Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
of
Workshop on Dissemination of
Learnings of CoSMiLE
Edited by
Sanjay Mande
Jalajakshi C K
00-Prelims.p65
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ISBN 81-7993-147-1
All rights reserved. No part of this publication may be reproduced in any form or by any
means without prior permission of The Energy and Resources Institute.
Published by
T E R I Press
The Energy and Resources Institute
Darbari Seth Block
IHC Complex, Lodhi Road
New Delhi 110 003
India
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Contents
Foreword
Preface
vii
00-Prelims.p65
ix
Keynote presentation
Chapter 1
Gasifier applications in small and micro enterprises in rural
areas: potential and case studies
19
Chapter 2
Benefits of an optimally designed divided blast cupola
results from an actual case in Indian foundries
25
Chapter 3
Improving the performance of Kolar and Malur brick clusters
in Karnataka
37
Chapter 4
Air pollution issues in a small- and medium-scale industry
42
Chapter 5
Techno-social interventions in the puffed rice sector
49
Chapter 6
Elements of energy audit in small and micro enterprises
60
Chapter 7
Role of energy efficiency in small and micro enterprises
65
Chapter 8
Energy initiative in small enterprises manufacturers
perspective
70
Chapter 9
Scope on technology upgradation in scrap aluminium melting
units in Karnataka
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iv
Contents
81
Chapter 10
Efficient biomass energy use in the tiny sector of Karnataka
97
Chapter 11
Initiatives of the Karnataka Council for Technological
Upgradation
103
Chapter 12
Role of small enterprises
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Foreword
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vi
Foreword
R K Pachauri
Director-General, T E R I
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vii
Preface
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00-Prelims.p65
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Keynote
presentation
Energy
efficiency and
environmental
improvement
in small and
micro
enterprises
Technology
development
and
demonstration
00-Prelims.p65
Sector
Focus region/state
Foundry
Brick
Glass
Puffed rice
Thermal gasifiers
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Keynote presentation
Technology
dissemination
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xi
Keynote presentation
Thermal gasifier
applications
Brick
Puffed rice
Conventional cupola,
wet cap, dry cyclone
Coal/natural-gas-fired
pot furnace
Coal-fired muffle furnace
Improved technology
Key features
Coke savings of 25%65%; SPM
emissions brought below 70 mg/Nm3
Energy savings of 25%50% (and
significant pollution reduction)
SPM suspended particulate matter; Nm3 normal cubic metre; BTK bulls trench kiln
00-Prelims.p65
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xii
Keynote presentation
Table 3 Economic attractiveness, replication status, and the cumulative reduction in
environmental impact of various CoSMiLE technologies
Application Technology
Foundry
Glass
Brick
Puffed rice
Silk
Large
cardamom
processing
Upfront
investment
(Rs)
Divided blast
750 000
cupola,
pollution control 1 500 000
system for cupola
Natural-gas-fired
250 000
pot furnace,
natural-gas-fired
20 000
muffle furnace
Vertical shaft
600 000
brick kiln
2 000
Simple
payback
period
(years)
Status of
replication
units
CO2 emission
reduction
(tonnes) (up to
December 2004)
21 cupolas
installed
3 installed
10 900
25 installed
21 575
100 000
38 installed
69 994
100 000
27 installed
15 000
162 in Sikkim
and several more
in Nagaland,
Bhutan, and Nepal
Capacity
building
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xiii
Keynote presentation
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13
Foundry
Glass
Biomass
Brick
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xiv
CoSMiLE
Services
Keynote presentation
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Chapter 1
Abstract
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Biomass
gasification
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Figure 1 Types of dense phase gasifiers: (a) Updraft gasifier (b) Downdraft
gasifier (c) Cross-draft gasifier
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get process heat) despite their higher tar content as they give
relatively more flexibility than downdraft gasifier with regard to
fuel size and moisture content. Therefore, these two types of
fixed bed gasifiers are more in use in developing countries like
India. No elaborate gas cleaning is normally required for thermal
applications while gas has to be cooled (to improve engine
volumetric or breathing efficiency) and cleaned thoroughly (to
minimize damage to the engine and maintenance requirement)
for engine or power applications.
Gasifier for
process heat
in SMiEs in
India
Thermal
energy needs
of SMiEs
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Low
temperature
applications
Water boiling
High
temperature
applications
Kilns
Various types of kilns are used for baking of tiles, bricks, and
potteries or for heat treatment purpose (such as hardening
and annealing). Normal temperature requirements for such
applications are in the medium range (800950 C).
Furnaces
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Gasifier
thermal
systems for
biomass-using
industries
Gasifier
thermal
systems for
fossil-fuelusing
industries
Specific firewood
consumption (approximate)
Cremations
Tea drying
Large cardamom curing
Small cardamom curing
Silk reeling
Ceramic tiles
Brick making
Rubber sheet smoking
Tobacco leaf curing
Dyeing and fabric
printing of saris
and cloth
Road tarring
Vanaspati ghee
Fish smoking
Lime making
Distilleries
45 MT
0.51 MT
0.050.07 MT
0.1 MT
0.15 MT
0.2 MT
9 MT
0.06 MT
0.4 MT
1.87 MT
23 tonne per km
0.67 kg per kg ghee
0.21.6 kg/kg
0.52.0 kg per kg limestone
0.2 kg/litre
0.37 MT
0.63 MT
0.02 MT
100 tonnes
0.6 MT
MT million tonnes
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There are about 300 forging units spread widely in India. The
forging furnace is used for preheating billets and ingots to
attain a forge temperature maintained at around 1200 C to
1250 C. Forging furnaces use an open fireplace system and
most of the heat is transmitted by radiation. The typical
loading in a forging furnace is 56 tonnes, with the furnace
operating for 1618 hours daily.
Re-rolling mill furnaces
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Gasifier
selection,
sizing, and
cost
economics
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Price
(Rs/kg)
Wood
kg fuel
Wood price
(Rs/kg)
Wood cost
(Rs/kg)
Wood
Kerosene
Diesel
LPG
1.5
20
38
25
0.5
3.5
4.0
4.0
2.0
2.0
2.0
2.0
1.0
7.0
8.0
8.0
33
65
79
68
1.5
20
38
25
10 kg/hr 20 kg/hr
40 kg/hr
100 kg/hr
10
37
75
43
40
149
300
170
100
371
750
425
20
74
150
85
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10
Selected case
studies of
TERI gasifier
systems
Silk reeling
units in South
India
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11
Gasifier-based
dyeing ovens
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12
Wood gas
system for
large
cardamom
curing
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13
Figure 4 Wood gasifier system for large cardamom drying installed in Sikkim
Gasifier-based
furnace for
magnesium
chloride
production
01-Chapter.p65
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14
An updraft
gasifier system
for green brick
drying
Green bricks are required to be air-dried (sometimes sundried in later stages) to reduce moisture content from about
25% (immediately after moulding) to about 4%5% (just
before loading them in brick kiln). After moulding, bricks are
stacked closely for 12 weeks and are then air-dried in a
honeycomb structure arrangement for 34 weeks. Totally, it
takes about 45 days (34 days less if sun-dried in later stage)
to dry the bricks completely before loading them in the brick
kiln. This calls for large inventory of green bricks and large
shed areas for drying. In regions like Kerala, where it remains
cloudy for several months, green brick drying becomes very
difficult. This is a major bottleneck in continuing brick
production when brick prices are high.
In the traditional artificial drying method being followed
presently, green bricks are stacked in a cylindrical bin
structure (89 feet in diameter and 67 feet in height) and
wood logs are burnt inside. About 1500 bricks are stacked in
one bin. About 700800 kg wood logs are consumed in about
23 days time. It is a very inefficient method of drying, as
most of the heat is lost through the large fuel port opening
(2 ft 3 ft) and due to low residence time of gas as it passes
through openings of the honeycomb structure. It also results
in non-uniform drying; bricks in the lower portion get overdried, while those in upper portion remain under-dried.
01-Chapter.p65
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15
(b)
(a)
Figure 6 (a) An updraft gasifier operating on natural draft mode for green
brick drying installed in Kerala (b) Flame arrestor/heat distributor
Since most of the brick kilns are located along the river and in
unelectrified locations, an updraft gasifier system was developed,
which operates on natural draft mode (Figure 6).
A multiple producer gas burner operating under natural
draft mode was developed to achieve uniform drying of bricks.
The major benefits of gasifier systems include (a) substantial
reduction in fuelwood consumption (from 700800 kg to
250300 kg for drying about 2000 bricks in one batch);
(b) reduction in drying time (from 3648 hours to 1824
hours); (c) low green brick inventory requirement needing less
shed area for drying; and (d) improved working conditions (no
smoke).
Gasifier
system for
crumb block
rubber drying
units in Kerala
01-Chapter.p65
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16
(a)
(b)
Figure 7 Gasifier system for crumb rubber drying units in Kerala (a) Gasifier
unit (b) Crumb rubber trolleys
(a)
(b)
01-Chapter.p65
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17
Traditional
Gasifier system
Parameter
stove
stove
With blower
Without blower
Breakfast
Upma: 6 kg
4555
1519
1823
2.02.5
1.01.25
1.752.25
1519
2327
2023
2528
2.02.5
2.53.0
1.01.25
1.51.75
1.502.00
2.503.00
90109
98123
7.08.5
4.04.75
6.757.75
Lunch/dinner
Rice: 40 kg 4560
Dalma: 6 kg 6575
dal+10 kg
vegetables
Total (daily) 265325
Conclusion
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01-Chapter.p65
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Chapter 2
Abstract
Background
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20
Features of
the DBC
technology
02-Chapter.p65
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Replication
plants
Replication
project
Shining
Engineers and
Founders,
Rajkot
02-Chapter.p65
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22
Benefits of the
DBC
technology
02-Chapter.p65
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23
Consumption
before, %
of metallics
charged
(A) Savings in materials + energy
Coke usage
9.1%
Ferro-silicon
0.21%
Ferro-manganese
0.13%
Total (material
+ energy)
Less: Additional
power consumption
in blower
Net savings (material
+ energy)
Consumption
after, % of
metallics
charged
Savings
after
implementation of DBC
Approx. unit
cost at
Rajkot
(Rs/tonne)
7.4%
Nil
Nil
30%
100%
100%
11 000
42 000
60 000
Monetary
savings
(Rs/tonne
of molten
metal )
187
92
78
357
(26)
331
225
450
781
Conclusion
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24
Acknowledgements
02-Chapter.p65
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Chapter 3
Abstract
Issues
related to the
brick sector
03-Chapter.p65
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26
Options to
improve
performance
of
downdraught
brick kilns
In downdraught kilns
(Figure 24), dry bricks are
stacked, fired, cooled, and
taken out. These kilns are
generally constructed using
red bricks, with the inner
layer being refractory bricks.
The thickness of the wall is
about 5 feet. The total time
required for one cycle of
loading green bricks to
Figure 2 A downdraught kiln
cooling of fired bricks is
about seven days. The
production capacity of
downdraught kilns is
20 00040 000 bricks per
batch operation. There are
about 12 fireboxes in a
downdraught kiln, with six
fireboxes located on each
side. Figure 5 shows the
sketch of a downdraught
kiln.
Figure 3 Existing firing practices in
downdraught kiln
Dry bricks are stacked in
the downdraught kilns.
Generally, no gap is provided between
the bricks and the wall of the kiln. The
openings are sealed off and firing is
initiated. Eucalyptus branches and
firewood are used as fuels for firing of
bricks. Fuel is fed from all fireboxes
from both sides; firing is continued till
a temperature of about 500 oC is
attained. The operator uses his
experience to judge the temperature by
Figure 4 Stack emissions
observing the colour of bricks.
from a downdraught kiln
Temperature monitoring is not in
03-Chapter.p65
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Details
Production
Weight of brick (average)
Cycle period
03-Chapter.p65
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Detailed
energy audit
Improving the
operating practices
in a downdraught
Result of improved practices
kiln was
P Fuel savings of up to 20%
demonstrated in
P Reduction in firing cycle:
one of the units in
23 hours
the Kolar cluster,
P Reduction in the number of
which involved the
over-burnt and under-burnt
following.
bricks
P Quantification
of various inputs
such as weight
of bricks and fuel consumption before firing and after firing
P Adoption of uniform fuel-feeding pattern depending on
temperature requirements to enable uniform distribution of
heat and highest possible heat transfer
P Continuous monitoring of temperatures of firing zone (in
few selected locations) and flue gas temperature using
thermocouples
Adoption of BOP (best operating practices) helped in
saving fuel (energy) consumption, up to the extent of 20%,
improving product quality and reducing heat losses. The
following observations were made while demonstrating the
best operating practices in downdraught kilns (Table 2).
Options for
best operating
practices in
downdraught
kiln
Results
15.8 tonnes
800850 oC
7.4 MJ/kg fired bricks
95%98%
20%
MJ megajoule
03-Chapter.p65
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Operation up to 500 oC
Initial heating up to
500 oC is done gradually.
This means measured
quantity of fuel must be
fed at constant rate for
removal of mechanically
Figure 6 Existing firing practices in
held water and then
downdraught kiln
chemically held water.
Dampers must be open to
aid this process. Fuel feeding is done through half of the
fireboxes, and the remaining half must be kept closed until a
temperature of 500 oC is reached. For example if the kiln has 12
fireboxes, six fireboxes must be used. It is also recommended that
alternate fireboxes must be used during this phase.
Operation from 500 oC onwards
With the removal of chemically held water, the firing rate is
increased. Fuel feeding must be continued from all fireboxes
on both sides of the kiln. Damper openings must be reduced
to retain heat inside and temperature inside the kiln for
maximizing heat transfer to the bricks. During this stage,
flue gas heat losses are also reduced due to reduced air flow.
The firing temperature of bricks in the Kolar region is about
800850 oC. Firing must be continued from all sides to enable
soaking of bricks for about 3 hours in the same temperature
range. Firing is stopped at this point and all fireboxes are
03-Chapter.p65
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30
Weight
4.54 kg
3.76 kg
3.58 kg
17.3%
4.6%
Summer
Rainy
Winter
610
2025
1518
03-Chapter.p65
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03-Chapter.p65
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32
P
P
P
P
P
Brick kiln units in Kolar and Malur extensively use sheds for
both drying as well as storing of bricks. Figure 10 shows a
typical shed used in a brick kiln unit. A close look at the
sheds used in the cluster indicates scope for improvements in
the drying process. TERI demonstrated the benefits of
adoption of improved drying sheds in one of the brick kiln
units at Malur.
03-Chapter.p65
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33
Direction of sheds
Drying sheds are located in the northsouth, as well as in the
eastwest direction, depending on the convenience of the unit.
These sheds must be relocated mainly in the eastwest
direction, to match with the direction of wind flow, which
would improve the drying process.
Distance between adjacent sheds
Most of the drying sheds inside a brick kiln unit are built
close to each other with very little gap in between them.
Closely located sheds reduce the rate of heat transfer. In each
brick kiln unit, a space of about 5 feet must be left between
the adjacent sheds, which would help in improving convection
and hence removal of moisture.
Enhancing solar heating with translucent/glass tiles
The sheds of brick kiln units in Kolar/Malur are constructed
with clay tiles. These tiles do not allow sunlight to pass
through. It is recommended that at least 3%5% of existing
tiles in the sheds must be replaced with translucent tiles,
which would allow sunlight to pass through and help in
speeding the drying process. These glass tiles must also be
staggered (say, in a zigzag pattern) to ensure availability of
heat across different sections of the shed.
Provision of hoods in roof
03-Chapter.p65
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34
Use of
additives to
improve
strength of
green bricks
03-Chapter.p65
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35
New
technologies
VSBK
Changes in
initial firing
03-Chapter.p65
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36
The gap between the kiln wall and the brick column inside the
shaft was slightly increased and uniformly maintained. This
prevents falling of bricks, which otherwise would lead to kiln
stoppage and restarting. This problem has now been totally
eliminated.
Future
directions for
the Malur/
Kolar brick
industry
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Chapter 4
Abstract
Introduction
04-Chapter.p65
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38
Environmental
monitoring
04-Chapter.p65
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39
Duration of sampling
HH
Kitchen
About 1 m distance
from the stove
HH
HH
Living room
Ambient
Unit
Indoor
Unit
Ambient
Centre of room
Outside the house
(normally, one ambient
measurement for 45 HHs
in the same locality)
About 1 m distance
24 hours
from the stove
Outside the unit
24 hours
HH household
#
Concentration
of PM10 in
the units
PM 10 concentration
Average
Number of samples
Maximum
Minimum
NAAQS industrial area for RSPM
Indoor micro
environment (g/m3)
Ambient micro
environment (g/m3)
1006
n=10
2868
123
510
n=7
1000
137
24 hrs: 150g/m3
04-Chapter.p65
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40
Concentration
of PM10 in
the
households
PM 10 concentration
community
Average
Number of samples
Maximum
Minimum
Initial number of samples
Number of sample values
deleted
NAAQS for residential areas
Kitchen micro
environment
(g/m3)
Living room
Ambient micro
micro environment environment
(g/m3)
(g/m3)
274
(n=39)
1039
43
40
1
275
(n=5)
436
67
6
1
130*
(n=7)
276
19
9
2
24-hour average:
100 g/m3
Comparison of
observed
values with
available
Indian
standards
Statistical
tests for
correlations
04-Chapter.p65
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41
Observations
from the pilot
study
04-Chapter.p65
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Chapter 5
Abstract
Introduction
05-Chapter.p65
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Objectives
Understanding
the cluster
05-Chapter.p65
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05-Chapter.p65
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Competence
pooling
05-Chapter.p65
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05-Chapter.p65
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Techno-social
interventions
Dust arrestors
05-Chapter.p65
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48
members have utilized the loans for various incomegeneration activities such as poultry rearing, purchase of
paddy and clearing of existing debt of moneylenders and
hence freeing themselves of the vicious cycle of debt due to
high interest rates. The SHGs of puffed rice owners are very
confident about taking up cooperative paddy selling and
investing in high-end technologies such as the gasifier.
Conclusion
05-Chapter.p65
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49
Chapter 6
I Thanumoorthi, T E R ISRC
Abstract
06-Chapter.p65
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What is an
energy audit?
Energy audit is the key to a systematic approach for decisionmaking in the area of energy management. It attempts to
balance the total energy input with its use, and serves to
identify all the energy streams in a facility. It quantifies energy
usage according to its discrete functions. Industrial energy
audit is an effective tool in defining and pursuing a
comprehensive energy management programme.
As per the Energy Conservation Act 2001, energy audit is
defined as the verification, monitoring, and analysis of use of
energy, including submission of technical report containing
recommendations for improving energy efficiency with cost
benefit analysis and an action plan to reduce energy
consumption.
In any industry, the three main operating expenses are often
found to be energy (both electrical and thermal), labour, and
materials. If one were to relate to the manageability of the cost or
potential cost savings in each of the above components, energy
would invariably emerge on top, and thus, energy management
function constitutes a strategic area for cost reduction. Energy
audit will help in better understanding of the ways energy and
fuel are used in any industry, and help in identifying the areas
where waste can occur and where scope for improvement exists.
Energy audit would give a positive orientation to energy
cost reduction, preventive maintenance, and quality control
programmes, which are vital for production and utility
activities. Such an audit programme will help to keep alive
variations that occur in the energy costs, ensure availability
and reliability of supply of energy, decide on appropriate
energy mix, and identify energy conservation technologies,
retrofit for energy conservation equipment and the like. In
general, energy audit is the translation of conservation ideas
into realities, by lending technically feasible solutions with
economic and other organizational considerations within a
specified time frame.
The primary objective of energy audit is to determine ways
to reduce energy consumption per unit of product output or
to lower operating costs. Energy audit provides a benchmark
(reference point) for managing energy in an organization. It
also provides the basis for planning a more effective use of
energy throughout the organization.
06-Chapter.p65
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Preliminary
energy audit
06-Chapter.p65
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Detailed
energy audit
Plan of action
Purpose/results
Step 1
P
P
P
P
P
Step 2
Step 3
P
P
P
P
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53
Step
Plan of action
Purpose/results
P
P
Step 4
Step 5
Trials/experiments
Load variations trends in pumps, fan
compressors, and so on
24-hour power monitoring (maximum
demand, power factor, unit consumption, and so on)
Boiler/efficiency trials for (48 hours)
Furnace efficiency trials
Equipment performance experiment
Step 6
Step 7
P
P
P
P
Step 8
Cost-benefit analysis
P
P
Step 9
Step10
Measurements
Motor survey, insulation, and lighting
survey with portable instruments for
collection of more and accurate data.
Confirm and compare operating data
with design data
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54
Information to
be collected
Energy audit
instruments
Key
instruments
for energy
audit
06-Chapter.p65
54
4959
22/02/2008, 3:13 PM
55
06-Chapter.p65
55
4959
22/02/2008, 3:13 PM
56
Fyrite
Figure 4 Fyrite
Contact thermometer
06-Chapter.p65
56
4959
22/02/2008, 3:13 PM
57
Figure 9a Tachometer
Figure 9b Stroboscope
06-Chapter.p65
57
4959
22/02/2008, 3:13 PM
58
Economic
analysis of
investments
Payback
period
criterion
Conclusion
06-Chapter.p65
58
4959
22/02/2008, 3:13 PM
59
Conventional
technology
Improved
technology
Key
features
Foundry
Coke savings of
25%65%
Energy savings of
25%50%
Energy savings of
35%60%
Energy savings of
20%40%
Energy savings of
10%15%
Energy savings of
15%45%
Bibliography
06-Chapter.p65
59
4959
22/02/2008, 3:13 PM
60
Chapter 7
Abstract
Need for
efficient use
of energy in
SMiEs
07-Chapter.p65
60
6064
22/02/2008, 3:13 PM
61
Policy issues
Purpose of
energy
efficiency
studies in
SMiEs
07-Chapter.p65
61
6064
22/02/2008, 3:13 PM
62
Energy
efficiency as
an effective
tool
Requirement
of a clusterbased
approach
Need for
energy
efficiency
training in
SMiEs
07-Chapter.p65
62
6064
22/02/2008, 3:13 PM
63
Conclusion
Industry
AL-LAN textile
processors
Unifront textile
processors
Network
clothing
company
Krishna textile
processors
CETP plant
associated
with the textile
cluster
Type of
equipment
focused
Percentage
fuel
savings (wood)
Percentage
electrical
energy savings
Reference
Boilers, thermic
fluid heater,
compressors,
pumps, and drives
Boilers, thermic
fluid heater,
compressors,
pumps, and drives
Boilers, thermic
fluid heater,
compressors,
pumps, and drives
Boilers, thermic
fluid heater,
compressors,
pumps and drives
Boilers, pumps,
and drives
12%
8%
TERI Report
2005BB011
(AL-LAN)
7.3%
10.1%
TERI Report
2005BB011
(Unifront)
15%
6%
TERI report
2005BB011
(NCC)
27%
13%
TERI Report
2005BB011
(Krishna)
12%
8%
TERI Report
2005BB011
(CETP)
07-Chapter.p65
63
6064
22/02/2008, 3:13 PM
64
Bibliography
Website
http://www.smallindustryindia.com
07-Chapter.p65
64
6064
22/02/2008, 3:13 PM
65
Chapter 8
Abstract
Clean
Development
Mechanism
08-Chapter.p65
65
6569
22/02/2008, 3:13 PM
66
Appropriate
combustion
way to energy
efficiency
Importance of
perfect
combustion
08-Chapter.p65
66
6569
22/02/2008, 3:13 PM
67
Optimizing
excess air and
combustion
08-Chapter.p65
67
6569
22/02/2008, 3:13 PM
68
Figure 2 Relation between CO2 and excess air for fuel oil
Case study of
energy
efficiency in
small-scale
industries
Bibliography
08-Chapter.p65
68
6569
22/02/2008, 3:13 PM
69
Process
Equipment
Upgradation
Sand drying
Oil-fired rotary
sand drier
Insulation, enclosure,
combustion system
30
Yes
Shell sand
resin coating
Resin coater
20
Yes
Core baking
Core oven
30
Yes
20
Yes
Ladle preheating
Ladle preheater
50
Yes
Heat treating
Heat treatment
High velocity burner
20
furnaces oil/gas insulation, recuperator,
electrical
high insulation material 20
Yes
New combustion
technology, totally
enclosed, recuperation
2050
Yes
2050
Yes
Wire annealing
Pot furnace
New combustion
technology, totally
enclosed, recuperation
20
Yes
Continuous operation,
improved operation,
recuperation
25
Yes
20
Yes
Tank heaters
69
Yes
Ceramic shell
heating (investment casting)
08-Chapter.p65
2050
6569
22/02/2008, 3:13 PM
70
Chapter 9
Abstract
09-Chapter.p65
70
7080
22/02/2008, 3:13 PM
71
Introduction
09-Chapter.p65
71
7080
22/02/2008, 3:13 PM
72
Profile of
typical
aluminium
melting
operation
Pouring of molten
metal into the
moulds
Final product
09-Chapter.p65
72
7080
22/02/2008, 3:13 PM
73
Unit
Quantity
Capacity of crucible
Size (diameter x height)
Quantity of aluminium processed
Number of workers
Operation time
Quantity of fuel consumption
Specific fuel consumption
Price of fuel
Calorific value of fuel*
Fuel burning rate
Cost of fuel consumption
Number of annual working days
Cost of fuel in a year
kg
cm
kg/day
Number
h
kg/day
kg/kg
Rs/kg
kcal/kg
kg/h
Rs/day
Days/year
Rs (in million)/year
300
73 44
1200
4
10
176
0.16
25
10 500
17
4000
300
1.2
*<http://www.energyefficiencyasia.org/docs/tools/training_materials/
energy_equipment/>
Source Primary Survey, October 2007
Furnace
Performance
analysis
09-Chapter.p65
73
7080
22/02/2008, 3:13 PM
74
Symbol
Unit
Time of operation
Type of fuel
Total quantity of aluminium used
Quantity of pure aluminium used
Quantity of scrap used
Ambient temperature
Maximum temperature
Total quantity of aluminium
blocks produced
Quantity of fuel used
Fuel burning rate
Specific fuel consumption
Calorific value of fuel
mal
kg
%
%
C
C
kg
2:55
2:45
Furnace oil
368.2
448.0
46.2
61.7
53.8
38.3
26.0
30.0
813.0
750.0
334.8
372.0
kg
kg/h
kg/kg
kcal/kg
kJ/kg
MJ
MJ
%
%
%
51.9
42.9
17.8
15.6
15.5
11.5
10 500
44 000
2284.5 1887.6
418.0
480.4
18.3
25.4
3.4
3.9
7.1
8.2
Heat input
Heat output
Efficiency (useful heat)
Heat losses through side walls
Heat losses due to opening
Tambient
Tmax
msheets
mfuel
SFC
hfuel
Qinput
Qoutput
h
09-Chapter.p65
74
7080
22/02/2008, 3:13 PM
75
09-Chapter.p65
75
7080
22/02/2008, 3:13 PM
76
Energy flow of
the melting
process
Cost
economics
09-Chapter.p65
76
7080
22/02/2008, 3:13 PM
77
Improvements
Thermal
gasifier based
on biomass
Unit
Value
kg/h
MJ/kg
17.9
44.0
MJ/h
788.3
MJ/kg
16.8
MJ/kg
13.4
kg/h
58.8
%
%
%
kg/h
18
40
55
26
09-Chapter.p65
77
7080
22/02/2008, 3:13 PM
78
Unit
Value
1 200 000
2 544 000
3 744 000
Rs/year
273 000
Rs/year
24 000
Rs/year
2 419 500
2 716 500
Rs/year
1 027 500
27
09-Chapter.p65
78
7080
22/02/2008, 3:13 PM
79
Improved
furnaceoilbased melting
unit
Particulars
Unit
0.25
0.05
0.3
Initial gasifier cost/annual savings
Rs 0.3 million/Rs 1.027 million
0.29 years = 3.5 months
09-Chapter.p65
79
7080
22/02/2008, 3:13 PM
80
Conclusion
Acknowledgements
References
Bibliography
09-Chapter.p65
80
7080
22/02/2008, 3:13 PM
81
Chapter 10
Abstract
* Field Coordinator, Rural and Renewable Energy Area, TERI, 4th Main, 2nd
Cross, Domlur 2nd Stage, Bangalore 560 071, Email: nagaraju@teri.res.in
#
Associate Fellow, Rural and Renewable Energy Area, TERI, 4th Main, 2nd
Cross, Domlur 2nd Stage, Bangalore 560 071, Email: ckjalaja@teri.res.in
10-Chapter.p65
81
8196
22/02/2008, 3:13 PM
82
Jaggery
making
Conventional
jaggery
making
10-Chapter.p65
82
8196
22/02/2008, 3:13 PM
83
Types of
ovens
Two preheating vessels are used with the main heating vessel.
These types of ovens are used in Mandya and Bidar districts.
10-Chapter.p65
83
8196
22/02/2008, 3:13 PM
84
Two-pan
oven
Three-pan
oven
Four-pan
oven
1213
1620
2.0
1.5
1.251.0
1.00.75
0.090
0.090
0.095
0.110
Time required to
process 0.1 tonne of
jaggery (minute)
180
150
120
45
Details
Source Primary discussion with entrepreneurs in Mandya and TERI field experience
10-Chapter.p65
84
8196
22/02/2008, 3:13 PM
85
Need for
intervention
TERI
interventions
in single-pan
jaggerymaking units
10-Chapter.p65
85
8196
22/02/2008, 3:13 PM
86
Modified
jaggery oven
1200
1207
180
150
235
450
Description
Weight of sugar cane juice
processed per batch (kg)
Time of operation (minutes)
1.9
10-Chapter.p65
86
Advantages of
modified oven
Time saving of
30 minutes (15%)
Almost same
Fuel savings of
50 kg/batch (10%)
8196
22/02/2008, 3:13 PM
87
Cost benefits
Cost of the improved single pan oven is Rs 18 000 and
payback on investment is three months.
P Cost of one kg of bagasse is Re 1.
P Fuel savings 50 kg/batch 4 batches/day Rs 1/kg
= Rs 200/day
Tobacco
processing
Different
types of
tobacco curing
Air-curing
10-Chapter.p65
87
8196
22/02/2008, 3:13 PM
88
Process details
of dryer
(size 3962
3962 3962)
Number of
units
75
25
10-Chapter.p65
88
8196
22/02/2008, 3:13 PM
89
Need for
intervention
10-Chapter.p65
89
8196
22/02/2008, 3:13 PM
90
Bakery
Gasifier for
thermal
applications
10-Chapter.p65
90
8196
22/02/2008, 3:13 PM
91
Gasifier-based
bakery oven
Mid-day meals
10-Chapter.p65
91
8196
22/02/2008, 3:13 PM
92
Gasifier to
prepare midday meals
Crematoria
10-Chapter.p65
92
8196
22/02/2008, 3:13 PM
93
TERIs
intervention in
developing
gasifier-based
crematorium
10-Chapter.p65
93
8196
22/02/2008, 3:13 PM
94
Potential for
installation of
gasifier-based
crematorium
10-Chapter.p65
94
8196
22/02/2008, 3:13 PM
95
Conclusion
Jaggerymaking oven
Tobacco
processing
Gasifier for
thermal
applications
10-Chapter.p65
95
8196
22/02/2008, 3:13 PM
96
Acknowledgements
References
Websites
10-Chapter.p65
96
8196
22/02/2008, 3:13 PM
97
Chapter 11
Abstract
Technology
Management
Programme
Activities
under Phase I
Cluster study
11-Chapter.p65
97
97102
22/02/2008, 3:13 PM
98
Activities
under Phase II
Sector-specific studies
Case studies are being prepared for the tobacco and jaggery
sectors.
Workshop on Dissemination of Learnings of CoSMiLE
11-Chapter.p65
98
97102
22/02/2008, 3:13 PM
99
1998/99 1999/2000 2000/01 2001/02 2002/03 2003/04 2004/05 2005/06 2006/07 Total
Bangalore (U)
6
Bangalore (R)
0
Mysore
2
Belgaum
0
Udupi
0
Dharwad
0
Tumkur
0
Shimoga
0
Chikmagalur
0
Dakshin Kannada
0
Mandya
0
Kolar
0
Gadag
0
Uttar Kannada
0
Davangere
0
Bellary
0
Gulbarga
0
Total numbers
8
Amount (Rs million) 0.6
17
0
0
0
0
1
2
0
0
0
0
0
0
0
0
0
0
20
1.5
12
0
1
2
1
2
0
0
0
0
0
0
0
0
0
0
0
18
1.35
8
0
0
1
0
1
0
0
0
0
0
0
0
0
0
0
0
10
0.68
17
0
0
2
0
2
2
1
0
4
1
1
0
0
0
0
0
30
2.05
5
0
0
9
0
0
1
1
0
1
0
1
0
0
0
0
0
18
1.00
45
1
14
20
2
7
3
23
1
0
0
0
1
0
0
0
0
117
6.63
11-Chapter.p65
99
42
0
14
6
2
2
1
6
0
1
0
1
0
1
5
1
1
83
4.07
37
1
4
6
0
6
1
5
0
0
0
0
0
0
8
0
0
68
2.95
97102
22/02/2008, 3:13 PM
189
2
35
46
5
21
10
36
1
6
1
3
1
1
13
1
1
372
20.84
100
Figure 1 Assistance extended to industries under the ISO and ISI incentives
11-Chapter.p65
100
97102
22/02/2008, 3:13 PM
101
11-Chapter.p65
101
97102
22/02/2008, 3:13 PM
102
Number of units
Remarks
2001/02
2002/03
2003/04
2004/05
2005/06
2006/07
2007/08
Total
8
18
21
17
17
17
3
101
11-Chapter.p65
102
97102
22/02/2008, 3:13 PM
103
Chapter 12
Abstract
Definition of
small
enterprises
12-Chapter.p65
103
103109
22/02/2008, 3:13 PM
104
Significance of
small
enterprises
12-Chapter.p65
104
103109
22/02/2008, 3:13 PM
105
Performance
of small
enterprises
12-Chapter.p65
105
103109
22/02/2008, 3:13 PM
106
Number of units
Bagalakote
Bangalore (U)
Bangalore (R)
Belgaum
Bellary
Bidar
Bijapur
Chamarajnagar
Chikkaballapur
Chikmagalur
Chitradurga
Dakshin Kannada
Davangere
Dharwad
Gadag
Gulbarga
Hassan
Haveri
Kodagu
Kolar
Koppal
Mandya
Mysore
Raichur
Ramanagara
Shimoga
Tumkur
Udupi
Uttar Kannada
Total
6 788
61 008
16 375
30 243
13 768
7 513
7 345
7 568
37
6 890
8 747
17 581
7 598
14 689
6 947
14 104
10 124
8 252
3 352
13 350
4 462
8 393
20 764
8 389
5
13 401
19 970
7 215
8 344
353 222
1 346.72
21 588.53
4 310.55
5 532.86
4 327.89
1 376.35
1 327.38
810.20
5.31
1 108.18
1 493.98
3 739.10
1 646.35
3 518.82
955.39
2 308.26
1 798.86
1 130.96
631.28
4 840.81
1 656.85
1 548.50
3 995.15
1 775.71
51.00
2 064.09
4 104.63
3 204.74
1 896.99
84 049.517
31 330
526 373
84 422
127 115
64 778
40 866
40 051
32 868
184
29 575
36 374
91 455
35 533
127 151
25 530
61 032
44 048
31 174
22 680
83 732
29 122
38 303
107 720
40 262
54
55 457
102 460
46 967
44 620
2 001 236
Major issues
and
challenges
12-Chapter.p65
106
103109
22/02/2008, 3:13 PM
107
Labour
problems and
developing
human
resources
Land
availability
and
infrastructural
bottlenecks
Increasing the
exporting
capacity
Inadequate
finance
Delayed
payments
12-Chapter.p65
107
103109
22/02/2008, 3:13 PM
108
Sick small
enterprises
Policy
initiatives by
the
government
12-Chapter.p65
108
103109
22/02/2008, 3:13 PM
109
Conclusion
12-Chapter.p65
109
103109
22/02/2008, 3:13 PM