Strategic activities to promote the dissemination of Japanese low … · 2020-02-07 · Strategic activities to promote the dissemination of Japanese low carbon technologies in India

Project code: 2018IE06

Final Report

Strategic activities to promote the

dissemination of Japanese low carbon

technologies in India, in general, and in

Gujarat state, in particular

(FY 2019)

Submitted to

Institute for Global Environmental Strategies

(IGES)

Prepared by

The Energy and Resources Institute

February 2019

© The Energy and Resources Institute 2019

Suggested format for citation

T E R I. 2019 Strategic activities to promote the dissemination of Japanese low

carbon technologies in India (FY 2019)

New Delhi: The Energy and Resources Institute. [Project Report No. 2018IE06]

For more information Project Monitoring Cell

T E R I Tel. 2468 2100 or 2468 2111 Darbari Seth Block E-mail [email protected]

IHC Complex, Lodhi Road Fax 2468 2144 or 2468 2145

New Delhi – 110 003 Web www.teriin.org India India +91 • Delhi (0)11

Contents

1.0 BACKGROUND ............................................................................................................................................... 1

2.0 OBJECTIVE............................................................................................................................................................... 1

3.0 KEY ACTIVITIES IN INDIA ...................................................................................................................................... 1

3.1 Information collection and “on line” sharing ................................................................................................. 1

3.1.1 Website location: http://www.jitmap.org/Japanese-technology.php ....................................... 1

3.1.2 Website location: http://www.jitmap.org/stimulating-policies-Indian-side.php ................... 2

3.1.3 Website location: http://jitmap.org/stimulating-policies-Japanese-side.php ........................... 3

Read more at http://climatepolicydatabase.org/index.php/Country:Japan ..................................... 3

3.1.4 Website location: http://www.jitmap.org/stimulating-financing-programmes-Indian-

side.php ......................................................................................................................................................... 3

3.2 Awareness creation and capacity building ..................................................................................................... 3

3.2.1 Organization of a dissemination workshop in Gujarat .................................................................. 3

3.2.2 Participation in ISAP2018 and to site visits and meetings with relevant stakeholders in

Hyogo Prefecture .......................................................................................................................................... 5

3.2.3 Disseminate IGES-TERI findings through presentation at workshop(s) and/or media

coverage(s). .................................................................................................................................................... 8

3.3 Matchmaking ...................................................................................................................................................... 9

3.3.1 Feasibility of Bando belts in chemical factories in Ankleshwar ................................................... 9

3.3.2 Feasibility of Kobelco’s air compressor at a textile factory in Daman....................................... 12

4.0 WAY FORWARD ..................................................................................................................................................... 12

ANNEXURE 1: AGENDA OF THE AWARENESS WORKSHOP - DISSEMINATION OF JAPANESE LOW CARBON

TECHNOLOGIES IN INDIA AND A CIRCULAR SENT BY AIA TO ALL THEIR MEMBERS

ANNEXURE 2: DETAILS OF SITES WHICH SHOWED INTEREST IN BANDO BELTS IN THE CLUSTER

ANNEXURE 3: DETAILED FEASIBILITY REPORT OF KOBELCO’S AIR COMPRESSOR AT A TEXTILE FACTORY IN

DAMAN

1

1.0 Background

Japan-India cooperation on clean technologies offers an exciting opportunity to save energy, mitigate greenhouse gas emissions and contribute to overall economic growth of both

countries. An innovative, business-to-business (B2B) model of technology cooperation has

been successfully demonstrated by IGES and TERI through several recent joint projects (2010-2017). On Jul. 13th 2016, IGES and TERI signed an MOU to launch Japan-India

Technology Matchmaking Platform (JITMAP).

Given this backdrop, and considering the vast technological expertise in clean technologies available with businesses in Hyogo and other prefectures in Japan and the scope for

adoption of clean technologies in Gujarat and other Indian states, a collaboration to match

Japanese technologies and best operating practices (BOP) with end-users in India and strengthen network between stakeholders in both countries is deemed necessary.

2.0 Objective

Strengthen network between stakeholders in Japan and India in general, and between Hyogo Prefecture and Gujarat state in particular, through a structured approach including

“on the ground projects” and matchmaking activities.

3.0 Key activities in India

IGES and TERI continued collaborating on dissemination of Japanese technologies in India.

A large number of joint feasibility studies and workshops/seminars were conducted. The

activities have led to the development of a Japan India Technology Matchmaking Platform called JITMAP.

The following activities were undertaken under the project during the FY:

1) Information collection and “on line” sharing

2) Awareness creation and capacity building

3) Matchmaking

3.1 Information collection and “on line” sharing

To support the dissemination of Japanese low carbon technologies in India, TERI collected,

arranged and uploaded relevant information on technologies, feasibility studies, financing

options, policies/regulations and so on for the JITMAP web-site. A summary of information collected and uploaded in the JITMAP web-site (www.jitmap.org) is given below location-

wise.

3.1.1 Website location: http://www.jitmap.org/Japanese-technology.php

Green Technology Transfer

Green Technology Transfer (GTT) is a platform that facilitates transfer of low-carbon

technologies (LCTs) from Japanese LCT manufacturers to end-users in countries of South Eastern Europe. GTT features the ‘Leading Low-carbon Technologies (L2-Tech)

list’. The ‘L2-Tech certified product list’ is a list that includes more than 3000 Japanese

technologies. The list has to be updated twice a year. The provisional translated

http://www.jitmap.org/

http://www.jitmap.org/Japanese-technology.php

Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)

2

version as of 13 Oct.2017 is available at the Green Technology Transfer Platform that is

developed by The Regional Environmental Center for Central and Eastern Europe (REC).

Read more at https://www.greentechtransfer.eu/

3.1.2 Website location: http://www.jitmap.org/stimulating-policies-Indian-side.php

Maharashtra Energy Development Agency (MEDA)

The Maharashtra Energy Development Agency (MEDA) is the State Designated Agency (SDA) for the state of Maharashtra. Under its Energy Conservation

Programme, MEDA has launched a number of initiatives for facilitating energy

efficiency and renewable energy development

Read more at

https://www.mahaurja.com/meda/energy_conservation/energy_conservation_progr

am

Haryana Renewable Energy Development Agency (HAREDA)

The Haryana Renewable Energy Development Agency (HAREDA), as the State Designated Agency for Haryana, has a number of schemes/initiatives to promote

energy conservation and renewable energy.

Read more at http://hareda.gov.in/index.php?model=pages&nid=2

Startup India

Startup India is a flagship initiative of the Government of India, intended to build a

strong ecosystem that is conducive for the growth of startup businesses, to drive sustainable economic growth and generate large scale employment opportunities. The

Government through this initiative aims to empower startups to grow through

innovation and design.

Read more at https://www.startupindia.gov.in/

NewClimate Institute

NewClimate Institute (NCI) generates and shares knowledge on policies and

initiatives related to climate change. NCI’s website carries a ‘good practice GHG reduction policy menu by 30 major greenhouse gas emitting economies including

India.

Read more at http://climatepolicydatabase.org/index.php/Country:India

https://www.greentechtransfer.eu/

http://www.jitmap.org/stimulating-policies-Indian-side.php

http://www.jitmap.org/stimulating-policies-Indian-side.php

https://www.mahaurja.com/meda/energy_conservation/energy_conservation_program

https://www.mahaurja.com/meda/energy_conservation/energy_conservation_program

http://hareda.gov.in/index.php?model=pages&nid=2

https://www.startupindia.gov.in/

http://climatepolicydatabase.org/index.php/Country:India


3

3.1.3 Website location: http://jitmap.org/stimulating-policies-Japanese-side.php

NewClimate Institute

NewClimate Institute (NCI) generates and shares knowledge on policies and

initiatives related to climate change. NCI’s website carries a ‘good practice GHG

reduction policy menu by 30 major greenhouse gas emitting economies including Japan.

Read more at http://climatepolicydatabase.org/index.php/Country:Japan

3.1.4 Website location: http://www.jitmap.org/stimulating-financing-programmes-Indian-side.php

Tamilnadu Industrial Investment Corporation Ltd

Tamilnadu Industrial Investment Corporation Ltd (TIIC) is a State Financial

Corporation that fosters industrial development in Tamil Nadu by providing financial

assistance to industries for purchase of land, machinery and construction of buildings. About 90% of TIIC assistance goes to the MSME sector; of this, about 40% goes to first

generation entrepreneurs.

Read more at http://www.tiic.org/tiic_finance.html

Tamilnadu Small Industries Development Corporation Limited

Tamilnadu Small Industries Development Corporation Limited (TANSIDCO), a state

government undertaking, plays a catalytic role in the promotion and development of

small scale industries in Tamil Nadu through schemes in key areas like: development of industrial estates with infrastructure facilities and provision of work sheds &

developed plots; raw materials supply; marketing assistance; and guidance to

entrepreneurs.

Read more at http://www.sidco.tn.nic.in/home.asp

In addition, the relevant events/activities and feasibility studies sections were updated with

the new activities and feasibility studies conducted during the year. In addition, NaPanta

(http://www.napanta.com/cold-storage) and ZaubaCorp

(https://www.zaubacorp.com/company-list) were added under http://jitmap.org/useful-

links.php.

3.2 Awareness creation and capacity building

3.2.1 Organization of a dissemination workshop in Gujarat

Under the project, TERI was

entrusted to organize a workshop in Gujarat state, to introduce Japanese

low carbon technologies to relevant

Indian stakeholders, including end users.

http://jitmap.org/stimulating-policies-Japanese-side.php

http://climatepolicydatabase.org/index.php/Country:Japan

http://www.jitmap.org/stimulating-financing-programmes-Indian-side.php

http://www.jitmap.org/stimulating-financing-programmes-Indian-side.php

http://www.tiic.org/tiic_finance.html

http://www.sidco.tn.nic.in/home.asp

http://www.napanta.com/cold-storage

https://www.zaubacorp.com/company-list

http://jitmap.org/useful-links.php

http://jitmap.org/useful-links.php


4

The awareness workshop was organised by IGES and TERI at Ankleshwar (Gujarat) on 30th

August 2018. The event was organised jointly with Ankleshwar Industries Association (AIA). AIA is the nodal association for all industries located in Ankleshwar GIDC

estate. There are about 1200 industries, consisting of chemicals, pesticides, pharmaceuticals,

bulk drugs, petroleum products, engineering, textiles, plastics, rubber and packaging located within the GIDC estate.

Leading government agencies and business associations in Gujarat, namely, Gujarat Energy

Development Agency (GEDA), Gujarat Industrial and Technical Consultancy Organisation

Limited (GITCO), and Dahej Industries Association (DIA) were invited to the event. The agenda of the workshop and a circular sent by AIA to all their members are provided in

Annexure 1.

The total number of participants exceeded one hundred (about 110), most of them

representatives of private companies in Ankleshwar.

The workshop included an inaugural session followed by a technical session. At the

inaugural session Mr. Prosanto Pal (TERI), Mr. Rajesh Kansara (GEDA), Mr. K H Kakkad

(GITCO), Mr. Mahesh J Patel (AIA) and Mr. Dinesh Patel (DIA) recognised and endorsed the need for initiating JITMAP as a means to

promote LCTs in India through

facilitating/accelerating businesses-to businesses matching. They encouraged

the participants to identify proactively

what LCTs they need at Ankleshwar cluster, in general, and at their factories,

in particular, to explore matching them

with the appropriate Japanese suppliers under JITMAP. Dr. Abdessalem Rabhi

(IGES) concluded the inaugural session

by explaining further the features of JITMAP and its mode of operation,

while thanking AIA and DIA for their interest to be included among JITMAP’s dialogue

members.

In the technical session, Mr. R Ramesh, from Bando Chemicals, introduced and explained

about its company’s technologies regarding energy efficient transmission belts; whereas, Mr. Rakesh Pandita, from Kobelco Compressors India, introduced and explained about its

company’s technology regarding air compressors. Both, transmission belts and air

compressors, have wide application in Ankleshwar industrial cluster; however, it was interesting to find that more than 90% of those who filled the workshop feedback evaluation

forms, from the participants, did not know

about Bando Chemicals India, and about Kobelco Compressors India, before.

Therefore, the workshop was a good

awareness creation opportunity for them about those technologies and about their

suppliers, as well as a good business


5

matching opportunity for those suppliers (Bando Chemicals and Kobelco Compressors) to

get in touch with more than 90 representatives of private companies at a single event.

At the end of the workshop, a number of representatives of private companies approached

Mr. R Ramesh and Mr. Rakesh Pandita to visits their sites for onsite investigation about the potential implementation of those technologies at their sites. That was an additional sign

that such kind of awareness workshops, in particular, and activities under JITMAP in

general are able to facilitate/accelerate the businesses-to-businesses matchmaking; hence able to contribute to promoting LCTs in India.

Within Gujarat, Vapi is another prominent industrial cluster with about 300 medium and large enterprises mainly manufacturing chemicals and allied products. A second

dissemination workshop for promoting the implementation of energy efficient Japanese

technologies was organised on 18th December 2018 at Vapi, Gujarat. About 40 participants from local businesses including a JITMAP dialogue partner (GITCO) and office bearers of

Vapi Industries Association attended the workshop. The workshop commenced with an

inaugural speech by Mr Prakash Bhadra, President, Vapi Industries Association, followed by the remarks from Mr Toshizo Maeda, Deputy. Director, IGES-Kansai Research Center, Mr

Girish Sethi, Senior Director, TERI, and Mr Ketan Kakkad, Senior Consultant, Gujarat

Industrial and Technical Consultancy Organization Limited (GITCO).

The workshop created awareness about the energy efficiency in steam and compressed air

systems used in industry. Experts from TLV Japan and TLV India, Mr Takaharu Nakashima and Mr Ashwin Sanyal, respectively, gave the presentation on steam management. Mr

Rakesh Pandita from Kobelco Air Compressors India and Mr Hitesh Vaishnav from Vintage

Air Technology presented on the compressed air system. In the Q&A session, the participants asked the reasons for steam trap failure and ways to detect early leakage in

steam traps as well as impacts of high summer temperatures and the variations between

safety standards in Japan and India on compressed air systems. The post-training feedback survey showed that more than 80% of the participants became familiar with the energy

efficiency of both technologies. Additionally, the workshop contributed to identify potential

end-users willing to implement these technologies.

Selected photographs of Vapi workshop

3.2.2 Participation in ISAP2018 and to site visits and meetings with relevant stakeholders in Hyogo Prefecture


6

IGES-KRC invited delegates from TERI and GITCO in India, to conduct site visit where

electric heat pump (EHP), Japan's low carbon technology (LCT), is actually installed, interact with Japanese manufacturing companies, and local government officials in Hyogo

Prefectural Government, Japan on 17th and 18th of July 2018.

On 17th July the delegates visited Hyogo Prefectural Museum of Art, where the electric heat

pump (EHP) technology manufactured by Mayekawa MFG. Co., Ltd. has been installed for

more than 17 years. The key objective of this visit was to enhance their awareness about application of EHPs in public buildings besides industries. The delegates were impressed

with the performance and long lifecycle of the EHPs. It was also an opportunity for them to

clarify about the technical issues related to EHP.

Visit to EHP site at Hyogo Prefectural Museum of Art

Following the visit for EHP, they visited TLV International, INC. in Kakogawa city to

interact with TLV’s experts and learn more about Steam System Optimization Programme

(SSOP). Followed by their factory visit, IGES, TERI, and GITCO discussed with TLV about

potential sectors and areas to introduce the SSOP in India.

On 18th July, the delegates had two meetings with Hyogo Prefectural Government. The first meeting was dedicated to exchange information with Mr. Akiyama, Chief Executive Officer

for Environment, executives from

Environment Development and Management Bureau etc. Through the second meeting, the

delegates discussed with officers from

Environmental Policy Division, Water & Air Quality Control Division, and International

Economic Development Division, about

potential activities to catalyze the

‘Memorandum of Understanding between the

Meeting with Hyogo Prefectural Government


7

Hyogo Prefectural Government, Japan and the State Government of Gujarat, Republic of

India on Mutual Cooperation’ signed between Hyogo prefectural Government in Japan and the State Government of Gujarat in India.

The visit to industrial sites, meeting in person with the technology providers and dialogue with Hyogo prefectural government were appreciated by the Indian delegates as well as the

Japanese counterparts as precious opportunities of obtaining reference and network for their

future activities through direct interaction and understanding of current situation under the JITMAP.

Participation in ISAP TT6 session on ‘Innovative Approaches to Promote Low Carbon Technologies and Best Practices’

The session commenced with opening remarks by Mr. Ryuzo Sugimoto of the Ministry of

Environment, Japan including promotion of overseas deployment of environmental infrastructure, recognition and support to Japan-India Technology matchmaking platform

(JITMAP) in Japan-India policy dialogue, and expectation for further promotion of low-

carbon technology (LCT).

IGES-KRC and UNU-IAS shared the key findings from their activities in LCTs in India

through background presentations.

At the panel discussion experts from the UNIDO, CIF, TERI and GITCO solicited their views

and experiences on common barriers and innovative approaches to promote the dissemination of LCTs in developing countries including India.

The panelists highlighted overcoming IPR-related barriers, establishing local delivery and support systems, creating an enabling environment for investment through banking and

non-banking finance institutes (NBFIs), conducting unit or cluster level LCT demonstration

projects, providing technical assistance, and engaging SMEs as key elements for the successful LCT promotion. To scale up the LCT promotion, a collaborative effort through

multi-stakeholder platforms was recommended.

Representative from Hyogo Prefecture acknowledged the importance of multi-stakeholder

platforms like JITMAP as an innovative approach for LCT promotion.

Visit to EHP facility (manufactured by Mayekawa MFG. Co., Ltd.) installed at Hyogo Prefectural

Museum of Art

Visit to TLV International, INC.


8

IGES-KRC’s director, Prof. Yutaka Suzuki made closing remarks about the conception of

JITMAP and emphasizing on importance of collaboration of multi-stakeholders from various level of regions to overcome the common barriers in LCT promotion.

Key Messages

The LCT projects should comprise of easy access to finance, technical assistance and demonstration for technologies. Innovative finance models through ESCOs, private

investments and NBFIs should be explored.

To ensure sustainability and continuity of LCT promotion, multi-stakeholder approach is the key. Stakeholders from business, finance, governments, NGOs could join hands

in it.

A shift from LCT transfer to LCT collaboration approach is the way forward, along with strong connection to global and national frameworks, innovation through

localization of LCTs is needed.

Photograph of the ISAP session

3.2.3 Disseminate IGES-TERI findings through presentation at workshop(s) and/or media coverage(s).

TERI was invited to make a presentation about their energy saving efforts among SMEs at a

customer meet, called ‘Aplicon’, organised by Tata Steel, in August 2018. A large number of

SME end-consumers of steel sheets from the appliance sector attended the meeting. TERI introduced the JITMAP initiative as well as the type of activities being undertaken with

support from Japan.

TERI and IGES participated and made a presentation at the Japan Chamber of Commerce

and Industry in India (JCCII) meeting named “Sanmokukai” held at Embassy of Japan at

New Delhi on October 2018. Having started with around 100 member companies in 2006,

today the organization has grown to a membership more than 400 companies mostly in and


9

around Delhi NCR. The JITMAP initiative was widely appreciated and several Japanese

companies let TERI and IGES after the presentation and showed interest in taking part in the initiative.

An Energy Efficiency Training Week for India organised by International Energy Agency (IEA) in December 2018. TERI made a presentation to the participants of the industry stream

on technology demonstration programs undertaken in SMEs. The heat pump technology

demonstrated under the Science and Technology Research Partnership for Sustainable Development (SATREPS) program was presented as a case-study. The industry stream was

attended by representatives of several state designated authorities (SDA) including Gujarat

and Punjab.

An article on JITMAP initiative and thematic track at WSDS was prepared and sent to

MCCIA for publication in the next issue of the newsletter SAMPADA magazine, published by MCCIA.

3.3 Matchmaking

TERI and IGES facilitated meetings and interaction among Indian and Japanese stakeholders, including the conduct of feasibility studies at selected sites in Gujarat state.

Specific matchmaking activities undertaken during the year are highlighted below.

3.3.1 Feasibility of Bando belts in chemical factories in Ankleshwar

TERI selected four sites in Ankleshwar, a large cluster of chemical producing SMEs in

Gujarat, and collected necessary information about the targeted sites, prior to the feasibility

studies. Feasibility studies were undertaken in the selected sites with team members from IGES and Bando Chemicals India on energy efficient technology (transmission belts).

The companies where feasibility studies on Bando belts were undertaken are mentioned below:

Meridian Chembonds Pvt Ltd.

Glenmark Pharmaceutical Ltd.

Gujarat Guardian Glass Ltd.

DCM Shriram Alkali & Chemicals Ltd.

Typical energy savings and other benefits of Bando belts: A case-study

Unit name: Meridian Chembonds Pvt Ltd.

Technology proposed: Cogged V-belt, with pulley where necessary


10

Existing drive arrangement After conversion (light drive arrangement)

Applications where belt can be replaced: Centrifugal fans, blower, air compressor systems

Advantages:

Better transmission and consequent energy saving

Stress relieved fabric with high stretchability improves performance during bends

More and better quality belt cord used to withstand high loads

Precision-moulded cogs increases flexibility

Better grip and minimum slip

Anticipated energy and cost saving:

Details Recommended Energy saving

Centrifugal fans Replacing existing belt by

cogged V-belt (1 unit)

28.5 Kw/hour

Blower Replacing existing belt by

cogged V-belt + pulley (1 unit)

20 Kw/hour

Air compressor Replacing existing belt by

cogged V-belt + pulley (4 units)

18 Kw/hour

Similar studies were also conducted in the other units and energy saving potential discussed with the plant management. Bando also supplied samples of their belts to some of the

companies visited. TERI and Bando Chemicals India subsequently followed up with the

SMEs, to ensure implementation of the technology. The follow-ups have resulted in implementation of Bando belts at a total of six sites in Ankleshwar.

Selected photographs of the visit are provided in figure 3.3.1.

Details of these and other sites which showed interest in Bando belts in the cluster are

provided in Annexure 2.


11

Feasibility studies conducted in Ankleshwar

3.3.2 Feasibility of TLV steam system at factories in and around Vapi

TERI selected five sites in Vapi for feasibility studies on steam systems with TLV

representatives.

The companies where feasibility studies on TLV steam systems were undertaken are

mentioned below:

Shree Rama Newsprint Ltd., Hazira

Welspun India Ltd, Vapi

Jay Chemicals Pvt Ltd., Vapi

Toray Kusumgar Advanced Textile Pvt. Ltd.,Sarigam

Raymond Ltd., Vapi

During the visits, a presentation on steam technologies was made by TLV. This was followed by walk-through surveys of the steam distribution line. TLV experts analysed the

condition of the steam traps and discussed about the issues they are facing with them.

Selected photographs of the visit are provided in figure 3.3.1.

Feasibility studies conducted in and around Vapi


12

3.3.2 Feasibility of Kobelco’s air compressor at a textile factory in Daman

A feasibility study of Kobelco’s air compressor was

also undertaken at a SME textile factory (Gautam

Enterprises) in Daman, India. TERI visited the factory during August 2018 to identify energy

savings potential in their compressed air system.

The major uses of energy in the plant are air jet looms and air compressors.

The plant was using five screw type air compressors for meeting the compressed air

requirement of air jet machines of loom sections.

However maintenance of the compressors were found to be very poor. A photograph of the compressor room is shown in figure 3.3.2.

Based on the study, the unit was recommended to replace two of the air compressors with new energy efficient invertor air compressors. The capital investment for installation of two

energy efficient invertor air compressors and associated piping in the unit was estimated to

be about Rs 30 lakhs, which would payback within 1.8 years, based on energy savings alone.

The detailed feasibility report was prepared and shared with the unit. The report is enclosed

in Annexure 3.

4.0 Way forward

Gujarat is one of the most industrialised states in India. It has a vibrant industry sector. The

major energy-intensive industries in Gujarat state include chemicals, pharmaceuticals, chemicals, metals, engineering, dairy and textiles. The energy consumption of these

industries and major geographical clusters/concentrations in the state are shown in figure

4.0.

Energy consumption of major energy intensive industries and their geographical distribution in

Gujarat

Figure 3.3.2: View of the compressor room


13

The strategic activities undertaken during the year have shown the important role that can be played by research institutes like IGES and TERI in promoting cooperation between

Hyogo Prefecture and Gujarat state. TERI, through its partners like GEDA and GITCO in

Gujarat, has promoted policy dialogue on relevance of Japanese LCTs in India with different state government agencies within India. Additionally, awareness of latest Japanese

technologies was promoted among large industrial associations in the state of Gujarat like

AIA and PIA through the project activities.

Some of the collaborative activities which can be facilitated by TERI and its partners for

Japanese stakeholders within the state include the following:

Identification of promising energy-intensive clusters for replication of Japanese

technologies

Organization of consultation meetings with state-level stakeholders (government departments, industry associations, financial institutions, technical/academic agencies).

Organization of awareness workshops and training programs with industry associations

to disseminate information about Japanese LCTs.

Organization of site visits/study-tours to demonstration sites for stakeholder groups.

Identification of potential industries and applications for adoption of LCTs.

Conducting of detailed feasibility studies at industry/application level and subsequent follow-ups and technical support during implementation.

Post-implementation monitoring and documentation of energy (cost) savings.

Replication of the successful installation in other industries/ cluster of industries. In conclusion, to accelerate the implementation of Japanese LCTs among a large number of

industrial units in Gujarat, it is recommended that a multi-year deep dive initiative should

be undertaken by IGES and TERI in a few promising clusters/sectors. Under the deep dive initiative, a large number of energy audits can be undertaken among the industries located

within the cluster/sector, jointly with Japanese experts, to identify techno-economically

feasible LCTs. Subsequently, IGES and TERI could be involved in follow-ups and technical back-up support to ensure large number of implementations and consequent GHG savings

within a relatively short time period.

15

Annexure 1: Agenda of the Awareness workshop - Dissemination of Japanese low carbon technologies in India and a circular sent by AIA to all their members


16

17

Annexure 2: Details of sites which showed interest in Bando belts in the cluster

Sr

No Company

Contact Person Contact

Number

Email address Belt implemented

No Yes Note (if any, such as around when belts have been

supplied/installed)

Companies which were visited (during Aug. mission)

1 Glenmark Pharmaceutical Ltd.

Harin Gandhi 9898593223 [email protected] Regular follow up for requirement

2 Meridian Chembonds Pvt Ltd

S.K Nair 9327467402 [email protected] Customer taking time for new install as per given

design.

3 Gujarat Guardian Glass Ltd √ Regular follow up for requirement

4 DCM Shriram Alkali & Chemicals

Ltd.

P.P.S Yadav 02645226021 √ Top management didn’t give approval for testing

Companies which approached to Bando at the workshop

5 Chiron Behring Vaccines Pvt Ltd Mahesh Hariharan 8980003123 [email protected] Company Process in for takeover by other company

6 Sayona Crop Limited Parth Patel [email protected] Regular use Bando V-belts

7 Camex Limited 9825039736 [email protected] Regular follow up for requirement

Companies which expressed interest in Bando’s belts through the workshop/survey feedback

8

Sajjan India Ltd

Gurupad Kondaguli [email protected] √ Given Bando V-belt for trial purpose.

Varun Kumar Rai 9167941103 [email protected]

Divyesh Donder 7046066618 [email protected]

9 Bakul Pharma Pvt Ltd Vanrajsinh Matieda 9428289998 [email protected] Regular follow up for requirement

10 Meghmani Organics Ltd Vasudeo Patil 94221185270 [email protected] Regular follow up for requirement

11 Rpg Life Science Vivek Chavan 9930810102 [email protected] Regular follow up for requirement

12 Eagle Filtration Product Pvt Ltd 9825324719 [email protected] Regular follow up for requirement

13 Shreenath Engineering Bipin Dudhat 9925250190 [email protected] Regular follow up for requirement

14

Coromandel International Ltd

Mitesh 7573042472 [email protected] Regular follow up for requirement

Madhan Raj 9724853231 [email protected],

[email protected]

15 Basic Pharma Joshi Mitesh 7567288241 [email protected] Regular follow up for requirement

16 Basf India Ltd Sharanbassappa Patil 8980023690 [email protected] Regular follow up for requirement

mailto:[email protected]















18

Sr

No Company


Number



supplied/installed)

Hanumant Pawar 9898658552 [email protected]

17 Skylark Pharmaceuticals Pvt.

Ltd.

Sky 4 Skylark Ind.Pro 02646221315 [email protected] Regular use Bando V-belts

18 Gujarat rubber reclaim Pragnesh Patel 9979124411 [email protected] Regular follow up for requirement

19

Surya Life Science

Mahesh Borase 9408708126 [email protected] Regular use Bando V-belts

Rishav Kumar 8200805897 [email protected]

Mahesh Prajapati 9428511150 [email protected]

Vikas Kumar 8200805897 [email protected]

20 Ganesh Remedies Dharmesh Jadav 9327115059 [email protected] Regular follow up for requirement

21 Cls India Rajesh Riziya 9833577378 [email protected] Regular follow up for requirement

22

Bharuch Enviro Infrastructure

Ltd

Mahesh Pandal 9978447294 [email protected] Regular use Bando V-belts

Dharmesh Patel 8128088158 [email protected]

Mayur Dobariya 8238022131 [email protected]

23 Suyoginc Pradip Patel 8347875000 [email protected] Regular follow up for requirement

24 Sunbeam Photochem Pvt Ltd

9824133608 [email protected]

25 Zone Exchange Jitendra Mistry 9979003037 [email protected]

26 Epgls Sachin Patel 02646230200 [email protected]

27 Hedbach India Prakash Jadhav 9879574910 [email protected] Regular follow up for requirement

28 Abhilashu Pharma M.D Soni 9227135395 [email protected]

29 Amsal Chem Pvt Ltd Mahesh Soni 8732923096 [email protected] Regular use Bando V-belts

30 Atul Limited Pankaj Prajapati 02646229159 [email protected] Regular follow up for requirement

31 Wockhardt Limited Kunal Singh 9722183177 [email protected] Regular follow up for requirement

Deepak Rana 02646661494 [email protected]

32 Subhasri Pigments Pvt Ltd

9227862815 [email protected] Regular follow up for requirement

Hitesh Rana 9227862803 [email protected]

33 Sunny Chemicals

Gopal Vekaria 9714911044 [email protected] Regular follow up for requirement



























19

Sr

No Company


Number



supplied/installed)

People which expressed interest in Bando’s belts through the workshop/survey feedback (wasn’t possible to identify to which companies they belong)

Parth Parmar 9924357015 [email protected]

Jignesh Gahil 9662165431 [email protected]

Bhaumik Patel 9909522479 [email protected]

Munoj Patel 9913305033

Dharmendra 9978471119 [email protected]

Malaysingh Borasiya 7874651056 [email protected]

Mahesh Patel 9428061280 [email protected]

Jagdish Rawal 9825224939 [email protected]

Sanjay Patel 9998350690 [email protected]

Manoj Thakur 9428685813

J Mulhu 7358406579 [email protected]

Legik Joseph 9328624003 [email protected]

Nirav Panchal 9510026171 [email protected]

Jayashbhai Patel 9377510253 [email protected] Regular customer for Bando V-belts[Traders]













Annexure 3: Detailed feasibility report of Kobelco’s air compressor at a textile factory in Daman

Feasibility Report

Feasibility Report

on

Compressed Air Systems

Prepared for

Gautam Enterprises, Daman

September 2018

Prepared by

The Energy and Resources Institute (TERI)

Table of Contents

1.1 Introduction .......................................................................................................................................... 1

1.2 Methodology ......................................................................................................................................... 2

1.3 Free air delivery (FAD) test ................................................................................................................... 3

1.4 Demand assessment .............................................................................................................................. 4

1.5 Recommendations ................................................................................................................................. 5

List of tables

Table 1.1: Design details of air compressors................................................................................................................ 1

Table 1.3: Performance of air compressors ................................................................................................................. 3

Table 1.4: Demand test of compressed air system ..................................................................................................... 4

Table 1.5.1: Energy saving calculation ......................................................................................................................... 6

List of figures

Figure 1: Compressed air distribution systems of Gautam Enterprises, Daman .................................................... 2

Figure 3: Leakage in valve near receiver ...................................................................................................................... 4

i

Executive summary

The report presents the key summary of the analysis and findings from the detailed field

assessment study and data collected at M/s Gautam Enterprises, Daman for energy efficiency practices in the compressed air system. It includes details of the literature review,

data collection and measurements, discussion on data and analysis related to topic areas,

conclusions drawn from data and information reviewed, as well as an analysis of new and applicable technologies.

A detailed field assessment study at M/s Gautam Enterprises, Daman was conducted during 30th – 31st August 2018 to identify the measures of energy savings in compressed air

system. The major sources of energy for the plant is electricity used in air jet looms, air

compressors and other auxiliaries. The total annual electricity consumption of the unit has been estimated to be 3.0 million units of electricity. The total equivalent energy consumption

of the plant is calculated to be 258 tonnes of oil equivalent (TOE) per year. The total CO2

emission during this period is estimated to be 2,460 tonnes.

The proposed energy conservation measures (ECM) for compressed air system at M/s

Gautam Enterprises, Daman containing the reduction in operating cost, energy cost and cost of investment required for implementation of measures, simple payback period of the

recommendation and impact on environment (reduction in CO2 emission).

The identified annual saving potential in electricity is about 397,511 electrical units. The total

annual energy cost saving potential is proposed to be Rs 16.9 lakh per year and the cost of

implementation for the proposals is estimated to be Rs 29.7 lakh. Key recommendation made in this energy performance/ study report is summarised in table below.

Key recommendation made in this energy performance/ study report

Energy

conservation

measure

Annual energy saving

Investment

(Rs in

lakh)

Monetary

savings

Simple

payback

period

(Years)

Emission

reduction

Electricity

(kWh)

Equivalent

(TOE)

(Rs in

lakh/

year)

(tonnes

of CO2)

Installation of VFD

enabled energy

efficient air

compressors

397511 34.2 29.7 16.9 1.76 326

1

1.0 Compressed air system

1.1 Introduction

The plant has installed five (05 no’s.) screw type air compressors for meeting the compressed air requirement of air jet machines of loom sections

(Gautam Enterprises and Siddhartha Enterprises). Out of

the five installed air compressors, one air compressor (compressor – 4) is enabled with speed-controller or

frequency-controller with integrated microprocessor for

capacity control.

Table 1.1 gives the design details of all air compressors

installed in the plant.

Table 1.1: Design details of air compressors

Particular Unit C-1 C-21 C-3 C-4 C-5

Make - ELGI ELGI ELGI Atlas Copco Atlas Copco

Model No - E55-10 E55-10 E55-10 GA-55 VSD

AFF

GAE 55 A FF

Type of compressor - Screw type Screw

type

Screw type Screw type Screw type

Capacity FAD CFM 290 290 290 270 328

m3/min 8.21 8.21 8.21 7.7 9.3

m3/hour 492.6 492.6 492.6 459.0 558.0

Rated pressure kg/cm2 9.5 9.5 9.5 13 8

Rated motor capacity kW 55 55 55 55 55

Type of cooling - Air Cooled Air cooled Air cooled Air cooled Air cooled

Capacity controlling

mechanism

- None None None VFD None

Receiver m3 2 (common

with

compressor 3)

1 2 (common with

compressor 1)

2 (common

with

compressor 5)

2 (common

with

compressor 4)

During the normal plant operation, four compressors are in operation whereas one

compressor has been kept as standby. The all other air compressors are operating in load

and unload mode. The compressors will be unloaded while reaching to the set pressure. This is analogous to start/stop control which controls the compressor functions, instead of

the motor. When compressors in unload mode, the motor continues to operate however at

much reduced load and no compressed air is delivered to the system. The compressed air pressure required at the end use point was observed to be about 4.0 – 5.5 kg/cm2(g).

The schematic diagram of existing compressed air distribution system of the plant is given in figure 1.0.

1 Air compressor – 2 was not in operation during the feasibility study


2

Figure 1.0: Compressed air distribution systems of Gautam Enterprises, Daman

1.2 Methodology

Air compressors are designed to deliver a fixed quantity of air at certain pressure. But, due

to ageing, wear and tear or poor maintenance, compressor may not be able to deliver the

same volume of air as specified by the manufacturer on the nameplate. By performing the

FAD (Free Air Delivery) test, actual output of a compressor with reference to the inlet

conditions can be assessed. This test determines the pumping capacity of the compressors in

terms of FAD, i.e. air pumped at atmospheric conditions. Following tests are generally

carried out for evaluating the operating capacity of compressors.

Pump-up test (free air delivery test)

Suction velocity method

The pump-up test of a compressor needs isolation of the air receiver and compressor from

rest of the plant. During the feasibility study, the pump up test was successfully conducted

for all four operational air compressors (air compressor 1, 3, 4 and 5).


3

1.3 Free air delivery (FAD) test

Based on the data measured/collected from the plant during energy audit, the actual output

of the compressors with respect to free air delivery was calculated and is given in table 1.3.

Table 1.3: Performance of air compressors

Operational parameters Unit C -1 C -3 C -4 C -5

Operating Pressure kg/cm2 7.5 7.5 6.5 6.7

Initial Pressure kg/cm2 0 0 0 0

Atmospheric pressure kg/cm2 1.0 1.0 1.0 1.0

Capacity of Receiver M3 2.0 1.0 2.0 2.0

Additional holdup volume M3 0.0 0.0 0.0 0.0

Pump-up time Seconds 106 55 81 83

Inlet air temperature oC 33.2 33.2 33.2 33.2

Suction velocity m/s 0 0 0 0

Suction area m3 0 0 0 0

Calculated/Analyzed parameters

Actual FAD (pump up test) M3/Min 8.4 8.1 9.5 9.6

Actual FAD (Suction velocity test) M3/Min 0.00 0.00 0.00 0.00

Actual FAD (considered for calculation) M3/Min 8.40 8.11 9.52 9.58

Volumetric Efficiency % 102.3 98.7 124.5 103.0

Isothermal Power kW 27.8 26.9 29.3 30.0

Motor input power kW 61.1 57.4 69.0 65.0

Efficiency of Motor % 92.1 92.1 92.1 92.1

Shaft input power kW 56.3 52.9 63.6 59.8

Isothermal Efficiency % 49.4 50.8 46.1 50.1

Specific power consumption kW/m3/min 7.28 7.08 7.25 6.78

Specific power consumption kW/cfm 0.21 0.20 0.21 0.19

The volumetric efficiency of the all tested air compressors was close to design (102.3%,

98.7%, 103.0% respectively), however the volumetric efficiency of compressor -4 (VFD

driven, designed at 13 kg/cm2) is close to 124.5%. The actual free air delivery was found in

the satisfactory range. It is to be noted that the FAD of any compressor should not be less

than 80% of their rated capacity in order to achieve optimum operational efficiency. The

graphical presentation of FAD test is given in figure 1.3.


4

Figure 1.3: Leakage in valve near receiver

Another important parameter to determine the performance of compressors is the specific

power consumption (SPC) – power consumed per cubic meter of compressed air delivery

per minute. The estimated SPC in the compressor – 1, 3, 4 and 5 is estimated to be 7.28

kW/m3/min, 7.08 kW/m3/min, 7.25 kW/m3/min and 6.78 kW/m3/min respectively. The

SPC of all compressors were higher than the designed SPC. The SPC in screw compressors is

generally in the range of 5.75 – 6.25 kW/m3/min for given pressure range.

1.4 Demand assessment

During the study of compressed air system, present operating pattern and actual air

requirements test conducted to understand the overall specific energy consumption pattern

of the plant. Based on the data measured/collected from the plant, the actual specific power

consumption of compressed air systems with respect to normal plant operation was

calculated and is given in table 1.4.

Table 1.4: Demand test of compressed air system

Particular Unit C -1 C -3 C -4 C -5 Total

Free air delivery of operating

compressor

m3/min 8.4 8.1 9.5 9.6 35.6

Loading (%) % 85.2 95.7 72.2 79.9 35.6

Total air generation m3/min 7.2 7.8 6.9 7.6 29.4

Total air demand per day m3/min/day 172 186 165 184 523

Specific power consumption kW/m3/min 7.3 7.1 7.2 6.8 7.09

The actual air requirement has been calculated by measuring the loading and unloading

pattern of individual compressors operating in normal plant operation and historical data

collected. The previous load and operation hours’ data (Individual Compressors) was also

taken in to account to estimated actual air requirement of the plant.


5

Average demand of the plant estimated using data logging of compressors during normal

plant operation. The average plant demand is estimated to be 29.4 m3/min i.e. 1,038 cfm

(actual average air requirement of plant during normal plant operation). The average

specific power consumption (based on measurement) is estimated to be 7.09 kW/m3/min.

1.5 Recommendations

Based on the analysis, four possible recommendations have emerged for conserving energy

in the compressed air systems. They are presented this section.

1.5.1 Installation of VFD enabled energy efficient air compressors

Background

The plant has installed five (05 no’s.) screw type air compressors for meeting the compressed

air requirement of air jet machines of loom sections (Gautam Enterprises and Siddhartha

Enterprises). During the normal plant operation, four compressors are in operation whereas

one compressor has been kept as standby. The total installed capacity of the compressed air

system is 41.58 m3/min whereas the operation capacity is about 33.4 m3/min.

During the filed assessment study, four compressors (C-1, C-3, C-4 and C-5) were in

operation. The compressor – 4 was controlled by variable frequency drive and the all other

air compressors are operating in load and unload mode. The compressors will be unloaded

while reaching to the set pressure.

The volumetric efficiency of the all tested air compressors was close to design and found in

the satisfactory range however, the SPC of all compressors were higher than the designed

SPC. The average specific power consumption (based on measurement) is estimated to be

7.09 kW/m3/min. Also, the average plant demand is estimated to be 29.4 m3/min i.e. 1,038

cfm (actual average air requirement of plant during normal plant operation) against the

operational capacity of 33.4 m3/min.

Due to less demand, the

unloading power of fixed

speed air compressor is

increasing and leading to

losses. In normal plant

operation, the actual air

requirement of the respective

compressor and percentage

loading period of each

compressor is given in table 1.5.


6

Recommendation

In many installations, the use of air is intermittent. This means the compressor will be

operated on low load or no load condition, which increases the specific power consumption

per unit of air generated. Hence, for optimum energy consumption, a proper compressor

capacity control should be selected. The nature of the control device depends on the function

to be regulated. One of the objectives of a good compressed air management system would

be to minimize unloading to the least as unloading consumes up to 30% of full load power.

It is recommended to replace the compressor-1 with VFD enabled air compressor. The

installation of VFD facilitates to reduce/increase the speed of the compressor as per the

plant compressed air requirement. This will completely avoid the unloading condition and

save unload power consumption, which is normally 25 – 35% of the full load consumption.

The detailed techno-economic calculation of measures is given in table 1.5.1.

Table 1.5.1: Energy saving calculation

Particular Unit Existing system Proposed system

C -1 C -3 C -4 C -5 Total C - 1 C - 1 Total

Designed FAD m3/min 8.21 8.21 7.7 9.3 33.4 14.9 14.9 29.8

Free air delivery of

operating compressor

m3/min 8.4 8.1 9.5 9.6 35.6 15.7 15.7 31.4

Loading (%) % 85.2 95.7 72.2 79.9 35.6 98.7 98.7 98.7

Total air generation m3/min 7.2 7.8 6.9 7.6 29.4 14.7 14.7 29.4

Total air demand per day m3/min/day 172 186 165 184 706 353 353 706.3

Average load power kW 57.4 54.5 49.8 64.8 80.3 80.3

Average unload power kW 27.1 28.8 0.0 39.8 0.0 0.0

Specific power

consumption

kW/m3/min 7.3 7.1 7.2 6.8 7.09 5.4 5.4 5.4

Average daily power

consumption

kWh/day 1,270 1,283 1,195 1,435 5,182 1,901 1,901 3802

Annual operating days Days/Year 288 288 288 288 288 288 288 288

Annual electricity

consumption

kWh/Year 14,92,409 10,94,897

Reduction in electricity

consumption

kWh/Year 3,97,511

Annual monetary

benefits (@ Rs. 4.25/kWh)

Rs. In

lakh/Year

16.9

Investment toward new

compressors (two units

and pipelines)

Rs. In lakh 29.7

Simple payback period Years 1.8


7

The other advantage of installing variable frequency drives are as follows

Using variable frequency drive the operating pressure can be precisely controlled. There

is no need to maintain a bandwidth as maintained in case of load/no-load control. This

leads to reduction in average operating pressure of the compressor hence reduction in

power consumption.

The leakage in the compressed air system is proportional to the operating pressure. Since

there is a significant reduction in operating pressure, volume of air leakage would also

reduce.

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