, alternate operation ofaerators fans in sewage and effluentplants by Ankur Textiles, A Division ofArvind Limited and energy conservationmeasures in refineryandprocess industrybyEngineersIndiaLimited(EIL).

The technical sessionswas followedbyaConcluding session which was presided

over Mr. Pankaj Kumar, Secretary, Bureau of Energy Efficiency. HementionedthatBEEhas initiatedtheKEPprogramwiththeviewtopromoteenergyefficiency and energy managementsystems approach asmeansof achievingcontinuous improvement in energyperformance of the industry sector inpartnership with IIP. Given the successof the initiative so far, BEE has recently extendeditsMoUwithIIP.HementionedthatBEEthroughthePATschemeaimstoenhance productivity and also contribute to India’s Nationally DeterminedContributions(NDCs)

The two day workshop had participationfrom over 280 distinguished speakers,eminentindustryleaders,representativesofaluminium,automobile,cement,chemical,chlor-alkali,dairy,DISCOMsfertilizer,glass,hospital, hotels, pulp&paper,iron& steel,ordnance factory, railway, refinery,sugar,textile, thermal power sectors, energyauditors and energy managers,Government agencies, State DesignatedAgencies, Industry associations, technology and service providers, and senior Industry professionals amongst many others.Various industries and organizations fromUnited Kingdom(UK) also participated inthe event, viz. British Electrotechnical andAlliedManufacturersAssociation(BEAMA),BristolBlueGreenLimited,Uniper,OrxaGrid,KiggLimited,Depatment for InternationalTrade-UK,BritishHighCommission,PowerStar, SeAB Energy, Clarke Energy and UKIndiaBusinessCouncil.

Mr. S. P. Garnaik with the panelists of sixth technical session (Part 2) Mr. Pankaj Kumar, Secretary, Bureau of Energy Efficiency, delivering his concluding remarks


Participants at the 2nd ‘National Workshop cum Technology Exhibition for Promoting Energy Efficient and Cleaner Production for Sustainable Industrial Growth’

Awards for Outstanding ContributionTheworkshop also recognized the contribution of the participating speakers, technology exhibition andposter exhibition throughanawardceremony.Theawardstothetechnology&posterexhibitionweregivenbasedonthefeedbackof theparticipants.A jurycomprisingofseniorindustryrepresentativeswasformedtoadjudgethespeakersoftechnicalsessions.Theceremonyalsorecognizedthecontributionof theSmallGroupActivity teammembers for theirefforts towardsenhancing the IndustrialEnergyEfficiency.Thewinnersunderthesecategoriesareasfollows:

Technology Exhibition: 1st Prize- JK Lakshmi Cement Limited

Technology Exhibition: 2nd Prize- Delta Power Solutions

Technology Exhibition: 2nd Prize- Atlas Copco (India) Limited

Technology Exhibition


Comments and feedback welcome: KnowledgeExchangePlatformSecretariatBureauofEnergyEfficiency,SewaBhawan,R.K.Puram,Sector-1NewDelhi-110066| E-mail: [email protected];[email protected],pleasevisitusat:www.knowledgeplatform.in

Disclaimer: None of the parties involved in the development and production of this Newsletter assume any responsibility, makes any warranty, or assume any legal liability for the accuracy, completeness, or usefulness of any information contained in this Newsletter. This Newsletter and the information contained therein, cannot be reproduced in part or full without the written permission of the KEP Secretariat.

Technology Exhibition: 3rd Prize - Raymond Limited Technology Exhibition - In recognition of valuable contribution - ARMEC Cooling Tower

Speaker: In recognition of valuable contribution - Dr. T.G.Sundararaman, General Manager, Seshasayee

Paper and Boards Limited

Speaker: 1st Prize - Mr. S.P.Garnaik, Chief General Manager, Energy Efficiency

Services Limited

Poster Exhibition: 1st Prize - Bharat Aluminium Company Limited

Poster Exhibition: 3rd Prize - Electrotherm India Limited

Upcoming Entrepreneur in the field of Energy Efficiency- Invotech Solutions & Systems

Speaker: 2nd Prize - Mr. Deepak Kumar, Senior Engineer, UltraTech Cement Limited

Unit - Rawan Cement Works

Poster Exhibition: 2nd Prize - Arvind Limited

Speaker: 2nd Prize - Mr. Paul Silcock, Chief Technical Officer,

Bristol BlueGreen Limited

Speaker: 3rd Prize - Mr. Sandeep Bhalla, Vice-President (Works), Umang Dairies Limited

Speaker: In recognition of valuable contribution- Mr. S.C. Gupta, General Manager (R & D Division),

Engineers India Limited (EIL)

Speaker: In recognition of valuable contribution - Mr. Milind Chittawar, CEO, SEE-Tech Solutions

Poster Exhibition Upcoming Entrepreneur in the field of Energy Efficiency

Speaker

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