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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 pmc@teri.res.in
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
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
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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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.
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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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
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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.
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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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
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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.
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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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 harin.gandhi@glenmarkpharma.com Regular follow up for requirement
2 Meridian Chembonds Pvt Ltd
S.K Nair 9327467402 gm@meridianchembond.in 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 mahesh.x.hariharan@gsk.com Company Process in for takeover by other company
6 Sayona Crop Limited Parth Patel parth.patel@sayona.co.in Regular use Bando V-belts
7 Camex Limited 9825039736 works@camexltd.com Regular follow up for requirement
Companies which expressed interest in Bando’s belts through the workshop/survey feedback
8
Sajjan India Ltd
Gurupad Kondaguli grk@sajjan.com √ Given Bando V-belt for trial purpose.
Varun Kumar Rai 9167941103 varun@sajjan.com
Divyesh Donder 7046066618 divesh@sajjan.com
9 Bakul Pharma Pvt Ltd Vanrajsinh Matieda 9428289998 vanarajsinhmatieda@gmail.com Regular follow up for requirement
10 Meghmani Organics Ltd Vasudeo Patil 94221185270 mol2.engineering@meghmani.com Regular follow up for requirement
11 Rpg Life Science Vivek Chavan 9930810102 vivek.chavan@rpgls.com Regular follow up for requirement
12 Eagle Filtration Product Pvt Ltd 9825324719 info@globefilters.com Regular follow up for requirement
13 Shreenath Engineering Bipin Dudhat 9925250190 shreenathengineering@gmail.com Regular follow up for requirement
14
Coromandel International Ltd
Mitesh 7573042472 miteshk@coromandelsqm.muruyappu.com Regular follow up for requirement
Madhan Raj 9724853231 madhanpower@gmail.com,
madhanraj@coromandel.murugappa.com
15 Basic Pharma Joshi Mitesh 7567288241 miteshjoshi@basi.com Regular follow up for requirement
16 Basf India Ltd Sharanbassappa Patil 8980023690 sharanbassappa.patil@basf.com Regular follow up for requirement
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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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)
Hanumant Pawar 9898658552 hanumant.pawar@basf.com
17 Skylark Pharmaceuticals Pvt.
Ltd.
Sky 4 Skylark Ind.Pro 02646221315 sky.skylark@yahoo.co.in Regular use Bando V-belts
18 Gujarat rubber reclaim Pragnesh Patel 9979124411 pragnesh.patel@grpweb.com Regular follow up for requirement
19
Surya Life Science
Mahesh Borase 9408708126 mahesh@suryalifesciences.com Regular use Bando V-belts
Rishav Kumar 8200805897 suryalifesciences@gmail.com
Mahesh Prajapati 9428511150 suryalifesciences@gmail.com
Vikas Kumar 8200805897 suryalifesciences@gmail.com
20 Ganesh Remedies Dharmesh Jadav 9327115059 dharmeshjadav@ganeshremedies.com Regular follow up for requirement
21 Cls India Rajesh Riziya 9833577378 rajesh@clsindia.com Regular follow up for requirement
22
Bharuch Enviro Infrastructure
Ltd
Mahesh Pandal 9978447294 mahesh.pandal@beil.co.in Regular use Bando V-belts
Dharmesh Patel 8128088158 dharmesh.p@beil.co.in
Mayur Dobariya 8238022131 mayur.dobariya@beil.co.in
23 Suyoginc Pradip Patel 8347875000 production@suyoginc.com Regular follow up for requirement
24 Sunbeam Photochem Pvt Ltd
9824133608 sunbeamphotochem@yahoo.co.in
25 Zone Exchange Jitendra Mistry 9979003037 ank.engg@zonexchange.co.in
26 Epgls Sachin Patel 02646230200 sachin.patel@epgls.com
27 Hedbach India Prakash Jadhav 9879574910 pjadhav@hedbach-india.com Regular follow up for requirement
28 Abhilashu Pharma M.D Soni 9227135395 info@abhilashupharma.com
29 Amsal Chem Pvt Ltd Mahesh Soni 8732923096 maintenance@amsal.com Regular use Bando V-belts
30 Atul Limited Pankaj Prajapati 02646229159 pankaj.prajapati@atul.co.in Regular follow up for requirement
31 Wockhardt Limited Kunal Singh 9722183177 kunals@wockhardt.com Regular follow up for requirement
Deepak Rana 02646661494 drana@wockhardt.com
32 Subhasri Pigments Pvt Ltd
9227862815 ramesh.vavodiya@subhasripigments.com Regular follow up for requirement
Hitesh Rana 9227862803 hitesh.rana@subhasripigments.com
33 Sunny Chemicals
Gopal Vekaria 9714911044 gopalvekaria002@gmail.com Regular follow up for requirement
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
19
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)
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 parmarparth41@gmail.com
Jignesh Gahil 9662165431 jigneshgahil1992@gmail.com
Bhaumik Patel 9909522479 bhaumikpatel911.ee@gmail.com
Munoj Patel 9913305033
Dharmendra 9978471119 dharm.vdsaya@gmail.com
Malaysingh Borasiya 7874651056 malayborasiya@gmail.com
Mahesh Patel 9428061280 mgpatel36@gmail.com
Jagdish Rawal 9825224939 ankura74@gmail.com
Sanjay Patel 9998350690 sanjaygj198009@gmail.com
Manoj Thakur 9428685813
J Mulhu 7358406579 mulhujaijam@yahoo.com
Legik Joseph 9328624003 legikjoseph19@gmail.com
Nirav Panchal 9510026171 nkpanchal@yahoo.com
Jayashbhai Patel 9377510253 jayeshske@gmail.com 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
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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).
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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.
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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.
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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.
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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
Strategic activities to promote the dissemination of Japanese low carbon technologies in India (FY 2019)
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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.
Recommended