Samit Jain - Advit Foundation

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Samit Jain - Advit Foundation

  1. 1. Panipat Textile Cluster & CDM opportunities CleanTech Conclave 24 th April 2010
  2. 2. Background <ul><ul><li>Willingness of association to be project proponent. </li></ul></ul><ul><ul><li>Individual unit’s interest in implementation of EE measures and their financial capability </li></ul></ul><ul><ul><li>Availability of proven technology </li></ul></ul><ul><ul><li>Total investment required </li></ul></ul><ul><ul><li>GHG reduction potential </li></ul></ul><ul><ul><li>Level of technology dissemination required </li></ul></ul><ul><ul><li>Earlier initiatives (if any) </li></ul></ul><ul><ul><li>Potential for introducing renewable energy & reducing conventional energy usage </li></ul></ul><ul><ul><li>Barriers for implementing & monitoring </li></ul></ul>
  3. 3. Objectives <ul><li>To develop program of CDM activities in Panipat Textile Mills Cluster so to help SME’s in reducing their energy consumption </li></ul><ul><li>Thus ensuring flow of carbon credits revenue and thereby helping SME’s in reducing their financial burden in implementing modern energy efficient, and renewable energy technologies </li></ul>
  4. 4. Methodology <ul><li>Visit to select industries in cluster for: </li></ul><ul><ul><li>Walk through audit; </li></ul></ul><ul><ul><li>Data collection on specific industry; </li></ul></ul><ul><ul><li>Number of similar industries & their respective capacities in the cluster; </li></ul></ul><ul><ul><li>Technologies & processes in use; </li></ul></ul><ul><ul><li>Opportunities available for introducing renewable energy technologies; </li></ul></ul><ul><ul><li>Energy forms used, quantum of energy use; and </li></ul></ul><ul><ul><li>Sources of Energy wastage . </li></ul></ul>
  5. 5. Methodology (contd.) <ul><li>Discussions with industry & association representatives to assess: </li></ul><ul><ul><li>Commitment to invest; </li></ul></ul><ul><ul><li>Interest in CDM activity; and </li></ul></ul><ul><ul><li>Ownership for bundled projects. </li></ul></ul>
  6. 6. Progress achieved <ul><li>Initially for the data collection, a draft questionnaire was prepared and piloted the same in couple of units. </li></ul><ul><li>Based on the inputs from these pilots, a revised questionnaire was finalized and sent to 350 Textile Industries through the Pollution Control Board (PCB). </li></ul><ul><li>This apart, 471 industries list available with Haryana Chamber of Commerce has also been approached through mailing questionnaire </li></ul><ul><li>The questionnaire focuses on electrical energy consumption, steam raising facilities and fuel consumption data specific to each of the industries. </li></ul>
  7. 7. Progress achieved <ul><li>Collected data through site visits and compiled cluster wide data </li></ul><ul><li>Using multi-criteria analysis selected 25 units for Detailed Energy Audits </li></ul><ul><li>Conducted Energy Audits in 25 industries </li></ul><ul><li>Analysed the data, identified opportunities and given reports to respective industries for inputs and way forward </li></ul><ul><li>Planned & organizing Stakeholder Workshop for dissemination </li></ul><ul><li>Planning for preparing PoA CDM PDD </li></ul>Contd..
  8. 8. LIST OF INDUSTRIES – ENERGY AUDITS CONDUCTED <ul><ul><li>TEXTILE DYEING UNITS 10 </li></ul></ul><ul><ul><li>PRINTING 2 </li></ul></ul><ul><ul><li>FINISHING 2 </li></ul></ul><ul><ul><li>SPINNING AND DYEING 7 </li></ul></ul><ul><ul><li>INTEGRATED 4 </li></ul></ul>
  9. 9. Energy audits conducted in the following industries <ul><li>Integrated Units </li></ul><ul><li>Pan Overseas </li></ul><ul><li>Mahajan Overseas </li></ul><ul><li>Shiv Shakti Exports </li></ul><ul><li>Luxmi Overseas </li></ul><ul><li>Dyeing Units </li></ul><ul><li>Triveni Industries </li></ul><ul><li>Sainik Industries </li></ul><ul><li>Shakti Om Processors </li></ul><ul><li>Pee Kay Industries </li></ul>
  10. 10. Dyeing Units <ul><li>Shree Industries </li></ul><ul><li>Rainbow Dye House </li></ul><ul><li>Krishna Processors </li></ul><ul><li>Shiva Textiles </li></ul><ul><li>Welworth House </li></ul><ul><li>Lovely Udyog </li></ul><ul><li>Spinning Industries </li></ul><ul><li>Wooltex </li></ul><ul><li>Gian Spinning Mills </li></ul><ul><li>Sai Ram Spinners </li></ul><ul><li>Gaurav Woolen Mills </li></ul><ul><li>Jyoti Spinners </li></ul><ul><li>Swatik Udyog </li></ul><ul><li>Sajdeh Processors Pvt. Ltd </li></ul>
  11. 11. <ul><li>Finishing Industries </li></ul><ul><li>National Woollen & Finishers </li></ul><ul><li>Ess Kay Finishers </li></ul><ul><li>Printing Industries </li></ul><ul><li>Raghav Prints </li></ul><ul><li>Unique Prints. </li></ul>
  12. 12. FINDINGS FROM CLUSTER VISITS
  13. 13. Potential Areas for reducing energy consumption <ul><li>Major energy forms used in the clusters are: electricity, Coal, Wood chips, Pet coke, Diesel oil etc; </li></ul><ul><li>Technologies & processes used are obsolete, energy in-efficient & pollution prone ; </li></ul><ul><li> Potential Areas for reducing electricity consumption </li></ul><ul><ul><li>Installation of VFDs for blowers, pumps & compressors </li></ul></ul><ul><ul><li>Improving power factor for reducing distribution losses </li></ul></ul><ul><ul><li>Replacing old/inefficient blowers, pumps and motors </li></ul></ul><ul><ul><li>Installing energy savers </li></ul></ul><ul><ul><li>Installing new energy efficient lighting devices. </li></ul></ul><ul><li>Potential for use of renewable energy exists . </li></ul>
  14. 14. <ul><li>Potential areas for reducing fuel consumption </li></ul><ul><ul><li>Improving condensate recovery </li></ul></ul><ul><ul><li>Waste Heat Recovery form processes </li></ul></ul><ul><ul><li>Waste Heat Recovery from blow down steam </li></ul></ul><ul><ul><li>Generation of low pressure steam by flash vessels </li></ul></ul><ul><ul><li>Monitoring of air fuel ratio for reducing flue gas losses </li></ul></ul><ul><ul><li>Efficient management of steam distribution systems </li></ul></ul><ul><ul><li>Automation & Temperature Controls </li></ul></ul><ul><ul><li>Fuel switching from fossil fuels to biomass fuels </li></ul></ul>
  15. 15. Conclusions <ul><li>CDM Opportunities Available </li></ul><ul><ul><li>Installation of solar energy for thermal use, </li></ul></ul><ul><ul><li>Fuel switch in boilers from fossil fuel to biomass, </li></ul></ul><ul><ul><li>Energy efficiency measures (waste heat recovery); </li></ul></ul><ul><ul><li>Reduction in steam consumption; </li></ul></ul><ul><li>Estimated GHG reductions potential in the cluster is 200,000 CERs. </li></ul>
  16. 16. Conclusions <ul><li>Ball park estimates suggested the following: </li></ul><ul><ul><li>Investments required - ~ INR 75 crores </li></ul></ul><ul><ul><li>Revenue earning from CER - ~INR 14.3 crores </li></ul></ul><ul><li>Associations Credibility – Strong Association, interested in CDM projects, willing to take ownership as project proponent. </li></ul>
  17. 17. Investment Grade Energy Audits 5 Apparel Units In National Capital Region
  18. 18. Unit A - Baseline 2009 Connected Maximum Demand (KVA) Annual Power Consumption (KWH) Annual Diesel Consumption (Ltrs.) Annual Power Bill (Rs.) Annual Energy Bill (Rs.Lakhs) Annual Energy + Power Bill (Rs.Lakhs) 499 536733 71784 22.67 23.69 46.36
  19. 19. Improvements & Investment payback period Energy Conservation Measures(ECM) Description / Sector Total Annual savings expected (kWh) Total Annual savings expected (Rs. In lakhs) Total Investment (Rs. in Lakhs) Simple Payback period in Months Tubelights replaced by high lumen o/p LED lights 23440 0.99 1.14 14 Install voltage optimizer in lighting circuits 20258 0.85 2.66 37 Dedicated LED lighting for Sewing m/c 57658 2.43 9.47 47 Solar steam generator to supplement steam generated by diesel fired boiler 31124 (equivalent KWH of diesel) 2.9 12 50 Grand Total 132480 7.17 58.66 37
  20. 20. Unit B - Baseline 2009 Connected Maximum Demand (KVA) Annual Power Consumption (KWH) Annual Diesel Consumption (Ltrs.) Annual Power Bill (Rs.) Annual Energy Bill (Rs.Lakhs) Annual Energy + Power Bill (Rs.Lakhs) 320 501912 246341 25.22 76.37 101.5
  21. 21. Improvements & Investment payback period Energy Conservation Measures(ECM) Description / Sector Total Annual savings expected (kWh) Total Annual savings expected (Rs. In lakhs) Total Investment (Rs. in Lakhs) Simple Payback period in Months Replace existing FTL with energy efficient high lumen output FTL 30234 1.52 1.57 12 Install voltage optimizer in lighting circuits 10767 0.54 1.14 25 Provide dedicated LED lighting for production Sewing m/c 24531 1.23 4.03 39 Solar steam generator to supplement steam generated by diesel fired boiler 236678 (equivalent KWH of diesel) 10.77 35.0 39 Replace conventional regulators with electronic regulators 11333 0.57 1.2 25 Grand Total 313543 14.63 42.84 28
  22. 22. Unit C - Baseline 2009 Connected Maximum Demand (KVA) Annual Power Consumption (KWH) Annual Diesel Consumption (Ltrs.) Annual Power Bill (Rs.) Annual Energy Bill (Rs.Lakhs) Annual Energy + Power Bill (Rs.Lakhs) 427 1065575 113411 49.2 37.4 86.6
  23. 23. Improvements & Investment payback period Energy Conservation Measures(ECM) Description / Sector Total Annual savings expected (kWh) Total Annual savings expected (Rs. In lakhs) Total Investment (Rs. in Lakhs) Simple Payback period in Months Pre heat Fuel oil with boiler exhaust gases 20160 0.93 0.75 10 Replace existing tube lights with high lumens o/p lights 11385 0.53 0.55 13 solar steam generator to supplement diesel fired boiler 212619 19.5 35.0 21 Install voltage optimizer for lighting circuits 10220 0.47 1.33 34 Provide dedicated LED lighting for production Sewing m/c 12580 0.58 2.1 42 Grand Total 266964 14.63 42.84 26
  24. 24. Unit D - Baseline 2009 Connected Maximum Demand (KVA) Annual Power Consumption (KWH) Annual Diesel Consumption (Ltrs.) Annual Power Bill (Rs.) Annual Energy Bill (Rs.Lakhs) Annual Energy + Power Bill (Rs.Lakhs) 405 460195 102255 20.9 33.74 54.64
  25. 25. Improvements & Investment payback period Energy Conservation Measures(ECM) Description / Sector Total Annual savings expected (kWh) Total Annual savings expected (Rs. In lakhs) Total Investment (Rs. in Lakhs) Simple Payback period in Months Arrest waste water 2500 0.12 Nil Immediate Replace heater for hand wash by heat recovery of waste steam 1620 0.07 0.05 8 Replace the existing life max with True light/super life max (NG80) 16102 0.73 0.78 13 Install voltage optimizer in lighting circuits for energy saving 24318 1.11 2.8 31 Install Solar steam generator to supplement steam generated by diesel fired boiler 236677 10.77 35.0 39 Provide dedicated LED lighting for production Sewing m/c 60803 2.77 9.9 44 Grand Total 342020 15.5 48.53 27
  26. 26. Unit E – Baseline 2009 Connected Maximum Demand (KVA) Annual Power Consumption (KWH) Annual Diesel Consumption (Ltrs.) Annual Power Bill (Rs.) Annual Energy Bill (Rs.Lakhs) Annual Energy + Power Bill (Rs.Lakhs) 405 364434 56350 16.49 18.0 34.49
  27. 27. Identified Improvements & Investment payback period Energy Conservation Measures(ECM) Description / Sector Total Annual savings expected (kWh) Total Annual savings expected (Rs. In lakhs) Total Investment (Rs. in Lakhs) Simple Payback period in Months Arrest water wastage 2263 0.1 Nil Immediate Install lighting voltage optimizers 31846 1.44 0.5 4 Install dedicated LED lights for production sewing m/c 47699 2.16 7.84 44 Grand Total 81808 3.7 8.34 24
  28. 28. <ul><li>Thank you! </li></ul>

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