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List of Energy Efficient Technologies

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List of Energy Efficient Technologies

 
S.No. Name Of Technology About Technology Potential saving(%) Sector Investment (₹ Lakh) Annual Monetry Saving (₹ Lakh) Payback (Months) Equipment Capacity
Electrical
1 Automation and Control System Automation and control system provides effective monitoring of process and utility for better resource utilization and loss reduction 5-15 % Cross-sectoral - Electrical 20-25 25-30 8-10 Not Applicable
1.1 Automation of Withering Troughs The automation of withering trough will ensure achieve optimum temperature and ensure effective control thereafter for proper withering of tea leaves 10-15% Cross-sectoral - Electrical 15-20 6-8 30-36 8 nos. of Enclosed Trough & 96 HP Motor
1.2 Combustion Control System for Boiler Combustion control system in boiler provides effective monitoring of flue gas parameters, their temperature and pressure for complete combustion 15-20% Cross-sectoral - Electrical 9-10 4-5 25-30 12 TPH
1.3 Energy Management System The EMS is effective in managing energy flow and consumption, reduce wastage and do necessary rectification in case of any fault 15-30% Cross-sectoral - Electrical 7-10 3-4 24-36 For 300 smart energy meters
2 Energy Efficient Turbo Blower Turbo blower is made of anodized aluminium impellers and air foil bearings. As a result it has low weight and high corrosion resistance bearings to provide excellent control over varying rpm 30-45% Cross-sectoral - Electrical 30-40 20-25 18-24 20,000 and 50,000 rpm
3 Gasifier for Electrical Application Gasifier gasifies coal or biomass to produce gas that can be used for power generation in gas genset or gas turbine 15-25% Cross-sectoral - Electrical 20-25 9-12 20-24 50 KW
4 Hanger Shot blast Machine Shot blasting systems offer you nearly unlimited options from deflashing, descaling, sanding and rust removal to roughening, matting, smoothing, edge rounding and shot peening. 30-40% Cross-sectoral - Electrical 18-20 8-10 24-30 500 Kg
5 IGBT based Induction furnace An induction furnace is a clean, energy-efficient furnace which provides well-controlled melting process, compared to conventional means of metal melting 20-30% Cross-sectoral - Electrical 20-25 15-20 15-18 750 KG
6 IGBT based temperature control Installing Insulated Gate Bipolar Transistor (IGBT) based temperature controller for furnace ensures precise controlling of temperature. 10-15% Cross-sectoral - Electrical 18-20 5-6 38-40 50-60 KW Furnace
7 Infrared (IR) Heaters Use of IR Heaters results in uniform heating and reduces the baking time. Infrared heaters are extremely quiet and energy-efficient heating devices that produce a very gentle heat. 10-20% Cross-sectoral - Electrical 3.5-10 1.8-2.0 18-24 100 Kg-5 MT per hour
8 Light emitting diode (LED) Lighting Light emitting diode (LED) is a semiconductor light source that emits light when current flows through it. These are energy-efficient lights with long life, durable, and offer better light quality than other types of lighting 35-50% Cross-sectoral - Electrical 13-15 30-35 3-5 connected load 625 kW
9 Micro Turbine Micro-turbines are tiny gas turbines that can generate both electricity and heat, and may vary in electrical output from around 25 kW to 250 kW 15-30% Cross-sectoral - Electrical 40-45 25-40 14-20 20 - 60 KW
10 Motors (IE3 or IE4 or IE5) EE motors are constructed with improved manufacturing techniques and superior materials, longer insulation and bearing lives, lower waste heat output, and less vibration, all of which increase efficiency and reliability 25-40% Cross-sectoral - Electrical 5-7 2-3 20-25 connected load 730 kW
11 Screw Compressor with Permanent Magnet (PM) motor Screw Compressor is driven by Permanent Motors and thus there is no rotor loss or transmission loss that results from rotor winding 15-20% Cross-sectoral - Electrical 6-7 3.5-4 18-24 20 HP; 92.5 CFM
12 Static Reactive Power Generator with Harmonics Filter In an electric power system, a load with a low power factor & Higher Harmonics draws more current and this results in higher current withdrawal and energy losses. The Static Reactive Power Generator, an IGBT based INVERTER, helps to compensate reactive power as well as selective harmonics (5th, 7th, 11th & 13th Order Only) created by the load and unbalance in the system. This helps to minimize losses 4-5% Cross-sectoral - Electrical 5 6 11-12 100 KVAr
13 Temperature controller for cooling tower fan This intervention increase the efficiency of electrical energy utilization in the cooling tower by automatic control of cooling tower fans, based on a feedback from the water temperature from the cooling circuit 10-25% Cross-sectoral - Electrical 0.2-0.3 0.2-0.3 12-15 Not applicable
14 Tri-generation Tri-generation technology provides thermal, cooling and electrical energy and it has higher efficiency compared to power generation and cogeneration plants 20-25% Cross-sectoral - Electrical 2500-3000 700-1000 36-40 Capacity: 2.75 MW, 20 TPH
15 Variable Frequency Drives (VFD) To control speed of various appliances like motors, pumps, compressor motors, ID fan, FD fan, hydraulic press, jet drying machine, Thermic Fluid Pump, Grinding Machine etc 30-40% Cross-sectoral - Electrical 2.5-3 3.5-4 8-10 connected load 430 kW
16 Variable Refrigerant flow (VRF) in HVAC Variable Refrigerant Flow (VRF) Systems are an excellent choice for buildings that require both heating and cooling to coexist simultaneously. VRF systems have the ability to regulate the flow of refrigerant to various indoor units so that one location can stay cool while the other remains warm. 15-20% Cross-sectoral - Electrical 45-50 15-20 36-48 100 TR
17 Vertical Roller Mill (VRM) Vertical roller mill is a type of grinder used to grind materials into extremely fine powder for use in mineral dressing processes, paints, pyrotechnics, cements and ceramics. It is an energy efficient alternative for a ball mill. Typical Sector: Cement, Ceramics, limestone, etc. 6-10 KWH per MT raw material Cross-sectoral - Electrical 20-24 5-6 36-48 1 TPH
18 Energy Efficient Screw Compressor The screw compressors are the most efficient one to generate compressed air as well as less heat compared to normal air compressor 25-40% Cross-sectoral - Electrical 2.5-6.5 1.5 - 7.5 20-25 15 - 150 HP
19 Energy Efficient Pumps - 5 Star Rating Pumps EE pumps have optimum impeller design, thereby leading to optimum discharge flow and pressure and energy consumption 15-30% Cross-sectoral - Electrical 0.7-4.5 0.25 - 5 20-25 10 - 20 HP
20 Electrical Servo Drives The servo drive is quite efficient in smooth start and stoppage of machine having frequent load fluctuation, and helps reduce energy wastage as well as wear and tear of machine 20-30% Cross-sectoral - Electrical 10-15 10-20 10-12 200 KVA
21 Light Pipe Light Pipes are primarily used for illuminating deep interior spaces where there is poor daylighting provisions from doors /windows 15-20% Cross-sectoral - Electrical 5.00 2.27 26 25 nos. Light Pipe for 9 KW Lighting Load
22 AI&ML based IoT platform for Energy and Asset management A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 15-20% Cross-sectoral 10-12 5-6 18-24 All types of buildings & industries
Thermal
23 Cogeneration Cogeneration technology provides thermal and electrical energy both and it has higher efficiency compared to power generation plant 30-50% Cross-sectoral - Thermal 1000-1200 200-250 50-60 2 MW and 12 TPH extracted steam at 6.5 kg/cm2 and 245 C
24 Condensate recovery system in boiler/jet dying machine For applications with zero contamination, the condensate recovery system can be effectively used to conserve and reuse water in boiler 10-15% Cross-sectoral - Thermal 12-15 7-8 18-20 4 TPH
25 Electric Dry Vacuum Pumps Electric dry vacuum pumps do not require any fluid to generate vacuum compared to steam ejectors, thereby eliminating the contamination of process vapours and providing better solvent recovery 40-50% Cross-sectoral - Thermal 18-20 Dec-15 18-24 6 TPH Boiler
26 Energy Efficient Boilers Energy Efficient Boilers offer effective combustion of fuel with maximum utilization of energy 10-15% Cross-sectoral - Thermal 25-30 5-6 55-60 4 TPH
27 Energy efficient Refrigeration Compressor The refrigeration compressor of latest technology, having good automation and higher Coefficient of Performance (COP) must be used to save electrical energy during refrigeration cycle 10-15% Cross-sectoral - Thermal 3.5-5 2-3 18-24 60 HP
28 Gas fired Annealing furnace The gas-fired annealing furnace is essential to ensure high level of operational efficiency of the furnace w.r.t the electrical-fired furnace, due to high GCV of Gas w.r.t electricity 20-30% Cross-sectoral - Thermal 14-15 5-6 30-36 1000 MT
29 Ground & Water source Heat Pumps (GSHP) GSHPs use water-to-water or water-to-air approaches to treat this stable thermal environment as a heat source in the heating season and a heat sink in the cooling season 35-40% Cross-sectoral - Thermal 1-1.5 0.2-0.3 36-60 1 TR
30 Heat Pump A heat pump is a device that can heat a building/utility by transferring thermal energy from the outside using the refrigeration cycle 30-40% Cross-sectoral - Thermal 30-35 20-25 15-18 339 KW
31 Hot Air Generator from Briquette Briquette is locally available and commercially cheap alternative fuel compared to coal /wood, prepared by using agro waste, and can be used for low temperature application 20-30% Cross-sectoral - Thermal 50-55 35-40 18-20 10 Lac Kcal /Hr
32 Hot Water Generator The hot water generator is of natural draft system and doesn?t have FD and ID fans. They are the efficient and cost-effective way to generate hot water instantly 20-25% Cross-sectoral - Thermal 2.5-3.5 1.68 - 1.85 19-23 1000 - 80000 Kcal/hr
33 PUF insulation Polyurethane Foam (PUF) is the most effective thermal insulation material and having high strength to weight ratio at low temperature, are durable for years, with high mechanical strength 20-30% Cross-sectoral - Thermal 3.5 - 4.0 0.6-0.7 60-72 100 sq.m surface of 120 mm thickness
34 DeSuperheater for Chiller Compressors A desuperheater recovers the heat from the super-heated refrigerant gas at the compressor outlet 10-15% Cross-sectoral - Thermal 4-5 1-2 30-36 41 KW Compressor
35 Steam operated pumping traps Steam operated pumping traps are operated on steam and is used for condensate evacuation under all operating conditions, thereby enabling high system uptime and enhanced productivity. 3-5% Cross-sectoral - Thermal 1.51 1.54 12 2 TPH Boiler
36 Mechanical Vapor Recompression (MVR) Evaporator A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 20-25% Cross-sectoral 60-80 40-60 18-24 5000 LPH
37 Back Pressure Turbine A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 15-30% Cross sector 55-70 55-90 7-12 200 - 250 TPD Plant
Thermal - Waste Heat Recovery (Low Temperature)
38 Heat Exchanger A heat exchanger is a system used to transfer heat between a source and a working fluid. 10-15% Cross-sectoral - Thermal 4-4.5 8-8.5 6-12 7000 Kg/h
39 Hot water generation from cement kiln The waste heat, which otherwise would escape in atmosphere may be recovered using appropriate heat exchanger to pre-heat water for use in utility or process 20-25% Cement - Thermal 100-125 30-40 30-36 3000 TPD kiln 60 TR VAM system
40 Low-Grade Waste Heat Recovery System (LGWHRS) Waste heat even below 100 C is recovered by LGWHRS and can be used in the low temperature applications. These heat exchangers are specially designed for low-grade waste heat recovery. 10-15% Cross-sectoral - Thermal 10-15 5-7 30-36 24-36 TPH
41 Thermo Compression Utilization of waste flash steam in chiller and process usage 20-25% Cross-sectoral - Thermal 150-200 70-80 24-30 3000TR
Thermal - Waste Heat Recovery (Medium Temperature)
42 Air Pre Heater & Drying Bed in furnace Use of waste flue gas to pre-heat the material and save fuel 18-20% Cross-sectoral - Thermal 5-5.5 5.5-6 12-14 1.5 TPH
43 Economiser in boiler/Thermic Fluid Heater The use is Economizer is highly recommended to save fuel in thermal application by use of high heat content in flue gas to pre-heat water, which can then be used in utility or process application 10-15% Cross-sectoral - Thermal 3-3.5 4-4.25 6-8 4 TPH
44 Gas-fired Reheating Furnace with WHR System A fully automated system ensures better control on temperature of metals in rolling mills, with efficient combustion owing to the use of gas as fuel. In addition, the WHR system will save substantial energy by preheating the metal to the extent possible before reheating 15-45% Cross-sectoral - Thermal 19-21 16 - 28 9-14 2 - 12 TPH
45 Waste Heat Recovery Boiler WHR Boiler is a system which recovers various kinds of waste heat generated from the production process of steel, chemical, cement etc and convert such recovered heat into useful and effective thermal energy 10-15% Cross-sectoral - Thermal 3.5-4 3-3.5 12-15 4 TPH
46 Waste Heat Recovery System for Coke Drying Quenching (CDQ) Smelting furnace generates flue gas at high temperature. This flue gas temperature is utilized to heat the atmospheric air that is utilized for coke drying 20-25% Cement - Thermal 300-350 200-250 18-24 7 TPH Coke Drying from 15% - 2% W/W
47 Waste Heat Recovery for power generation The WHR process is a fuel conservation measure where the heat from waste stream of gases is recovered to generate steam which in turn is used to drive turbine and generate power, instead of using conventional process of burning fuel 10-15% Cross-sectoral - Thermal 900-1100 230 54-60 1 MW
Thermal - Waste Heat Recovery (High Temperature)
48 Recuperators A recuperator is used to recover the waste heat, usually from the exhaust flue gas generated from furnace and use it to preheat the combustion air, thereby ensuring fuel saving and process efficiency 20-25% Cross-sectoral - Thermal 4.5-5 3.5-4 12-14 3 MT
49 Recuperative burner for heat recovery for high medium temperature furnaces A recuperative burner is the one where recuperator is the integral part of the burner, and the waste heat is recovered to pre-heat the combustion air, thereby ensuring substantial energy saving 25-30% Cross-sectoral - Thermal 200-225 200-225 12-15 15TPH rolling mill
50 Regenerative burners for high temperature furnaces In regenerative temperature can go to 1000 degC, resulting huge energy savings and improved furnace productivity. Applicable only for gas fired furnaces 15-20% Cross-sectoral - Thermal 20-30 20-30 12-15 One unit burner for 110 TPH furnace
Sectoral
51 Alternative Fuels & Raw Material (AFR) Utilization Utilize Alternative Fuels such as PTA Sludge, Syngenta Waste, Pines leaves etc, Municipal Solid Waste for thermal energy generation Thermal Substitution rate of 5-10% Cement 8000-10000 1600-2000 60-72 3.1 MTPA
52 Adiabatic Pre-reformer Adiabatic pre-reforming is a well-established process in modern syngas production and implies both economic and operational benefits. The adiabatic prereformer converts hydrocarbon feed-stocks by steam reforming reactions in the low temperature range, 350?550?C 4-10% Fertilizer 1500-1600 600-900 20-30 2000 TPD
53 BEE 5 Star Rated AC Replacement of Conventional Split/Window AC with 5-star AC having higher COP or EER /ISEER 20-45% Building 0.40-0.50 0.18-0.20 24-30 connected load 57 kW
54 Bleached Chemi Thermo Mechanical Pulp (BCTMP) It is an advanced technology for the production of high-quality chemi-mechanical pulps from hardwoods and annual plants, which is very reliable and achieves highest pulp quality at minimum operating cost and lowest environmental impact. 15-20% Pulp & Paper 40000-45000 10000-12000 48-50 1 Lac TPA BCTMP
55 Cascaded Condensate Recovery System Installing cascaded condensate recovery system increases condensate recovery up to 90% 5-7% Pulp & Paper 08-Oct 30-35 03-May Not applicable
56 CNC Machine (Special Purpose Machine) CNC machine helps enhance productivity and lower Specific Energy consumption as one machine take care of all cutting, boring, drilling, milling, grinding operations, etc. 30-35% Machine Tool 35-40 25-30 17-20 400 KN
56.1 CNC Bending Machine As above 32% Machine Tool 36.35 26.07 17 400 KN
56.2 CNC Gear Hobbing Machine As above 25% Machine Tool 225.00 72.27 38 NA
56.3 CNC Grinding Machine As above 23% Machine Tool 45.61 33.73 16 NA
56.4 CNC Horizontal M/c Centre As above 30% Machine Tool 151.00 67.73 27 NA
56.5 CNC Lathe Machine As above 30% Machine Tool 40.80 14.88 33 NA
56.6 CNC Milling M/C As above 30% Machine Tool 73.41 28.86 31 NA
56.7 CNC Turn ?Mill Centre As above 25% Machine Tool 50.48 17.62 35 NA
56.8 CNC Turret Punch Machine As above 41% Machine Tool 88.66 51.27 21 20 TON
56.9 CNC Wire Cut Machine As above 35% Machine Tool 61.00 26.07 28 NA
57 Divided blast cupola For replacement of conventional cold blast cupola for better melting of metals, generated less pollution and saves coal as well 20-25% Foundry 6-8 3-4.5 20-24 2 MT/Batch
58 Electrical Annealing Bogie Furnaces The energy cost in electrical annealing furnaces is low comparatively with wood fired furnaces due to more efficiency of electrical heating, less manpower cost and low energy cost. Further, this also ensures maintain uniform temperature throughout the furnace 25-30% Brass & Aluminium 8-10 4-5 22-24 60 kW
59 Energy Efficient Brushless Direct Current (BLDC) Fan BLDC fans consumes lower energy compared to conventional fans, having high reliability and life expectations as well 35-50% Building 4-6 1-2 24-36 connected load 243 kW
60 Energy efficient cyclone Energy efficient cyclone has 97.5% efficiency and it can be installed at the last stage in Pre-heater 1.03 KWH & 7000 KCal/MT of Clinker Cement 600-650 200-220 36-40 105 TPH
61 Energy efficient gas fired pot furnace It has several pots or crucibles in which different small batches of glass can be melted 30-35% Glass 10-15 10-15 10-12 10-12 pots, each of 500-550 Kg capacity
62 Energy efficient impeller Energy efficient Impeller 84% efficiency. The can improve the performance of Fans installed in industries 1.08 KWH/MT Clinker Cement 100-120 42-45 24-30 250 Ton of Clinker
63 Energy Efficient Modulating Burner These burners are provided with variable air/fuel ratio leading to better heat generation and drying of leaves, thereby producing good quality tea 10-15 % Tea Processing 5-7 8-10 9-12 Dryer 1 @450 kg/h; Dryer 2@250kg/h.
64 Energy Efficient Tank furnace Tank Furnaces are primarily used in glass industry where continuous flow of glass is needed to feed automatic glass forming machines. 15-20% Glass 400-450 200-300 24-30 25-40 TPD
65 Energy Efficient technology for ECBC/Eco-niwas Samhita The efficient building envelope helps prevent heat loss /gain between inside space of building and outside atmosphere, thereby ensuring more comfort, maintain appropriate building temperate and also reduce heating /cooling load, thereby saving electrical energy to a great extent. 15-25% Building 220-240 230-250 10-12 connected load 15000 kW
66 Energy Efficient Tray Dryer The Tray drying is a batch process used to dry materials that are liquid or wet cake, and works well for material that requires more gentle processing or cannot be atomized in an air stream due to viscosity. 15-20% Chemical 10-12 6-8 15-20 400 Trays
67 Exhaust humidity measurement & control system To control outlet moisture of Fabric on stenter and control blower motor speed and power consumption as well 5-15% Textile 2-2.5 1-1.25 24-30 1 unit
68 Fabricated Water Ring Vacuum Pumps Fabricated water ring vacuum pumps have precise design, reduced dead weight and reduced wear and tear compared to conventional cast iron water ring vacuum pumps 30-40% Pulp & Paper 50-55 45-47 18-24 230 GSM duplex paper with 2.62 TPH capacity
69 Fiberglass Reinforced Plastic (FRP) Fan in Withering Units The Fiberglass Reinforced Plastic (FRP) is light in weight compared to metallic blade and can resist any weather situation and withstand corrosion, waterborne bacteria, and organisms. 10 - 15 % Tea Processing 8-10 12-15 6-8 31 troughs, 39 nos. fans
70 Fluidised Bed dryer system The Fluidised dryer system will ensure better quality tea by ensuring effective drying of tea leaves 10-15% Tea Processing 15-20 7-10 24-30 500-700 Kg/hr
71 Forging Furnace The energy efficient forging furnace provides effective heat for the heating and reheating of large steel ingots, blooms and cast parts, with better temperature control and reduced skin losses from outer surface of chamber 15-20% Forging 20-25 20-25 10-12 250 KW
72 Gas Engine based co-generation technology A Cogeneration is a system having gas engine produces heat and electricity simultaneously in a single plant, powered by gaseous fuel having better combustion and less ash generation, thereby guaranteeing a better energy yield 30-40% Ceramics 800-1000 320-350 30-35 2.72 MW
73 Gas fired hot air generator system For replacement of conventional wood fired hot air generator system with better combustion control and less emission 20-25% Chemical 4-5 3.5-5 10-12 120000 Kcal/hr
74 Gasifier For Kilns The Gasifier is a cheaper energy source having better yield compared to conventional fuel for combustion in kilns 30-35% Limestone 55-65 24-30 28-32 30 TPD
75 Gasifier for Melting And Reheating Process Rice husk works as renewable source of energy. Hence use of rice husk reduced cost of production and waste utilization as well 20-25% Brass & Aluminium 40-45 25-30 18-24 500 KG
76 Hi-Consistency Pulper Hi-consistency pulper requires lesser amount of water compared to low consistency pulper. 10-15% Pulp & Paper 45-50 15-17 36-40 130 kW
77 High Efficiency Refiner Refiners are used for mechanical pulping (TMP refiners) and the post-refining of GWP (Ground wood Pulp) mills. Energy efficient refiners can reduce no-load power caused by motor, pumping, and friction losses. 7-20% Pulp & Paper 480-500 450-500 Dec-15 300 TPD
78 High Pressure Moulding Line in Moulding Area High pressure moulding line has advantages such as continuous mould preparation, fast pattern changing time, fully automatic machine and it does not require mould transportation, storage and maintenance which can reduce manpower 50-60% Foundry 150-175 26-30 60-72 2500 kg
79 Hot Charging of Billets Hot charging of billets can serve as an energy efficient alternative for this process in which the steel is melted at slightly higher temperature of 1650?C and then the molten steel is fed into CCM where the temperature of the billet (1150?C) at the output is controlled by PLC, which is directly sent to the rolling bay, thereby eliminating the need of re-heating. 100% - Complete elimination of re-heating Iron & Steel 150-200 300-350 06-Aug 1 Lacs TPA
80 Hydraulic Hammer Hydraulic hammers are 30-40% energy efficient than pneumatic hammers. Operation of the hydraulic hammers are very smooth and noise free as compared with pneumatic hammers. 30-40% Forging 150-170 50-70 46-50 10 ton
81 Induction Billet Heater For replacement of Oil Fired Furnaces with having better control on temperature and energy saving as well 20-25% Forging 38-42 37-42 10-12 3-4 ton capacity oil-fired furnace
82 Latest Generation High Efficiency Clinker Cooler It offers significant potential for electrical and thermal energy saving; The total heat loss of latest generation clinker is less than 100 Kcal /Kg Clinker compared to conventional cooler where heat loss is more that 120-150 kCal /Kg Clinker 15-20% Cement 1800-2000 400-500 48-60 3000 TPD Clinker
83 Liquid Ring Compressor This Liquid Ring Compressor will function as flare gas recovery system (FGRS) to recover the flare gas and sending it to Delayed Cooker Unit (DCU) wet gas compressor suction, which will further be directed to Fuel gas header to use it as fuel gas in refinery fired heaters. This has also avoided the requirement of dedicated FGRS. 10-15% Refineries 500-600 800-900 6-8 8.5 MT per day fuel oil equivalent
84 Louisiana State University (LSU) Port Dryer This technology ensured uniformly dried product and can be used for different types of grains as well 25-40% Food Processing 30-35 16-20 22-25 24 MT
85 Low Consistency Refining (LCR) The refining of pulp prior to papermaking process is one of the most energy intensive and involves the alteration of cell structure of pulp fibers by imparting mechanical action. Low consistency refining can optimize the current refining process to enhance the productivity and save significant amount of energy and chemicals. 20-30% Pulp & Paper 15-20 22-25 08-Oct 200 TPD
86 Low Thermal Mass cars in Tunnel Kiln The reduction in weight of kiln cars in Tunnel kilns provides significant amount of energy saving and improved material to car weight ratio 10-13% Glass & Ceramic 0.55 per car 2.5-3 2-3 1130 Kg per car
87 Medium frequency Induction Furnace The medium frequency induction heating furnace adopts the basic principle of induction heating. It is a high-tech product replacing the traditional oxygen, oven and salt slag furnace. It can save energy, save time, fast and improve the quality of the product 10-15% Iron & Steel 30-35 13-15 24-30 250 KW
88 Membrane Filter Press For replacement of conventional Filter Press with better drying of sludge 30-40% Chemical 40-45 15-20 30-35 60 Plates
89 Natural Gas fired Boiler Replacement of conventional Coal /Wood fired boiler with NG fired Boiler 20-30% Foundry 06-Aug 2-2.5 36-40 300 kg/hr
90 Nutsche Filtration and Drying Process ANFD is used for active pharmaceutical ingredient (API) filtration. It is a combination of slurry filtration, product washing, and vacuum drying processes into a single unit. 10-20% Pharmaceutical 25-30 20-25 15-18 3 KL
91 Oxyfuel Burner To increase the oxygen content, the induction furnaces are used with oxyfuel burners along with standard burners which also reduces the content of nitrogen from the air. This improves the efficiency of combustion process 30-40% Pulp & Paper 300-325 45-50 72-84 200 TPD
92 Palletisation plant - Sponge Iron The palletisation ensures agglomeration of fine iron ores which is easy to handle in blast furnace or EAF 10-15% Sponge Iron 4000-5000 800-1000 48-60 0.3 MTPA
93 Pocket Ventilation System Pocket Ventilators improve the drying rate, moisture profile and production for paper machines. The ventilators prevent sweating, corrosion and fibre build up. 5-15% Pulp & Paper 30-35 75-80 05-Jul Not applicable
94 Radiant Cooling Radiant cooling is a hydronic system that circulates chilled water through PEX pipes embedded in the floor or ceiling, or through copper pipes embedded in ceiling panels. Water passing through these pipes first cools the floor/ceiling surface, which then cools the enclosed space through radiation. 30-50% Building 1.2-1.5 0.3.-0.4 36-48 1 TR
95 Rapier or Auto Loom For replacement of conventional Power Loom thereby ensuring enhanced productivity and production, reduced energy and manpower cost 15-20% Textile 50-52 25-30 24-30 220 rpm
96 Recovery of BOF gas and sensible heat in Basic Oxygen Furnace The gas produced in the BOF has a temperature of approximately 1200?C and a flow rate of approximately 50-100 Nm3/t-steel. The gas contains approximately 70-80% CO when leaving the BOF and has a heating value of approximately 8.8 MJ/Nm3 (NEDO, 2008) or 0.84GJ/t-steel 3-5% Iron & Steel 3753.3 1003.8 45 30-400 MT
97 Replacement of steam turbine drive with high speed motor drive Replacement of steam turbine drive with high speed motor drive will result in saving of steam and extra power generation 15000 Ton of NG per year Refineries 22500-25000 7500-8000 48-50 7.5 MW High Speed Motor
98 Screw Washer For replacement of twin drum washing system with high efficient screw washer to save energy 10-15% Paper 45-50 18-20 24-30 20000-22000 TPA
99 Shoe Press Shoe press technology is a papermaking procedure that uses a large concave shoe instead of one of the conventional rotating cylinders; this extends dwell time, thus improving mechanical de-watering compared to that of conventional roll presses 20-30% Pulp & Paper 8000-9000 300-350 30-36 Paper machine of 5 m
100 Tube ice plant Tube ice machine performs continuous Freezing and Harvesting function, thereby ensuring steady supply of high quality ice at a rate determined by the user 10-15% Ice Making 17-20 8-10 30-35 20 TPD Plant
101 Ultra-High Power Electric Arc Furnace Ultra High Power (UHPs) have become one of main tools for the steel making process since they have high productivity, low cost and high quality of products 10-15% Iron & Steel 723.7 714 12 100-400 MT
102 VAM Chillers The working principle of VAMs is based on absorption where a concentrated salt and water solution is used to absorb water vapour and then pressurized by a low-pressure pump to generate chilled water 30-40% Building 200-250 100-125 24-36 10,000 TR
103 Veneering for Industrial furnaces Reduction in surfaces heat losses from furnaces and also store the residual heat during non-firing time 20-25% Foundry 6-7 6-7 11-12 Hearth area - 40 sq ft
104 Vertical Agitator System for Reaction Vessel The vertical agitation system is more versatile compared to horizontal agitation system, allowing mixing various feed material in one go, is easy to maintain and operate 20-25% Chemical 2-2.5 1-1.5 20-24 20 KL
105 Vertical shaft brick kilns It is a continuous, updraft, moving ware kiln in which the fire remains stationary while there is counter current heat exchange between air (moving upward) and bricks (moving downward) 15-20% Bricks 10-15 5-7 24-30 40-50 Lacs bricks per year
106 Zig-Zag Firing The zig-zag type firing ensure better turbulence and contact time between flame and bricks, thereby better productivity and reduced SEC 20-25% Bricks 30-50 15-20 24-36 20,000-60,000 bricks per day
107 Installation of Top Recovery Turbine in Blast Furnace TRT is basically an energy saving measure at the BF which utilizes the waste pressure energy of the BF top gas to generate electric power. 10-15% Iron & Steel 2500-3000 2000-2500 15-18 6.57 MW
108 Installation of Pulverized Coal Injection in Blast Furnace Pulverized coal injection (PCI) is a process which involves injecting large volumes of fine coal particles into the raceway of the blast furnace (BF). Pulverized coal is an important auxiliary fuel used in the BF ironmaking. 30-40% Iron & Steel 1500-2000 1200-1600 12-15 150 kg/thm
109 High Speed Blunger Blunger is a machine which can rapidly blunge raw material without changing non plastic raw material structure using stator rotor mechanism 35-40% Sanitaryware & Potteryware 12-15 6-7 22-24 24 TPD Charge production
110 Falling Film Chillers Falling Film Chillers are suitable for continuous chilling of liquids close to their freezing point. They are installed before Ice Bank Tank (IBT) to pre-chill the incoming process return water at higher temperature 20-22% Dairy 35-40 35-40 12-15 350 TR
111 Ice Bank Tank (IBT) This process of direct cooling ensures no cooling loss or addition of external heat and ensures low energy consumption at compressor due to higher suction pressure 25-30% Dairy 70.00 27.00 31 170 TR
112 Thermal Energy Storage for Bulk Milk Coolers (BMC) This system uses vapour compression cycle to form ice which is later used to provide cooling without the need of grid availability during cooling process, thereby eliminating the exposure of milk to higher temperature for a longer duration during their collections and also preserve freshness and aroma 15-20% Dairy 4.00 7.30 6 2000 Lit. BMC
113 Carbon Fiber Fan Carbon Fiber Fan impellers provide next-level speed, strength, and corrosion resistance for those who routinely need to move air in challenging environments without compromising strength 15-20% Textile 70-80 150-170 6-8 1200 mm dia for 100 fans
114 Air-Dyeing Technology Air dyeing technology uses air instead of water to apply colours into textile materials. This method will help to save water up to 95% and energy up to 86%. This method can be only applying on synthetic fibre materials. 86% Textile (Synthetic Dyeing) 2000-3000 2500-3500 12-15 400-450 Kg
115 Waterless Dyeing Technology Waterless Dyeing Technology uses supercritical CO2 gas rather than water to infuse fabric with color. Special temperature- controlled pressure chambers force the carbon dioxide to act as a fluid similar to water (the supercritical fluid CO2) which causes the polymer fiber to swell allowing the dispersed dye to easily diffuse within the polymer, penetrating the fibers, and carrying the dyes into the fabric and dyeing it. 60-65% Textile (Polyester Dyeing) 2000-3000 2500-3500 12-15 20-200 Kg
116 Direct Rolling in mini steel plants The Direct Rolling Technology refers to converting the billet in to a rolled product without any intermediate reheating arrangement, thereby avoiding wastage of sensible heat of steel. Here, the hot billets produced from continuous casting machine is not taken into the storing yard where they will cool down to ambient temperature thereby loosing energy, but are diverted in hot condition directly to the rolling section. 10-15% Iron & Steel 100-120 600-700 2-3 18 TPH
117 Pulser dyeing technique Pulser dyeing is a major breakthrough in the yarn dyeing process, where in liquor requirement per kg of yarn is reduced to 4:1 as against conventional 10:1 requirement, and pumping requirement to maintain flow an pressure of water is reduced to 1/3rd, thereby substantially reducing energy, water, chemical requirement 20-30% Textile 10-12 20-30 6-8 50-1500 Kg
118 Waste heat recovery in centrifugal compressor The waste heat is recoverd from each stage of compressor owing to losses in the form radiation loss and/or condensation heat and using them in pre-heating of boiler feedwater or process application 10-20% Textile 30-35 25-30 12-15 3000 CFM
119 Compressed Bio-Gas (CBG) Compressed Bio Gas or CBG is a purified biogas (methane content more than 90%) with zero trace of carbon dioxide and hydrogen sulphide gases and compressed to maximum 250 bar and filled up in cascades (group of high pressure cylindrical vessels). 25-30% Oil & Gas Sector 700 - 800 140 - 150 60-72 5 TPD
120 Cement Calcining Process - Suspension Preheater The Suspension Preheater process improves calcining efficiency by drying and preheating the feedstock using the kiln exhaust gas (waste heat). 14.3 kg of standard coal per ton of clinker Cement 4100-4200 4000-4200 10-12 2000 TPD
121 Boiler Conversion: Atmospheric Fluidised bed to Spouted bed A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 25-30% Pulp & Paper 1000-1200 1200-1300 10-12 117 TPH
122 Modern Brownstock Washers (BSWs) A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 10-20% Pulp & Paper 100-130 70-90 18-24 300 T/d pulp production
123 Gas fired stenters A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 30-40% Textile 35-40 38-40 10-12 1600 mm stenters
124 Black Liquor Gasification A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 15-20% Pulp & Paper 9000-13800 2000-3500 40-48 115-200 TPD plant
125 Drum pulpers A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 20-30% Pulp & Paper 90-120 50-65 20-25 300 T/d deinked pulp production
126 Vacuum blower A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 20-25% Pulp & Paper 110-130 140-160 15-20 Paper Machine of 70 TPD
127 Light weight carbon reinforced spinning pot A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 18-20% Textile 15-18 15-18 12-15 man-made sspinning plant with 20 ring spinning machines
128 Photocells for Speed Frames A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 0.05 kWh/kg Textile 350-370 200-220 20-24 15000 TPA Spinning Mill (90 ring frame machines)
129 High-speed carding machine A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 30-40 % Textile 80-100 50-70 18-24 27kW/machine
130 PLC based dyeing machine A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 20-25% Textile 4-6 3-4 22-24 23 kW jigger
131 High-speed Ring spinning frame A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 10-20% Textile 70-80 35-40 24-28 45kW conventional ring spinning machines
132 Light weight bobbins A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 7-20% Textile 45-50 48-50 10-12 15000 TPA Spinning Mill (90 nos. Ring Frames)
133 Synthetic sandwich tapes A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 5-15% Textile 35-50 25-45 15-20 15000 TPA Spinning Mill (90 nos. Ring Frames)
134 SITRA Excel fans A spouted bed combustor is a heterogeneous system where combustion takes place in the presence of circulating particles. This results into enhanced HP steam generation to rated capacity, due to increased bed coil depth and additional heating surface, efficient coal combustion & stoppage of PA fan and reduced DM water intake as well, followed by enhanced power generation. 15-20% Textile 35-55 70-110 4-6 90 nos. Ring Frames
135 Turbulators (for gas fired boilers) In a firetube boiler (Two- and Three-Pass), hot combustion gases pass through long, small-diameter tubes, where heat is transferred to water through the tube walls. Firetube boilers are categorized by their number of ?passes,? or the number of times that the hot combustion gases travel across the boiler heat-exchange surfaces. Turbulators can be a cost-effective way to reduce the stack temperature and increase the fuel-to-steam efficiency of single-pass horizontal return tubular (HRT) brick-set boilers and older two- and three-pass oil- and natural-gas-fueled firetube boilers. Improves boiler efficiency by 2-3% Boiler 5 - 6 8 - 12 6-9 2 pass boiler with 250 tubes
136 Zero gap CO2 electrolyzer Anode and Membrane replacement along with Zero gap conversion of Electrolyser helps in reducing ohmic losses in the electrolyte. Zero-gap electrolyzers are similar to fuel cells in design because the heart of the electrolyzer consists of two electrodes pressed against a membrane. These electrolyzers are called “zero-gap” because there is no gap between the cathodes, anodes, and the electrolyte. 300-400 Chlor-alkali 2200-2800 10-15% 80-100 250 TPD
137 Hydrogen fired Vapour absorption machine In Chlor-alkali plants, certail percentage of hydrogen released during elctrolysis remains unutilized and vented into the atmosphere. The vented hydrogen can be efficitively used in Hydrogen fired VAM to generate chilled water 40-60 10-15% 100-120 Chlor-alkali 24-30 250 TPD
138 Thyristor based Rectiformers The DC power required for electrolysis process is supplied by rectiformers in chlor-alkali plants. The rectifier consists of step down transformer and rectifier unit. The thyristor rectifiers are controlled electronically and are having higher reliablity and efficiency. 100-150 Chlor-alkali 200-300 4-6% 18-24 250 TPD
139 Vortex rectifier in mill The installation of vortex rectifier for the classifier has resulted in restoring a linear flow in the ductwork & maintaining homogeneous velocity distribution thus resulting in a lower pressure drop and reduced specific energy consumption 200-300 Cement 200-250 10-15% 6-12 Mill output 200-220 TPH
140 Lost foam casting technology Lost Foam Casting is a type of evaporative pattern casting foundry technology, also called LFC, where expanded polystyrene (EPS)/ STMMA-FD is used as pattern. This technology takes advantage of the low boiling point of polymer foams to simplify the investment casting process by removing the need to melt the wax out of the mold. 100-150 Foundry 150 15-20% 12-18 300 T/month
141 Particle size Distribution (PSD) analyser Traditionally, quality control in the cement manufacturing plant has been practised by collecting samples from different processing points at regular intervals and analyzing them in a central laboratory, either manually, or in some cases automatically. As an alternate, PSD analysis gives a complete grain size distribution of the finished cement. PSD anayzer gives a real time continous measurement, it is possible to dynamically control the speed of the seperators at the finish grinding mill and therefore optimize the fineness, maintain quality requirements and saving on the cost of energy required for grinding. 36-50 Cement 50-80 10-15% 18-24 Not Applicable
142 Modern multichannel burners Some cement kiln systems are equipped with direct-fired solid fuel systems that use a mono-channel burner pipe to the kiln. It not only decreases the specific fuel consumption but also nitrogen oxide emissions may be reduced due to the decreased oxygen availability in the core flame. Furthermore, these modern burners allow the use of significant amounts of secondary fuels. 100-250 Cement 200-300 5-10% 24-30 1 Million Ton clinker production plant
143 Flare gas recovery system (FRGS) A flare system is required for safety & operational reasons. As such every petroleum crude oil refinery is provided with a flaring system to continuously burn the vent gases before they are safely discharged to atmosphere. A small quantity of hydrocarbon gas is kept as purge gas in the flare system which gets burnt continuously in the flare. Also on occasions during abnormal conditions in the operation, vent-gases are sent to flare. Recovery of flare gases hence is direct fuel recovery. 2000-3000 Petroleum Refinery 1500-2000 Upto 80% recovery of flare gas 8-12 Approx. 90000 MSCM per year emission
144 Methane Capture technology It is generated by anaerobic treatment of effluent discharged instead of using aerobic treatment. FO or equivalent fuel will be saved due to usage of captured methane. Also due to downgrading of aerobic treatment electricity will be saved. 100-140 Dairy 200-300 2025 TOE per annum 24-36 2000 m³/hr dairy effluent
145 Rotoberatory Furnace Implementation of proposed energy efficient rotoberatory furnace equipped with waste heat recovery system and automatic control system having efficiency more that existing furnace would save energy. 20-25 Brass 25-30 20-25% 12-18 750 kg/batch
146 Auto loom Retrofitting of power looms with rapier/auto looms will reduces the power consumption & production cost and also increases the rate of production. 25-30 Textile 50-70 20-25% 24-36 120 TPA
147 High pressure roller press for pre-grinding for a ball mill In high-pressure roller press comminution, the feed material is exposed to very high pressure for a short time. The high pressure causes the formation of microcracks in the feed particles and generates a substantial amount of fine material. If the pressed material is fed directly to a ball mill, the power consumption required to produce finished cement will be much lower than that of a mill fed with unpressed material. This makes it possible to increase the throughput of a given size ball mill and to reduce the specific power consumption of the whole mill system. 3416 Cement 11770 10-15% 41.30 2 Million Ton clinker production plant
148 IGBT based welding machine Welding is a critical operation in the Indian Railways in locomotive manufacturing units, coach manufacturing facilities and workshops. During welding operation, an electric arc is formed between the consumable wire electrode and the work piece where the heat generated causing the work piece to melt and join together. In thyristor based welding machine, significant part of the power consumption goes into heating the transformer and the surrounding air, resulting in significant losses. This is avoieded to a significant level in case of inverter based machines. 14-20 Railway/others 40-50 10-15% 30-42 100 nos. of thyristor based welding sets
149 Aeroseal duct sealing technology Air Ducts are normally insulated and on many occasions are placed above false ceilings or service floors where access is extremely difficult. Even after diagnosing the leakage points in the ducts, sealing of these leakage points from outside would mean breaking / removal of false ceilings & insulation, all of which are expensive, time consuming and practically impossible in a running facility. The latest duct sealing uses the aeroseal technology which seals ducts from the Inside. 5-8 Building 15-20 10-20% 30-48 10,000 CFM
150 Copper inserted collector installation in Potline A high performance Cathode assembly for pots, using copper insert collector bar design and modified refractory lining, which will enable reduction in Specific Power consumption (SPC) and having provision for current creep in future therby increase in throughput. 2600-2700 Aluminium smelting 3700-3800 50-60% 18-24 700 TPD
151 Magnetic compensation loop (MCL) 1.Magnetohydrodynamic (MHD) instability or waves at the metal-bath interface in the aluminium reduction cell is the major hurdle for increasing energy efficiency and productivity. 2.To stabilize the interface at a smaller anode-cathode distance and higher anode current density, a magnetic compensation loop has been designed without altering the existing busbar system. 3.The effect of magnetic field compensation loops inside, outside, and on both sides of the potline circuit has been evaluated. Financial Break Up a) Design & Licence : 1650 lakhs (One time cost for licencing) b) Rectifier & Auxiliaries : 4125 lakhs c) Aluminium Busbar : 11962.5 lakhs 1800-1900 Aluminium Smelting 17000 -18000 10-15% 100-110 867 TPD
152 Electric Melting Furnace Electric melting furnaces are small capacity units used for melting or holding applications. They feature a circular furnace with electric elements that heat a ceramic crucible holding the metal. With higher efficiency (60-75%), they reduce oxidation losses and pollution while offering precise control over melting time and temperature. 8-12 Cross-sectoral 20-25 20-30% 24-36 500 kg per batch
153 Electric annealing furnace Electric annealing furnaces operate with remarkable efficiency (85-90%), benefiting from the use of electricity to achieve precise temperature control during the annealing process. This technology promises significant enhancements in product quality, resulting in reduced rejections in downstream processes. 1.5-2 Cross-sectoral 9-10 20-30% 60-72 1000 kg per batch
154 Electric Extrusion Melting An electric induction melting furnace has an efficiency between 60 - 75% and offers additional advantages, such as reduced oxidation due to the non-direct contact between the heat source and aluminum. Furthermore, it minimizes pollution and ensures greater purity and uniformity of the end product. 90-100 Cross-sectoral 70-75 20-30% 8-10 5000 kg per batch
155 Radio frequency heating Radio Frequency (RF) heating and drying systems utilize electromagnetic energy to rapidly heat and dry many types of bulk materials, as well as finished products with excellent speed and efficiency. 30-50 Food Processing 25-30 20-30% 6-12 80 kW
156 Ultrasonic technology Ultra-violet (UV) heating employs ultraviolet radiation to generate heat directly in materials, offering efficient and targeted heating for various applications such as curing, drying, and sterilization. 40-50 Textile 50-80 20-30% 12-14 NA
157 Plasma melting furnace A plasma melting furnace is used to liquefy a substance using a low-temperature plasma stream, usually produced by an electric arc heater known as a plasmatron. 150-200 Iron & Steel 1000-1200 30-40% 72-80 300 kw
158 Hydraulic Coupling A fluid coupling (FC) or hydraulic coupling is a device used for transmitting power from one shaft to another shaft by means of acceleration and deceleration of a hydraulic fluid. It is based on hydro-kinetic principles and requires that the output speed be less than the input. This difference in speed is called slip. 100-150 TPP, Other sectors 50-200 10-15% 6-24 4500 kW BFP
159 Desiccant-based cooling systems / DeVAP (Desiccant Enhanced Evaporative) HVAC DEVap is a concept of desiccant enhanced evaporative air conditioner (DEVap) with the objective of combining the benefits of liquid desiccant and evaporative cooling technologies into an innovative ‘cooling core.’ DEVap’s crucial advantage is the intimate thermal contact between the dehumidification and the cooling heat sink, which makes dehumidification many times more potent. This design uses membrane technology to contain liquid desiccant and water. A traditional A/C unit consumes a lot of energy during the refrigeration cycle, DEVap doesn’t. Instead, DEVap uses an absorption cycle to cool air that can be powered by natural gas or solar energy. Unlike most heating, ventilation, and air-conditioning systems, DEVap uses no environmentally harmful fluids, hydrofluorocarbons, or chlorofluorocarbons; instead, it uses water and concentrated salt water. 1.5-3 Building 5-7.5 15-20% 24-30 10 Ton
160 Oxy-fuel combustion in reheat furnace Oxy-fuel results in substantial increases in available heat (total energy input minus energy lost to the exhaust) as compared to air-fuel combustion. The increase in available heat is directly related to reductions in energy consumption. Oxy-fuel combustion can be used in reheating furnaces to improve thermal efficiency and decrease energy losses. 200-300 Iron & Steel 250-350 10-12% 12-18 Rehraeting furnace 280 TPH
161 Energy recovery ventilation (ERV) An ERV works by reusing the energy of the air being exhausted from the building transmitting energy to the outdoor air coming in to the building. This system will reduce the amount of work performed by the Air Handling Unit (AHU). 2-3 Building 7-10 5-15% 36-48 2500 CFM
Innovative decarbonisation technologies
162 Aluminium pipe for distribution of compressed air system Aluminium pipe doesn't rust, unlike mild steel pipes, due to moisture present in compressed air and this avoid leakages and saves 10-20% of losses 10-20% Cement, Iron & Steel, Textile, Other sectors 300-350 120-150 24-36 6000 MT per day of Clinker
163 Electric Vehicles and Charging Infrastructure Electric vehicles are power by battery and electric motor 1 Liter Diesel per 15 km Transportation 12-15 3-4 48-60 Diesel sedan car
164 Fuel efficient industrial furnace burners specially for rotary kiln Improved overall combustion efficiency of burners in rotary kilns in Alumina, chemical, lime, sponge iron plants using gas and liquid fuel 5-7% Cement, Iron & Steel 30-35 15-20 20-24 Not Applicable
165 Nano composite surface treatment for condenser in power plant It protects from fouling, scaling, and deposition resulting improvements in power generation efficiency 13000 tons of coal/Yr Power Plant 250-300 250-300 12-15 135 MW
166 Plasma Technology in steel melting shop The use of Plasma Technology ensures superhot electrically heated gases that are extremely efficient in melting metals 15-20% Iron & Steel 8000-10000 3200-4000 30-36 20 crore for each plasma torch
167 Torrefaction Technology Torrefaction is thermochemical conversion method to produce coal fuel (bio char) from biomass. It is carbon rich material can be easily burnt in industrial furnaces, boilers driers, etc. Not applicable Power Plant 15-20 15-20 12-15
168 XPLATE Nano device for Air side application for boilers to improve combustion efficiency XPLATE breaks Oxygen & Nitrogen clusters and frees Oxygen molecules which react fast with any fuel and increase combustion efficiency. Use of this technology can reduce excess air supplied and can maintain stoichiometric air fuel ratio. 3-8% Multiple sectors 5-80 10-160 3-8 5-300TPH
169 Oxygen Depolarized Cathodes (ODCs) Replacement of the hydrogen evolving cathodes in the classical membrane cells by ODCs allows for reduction of the cell voltage and correspondingly the energy consumption of up to 25-35% 25-35% Chlor-Alkali Industry 13500-14000 1100-1200 140-150 250 TPD
170 Hisarna Ironmaking Technology Hisarna is a new type of furnace in which iron ore is directly injected and liquefied in a high temperature cyclone so that it drips to the bottom of the reactor where powder coal is injected. The two react into liquid iron. 15-20% Iron & Steel 25000-25500 Dec-15 38-40 4.6 MT per day
171 Extended Delignification System for Cooking of Wood The extended delignification system recycles majority of the heat generated in the pulping process and stores the recycled heat in the form of black liquor and white liquor 50-60% Pulp & Paper 4000-4500 1100-1200 42-48 200 Tons of BD pulp/day
172 Gasification Based Production CCUS unit will undertake purification and compression of high conc. CO2 stream for further disposition. Source of CO2 stream is Outlet of the acid gas removal unit 90% Refineries 8000-10000 1 MTPA NA 70 ktpa H2
173 NG Based Steam Methane Reforming (SMR) for H2 production Cryogenic separation has been considered for CO2 capture from tail gas as it ensures high purity CO2 (99.9%) with additional H2 recovery. Source of CO2 stream is tail gas 60-65% Refineries 70000-80000 0.7 MTPA NA 130 ktpa H2
174 Pressure Swing Adsorption (PSA) Technology Pressure Swing Adsorption (PSA) Technology has been applied to separate gas mixtures, such as carbon dioxide capture in ammonia production and in hydrogen purification. PSA is highly cost-effectiveness, simple to operate, high performance at ambient temperatures, high regeneration rate, and low energy intensity. 90% Cement 160000-180000 2 MPTA NA 2.5 mtpa clinker
175 Water Gas Shift Reactor Water gas shift has been considered to ensure maximum CO2 capture from a single point and potential H2 recovery from the BF gas. Source of CO2 stream is BF gas 50% Iron & Steel 160000-200000 2 MTPA NA 2.0 mtpa BF BOF based ISP
176 Amine-based Post-Combustion Capture (PCC) Technology Amine-based carbon capture is a regenerative process using an amine solvent to remove CO2 from flue gas. Reversing the reaction releases pure CO2 for capture and frees up the solvent for re-use. This technology is primarily used for Carbon Capture & Storage 90% Refineries 110000-130000 1 MTPA NA 5 mtpa crude processing
177 Magnetocaloric Refrigerator Magnetic refrigeration is a cooling technology based on the magnetocaloric effect. This technique can be used to attain extremely low temperatures, as well as the ranges used in common refrigerators. A magnetocaloric material warms up when a magnetic field is applied. The warming is due to changes in the internal state of the material releasing heat. When the magnetic field is removed, the material returns to its original state, reabsorbing the heat, and returning to original temperature. To achieve refrigeration, the material is allowed to radiate away its heat while in the magnetized hot state. Removing the magnetism, the material then cools to below its original temperature. For the past 100 years, refrigerators have relied on a process called vapor compression that uses coolants which can be harmful to the environment. The new refrigerator is a revolutionary technology that uses a water-based cooling fluid, making it better for the environment and more efficient, which means lower energy bills and less carbon pollution. .05-.2 Commercial building, Residential buildings 0.15-0.5 15-20% 30-48 1.5-3 TR
178 ETEKINA (Heat pipe technology for thermal energy recovery in industrial applications) The EU-funded ETEKINA project has developed novel tailor-made heat pipe heat exchangers (HPHEs) successfully piloted in the ceramics, steel and aluminium industries. Heat pipes are tubes sealed at both ends and containing a working fluid at saturation, meaning any increase in temperature will cause it to vaporise. In an HPHE, the heat pipes are installed in bundles attached to a plate and placed in a casement. A heat source such as exhaust gas flows into the lower section. The working fluid vaporises and rises in the pipes, where a heat sink such as cool air flows into the top part of the shell and absorbs the heat. The enclosed structure minimises loss while the plate minimises cross-contamination between the exhaust gas and the air. HPHEs require smaller surface areas for greater heat transfer relative to conventional approaches. 45-60 Ceramics, Steel, Aluminium 130-150 20-25% 30-42 Heat recovery duty 80-90 kW
179 Steelanol Production of sustainable, advanced bio-ethANOL through an innovative gas-fermentation process using exhaust gases emitted in the STEEL industry. This advanced ethanol can then be used as a building block to produce a variety of products, including sustainable transport fuels, packaging materials, apparel, and even cosmetic fragrances, hence helping to advance the decarbonization efforts of the global chemical sector. 125,000 tonnes CO2 Steel 130000- 140000 125,000 tonnes CO2 NA 80 million liters per year