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Low Carbon Development in Large and Energy Intensive Sectors

Low Carbon Technology Roadmap for Cement Sector - Phase I

CII-Godrej GBC, as part of its efforts in promoting world class energy efficiency initiatives in cement plants, has initiated a project on developing Low Carbon Growth Roadmap for Indian cement plants.

CII-Godrej GBC, in partnership with CMA, NCB, and other stakeholders, undertook the estimation of average GHG emissions based on the Detailed Energy Audit carried out in various cement groups, and also from public available data, to identify reduction opportunities.

A roadmap was created for the Indian cement industry to achieve 20% reduction in its GHG emission intensity. The roadmap is based on a set of 27 technical papers developed by CII and NCB. These papers, collectively titled Existing and Potential Technologies for Carbon Emissions Reductions in the Indian Cement Industry (WBCSD, 2012), outline the current status of each technology, the impact on energy consumption and anticipated benefits from implementation, the CO2 reduction potential, the main parameters influencing implementation, cost estimation, and the conditions, barriers and the constraints of implementation.

Partners: International Energy Agency (IEA), World Business Council on Sustainable Development (WBCSD), Cement Manufacturers Association (CMA) and National Council for Cement and Building Materials (NCCBM)

Thematic Area: Resource Efficiency, Cleaner Production, GHG Mitigation

Duration: 2011-2013

Funded By: International Finance Corporation (IFC)

Low Carbon Technology Roadmap for Indian Cement Sector - Implementation

In continuation of the phase, the next step of the project was to analyse the plant-level feasibility of the identified technologies for GHG reduction. The objective was to translate the technology papers and the roadmap to actual emission reduction at the plant level.

CII initiated the study in five plants, and identified energy savings potential of USD 20 million, resulting in atleast 3,75,631 Tonnes of CO2 emission reduction.

The feasibility study indicates that there is significant potential to reduce GHG emission intensity by 130 kg CO2 per tonne of cement, and emission reduction potential of 28.8 million tonnes of CO2 for the Indian cement industry.

Partners: International Energy Agency (IEA), World Business Council on Sustainable Development (WBCSD), Cement Manufacturers Association (CMA), National Council for Cement and Building Materials (NCCBM), ACC Limited, Ambuja Cements Limited, and Shree Cements

Status: Ongoing

Thematic Area: Resource Efficiency, Cleaner Production, GHG Mitigation

Funded By: International Finance Corporation (IFC)

PAT Impact Assessment Study

The Perform, Achieve &Trade (PAT) Scheme by the Bureau of Energy Efficiency (BEE) is a market-based mechanism to improve energy efficiency in energy-intensive industrial sectors. The PAT scheme started with implementation of the first PAT Cycle I, from 2012-2015, in 478 designated consumers. It resulted in savings of 8.8 million TOE. With the objective of analysing sector-wise impact and achievements through PAT scheme, an impact assessment study for PAT Cycle I was commissioned by GIZ and BEE.

CII activities include assessment of overall impact of PAT Scheme (Energy, Cost and GHG emissions), impact of PAT scheme on energy intensity, comparison of energy efficiency impact under Business-as-Usual scenario and PAT scheme. Other activities include mapping of processes, technologies and energy consumption trends for the respective sectors, trend analysis for energy efficiency, data analysis of sector specific pro-forma, and review of policy framework for execution of subsequent PAT cycle in each sector. The modelling analysis for improvement of energy efficiency in each sector and their contribution in achieving NDC target were also assessed. Sector-wise case studies for high potential projects (for energy efficiency) were also prepared.

As a final outcome, the success of PAT scheme was assessed, and the overall transformation of energy efficiency in the industry through the PAT scheme was observed.

Partners: BEE and GIZ

Duration: 2017 -2018

Development of Pro-forma and other related documents for Petroleum Refineries and Petrochemicals under the PAT scheme

The objective of this project was to develop the pro-forma and M&V guidelines for the Petroleum Refineries sector, and data capture form for the Petrochemical sector. As petroleum refineries and petrochemicals were new sectors under the PAT scheme, the pro-forma and other documents for these sectors were prepared to enable proper data capture and normalisation.

The refinery specific pro-forma was developed to capture all the refinery energy consumption details, viz. MBN, NRGF, crude throughput, etc. Separate pro-formas were developed for different refineries to account for the variation in their process complexities. The normalisation and M&V guidelines were also prepared in discussions with all relevant stakeholders. A data capture form & Form 1 were also developed for the petrochemical sector.

Pro-forma was developed for 18 refineries, along with M&V and normalisation guidelines. Form 1 was developed for Petrochemical sector.

Duration: 2018-2019

Funded By: BEE, CHT, GIZ

Feasibility Study for Widening of PAT Scheme to the Chemical Sector

The main objective of the project was to conduct a study to estimate the distribution of energy consumption in the Chemicals sector. The study intended to support BEE in prescribing the threshold level of energy consumption in the sector, based on which a decision on including it in future PAT cycles will be taken, and possible energy saving potential can be identified. The Chemicals sector as a whole accounted for Alkali Chemicals (KOH, Na2CO3), Inorganic Chemicals, Organic Chemicals, Pesticides (Technical), Dyes, and Pesticides & Pharmaceuticals (API). This study also developed an overall methodology for calculating specific energy consumption along with the identification of various factors affecting it and its impact thereof.

The major activity of the project involved in developing unit-wise and product-wise energy consumption levels, based on the production and SEC numbers shared by the units. Both thermal and electrical energy numbers were evaluated to understand the overall energy consumption.

The targets were set for the overall sector by considering four separate sub-sectors. Overall category-wise energy consumption and reduction potentials were identified. A total of 59 units were analysed for target-setting, based on which the total energy consumption was 1.359 million TOE. A 5% reduction target was estimated, based on which there was a potential to have 37 DCs in the sector as a whole.

Duration: March - July 2019

Funded By: BEE

Cement Sector Energy Efficiency Benchmarking Study

The intention behind the benchmarking study was to continue the knowledge transfer and facilitate cement plants in comparing their performance with their peers. Such comparisons help in the identification of potential areas for performance improvement.

For collecting data, CII-Godrej GBC prepared a detailed questionnaire involving all sectional parameters, from crusher to packing plant. The questionnaire was sent to more than 140 cement factories.

The majority of plants from all over India participated in this benchmarking study, and different parameters were recorded in various sections, from the data provided by the plants. The collected data was classified into different sections, and each section was compared with respect to section wise Specific Energy Consumption and other parameters.

The study also highlighted more than 300 best practices implemented in national and international cement plants, and more than 50 performance indicators in the cement industry, all recorded at one place for the benefit of the industry.

Monitoring techniques, parameters to be monitored, and frequency of monitoring were also provided in each section to further aid the stakeholders in achieving energy efficiency.

The benchmarking reveals the best values at which the industry is operating in each section, and the best practices and technologies to be adopted for assuming leadership in energy efficiency.

Partners: Cement Manufacturing Association, leading cement plants

Status: Ongoing, four versions published

Thematic Area: Energy Efficiency, Benchmarking, Low Carbon Development

Benchmarking Study for Thermal Power Plants

CII executed the benchmarking of the power plant performance for one of the largest thermal power generation companies in India.

The main objective of the study was to assess the technical performance of the unit, internally compare the performance of units, and formulate strategies to bridge the gap in energy performance. The study included the analysis of various performance data for coal-based thermal power plants. The study also included the comparison of the performance of the major parameters. Further, the study provided analysis on gaps and reasons for deviations and variations in the performance.

CII developed a specific questionnaire for benchmarking and included Specific Energy Consumption norms, operational data (for last one year) and best practices and technologies implemented. Efforts were also made to have a sectional benchmarking and internal comparison for identifying major gaps and further suggestions to achieve the best numbers.

Under this study, CII conducted benchmarking studies in 19 coal-based thermal power plants, which constituted 20% of India's installed power capacity. More than 2,000 data points were collected and studied from each unit, and improvement opportunities were identified based on the analysis of performance levels between the best and worst performing plants.

Duration: 2018-2019

Funded By: Industry

Technology Compendium for Paper, Cement, Textile and Iron & Steel

CII, with the support of Shakti Sustainable Energy Foundation, developed five technology compendiums for five industry sectors, including Cement, Chlor-Alkali, Iron & Steel, Pulp & Paper, and Textile.

These industry-specific technology compendiums provide information on energy savings options, best practices, better/latest technologies, etc., with their financial implications.

Key activities undertaken were to complete the mapping of each of the sectors in terms of the processes/technologies being presently employed, the present level of technologies and scope for improvement keeping in mind the best operating practices worldwide, including identification of the range of technologies, energy efficiency equipment being used, etc., categorised as process-specific and utility. The other activity carried out was identification of national/international best practices, and preparation of fact sheets for each technology, and of the best operating practice option.

The compendiums were distributed among the industry, and helped DCs to prepare their energy efficiency action plans to achieve their SEC reduction targets under PAT.

Thematic Area: Energy Efficiency, Technology Implementation

Duration: 2013-15

Funded By: Shakti Sustainable Energy Foundation

Widening the Coverage of PAT Scheme in Subsequent Phasesby Adding New Subsector: Feasibility Study for Auto, Dairy, Beverages and Chemical Sectors

The Perform, Achieve & Trade (PAT) Scheme launched by BEE covers eight energy-intensive sectors. The first cycle of PAT started from April 1, 2012. BEE further plans to widen the coverage of the PAT scheme, in subsequent phases, by adding more new industrial subsectors, depending on the energy consumption. For new industrial segments, there is a need to study the energy consumption in detail, to establish the threshold limit for the eligibility for the designated consumers. This project was conceptualised for this purpose.

CII undertook the mapping of energy consumption in the automobile (assembly), beverages and distillery, chemical (other than petrochemical, chlor-alkali, and fertilizer), and dairy sectors in India.

CII also carried out the collection, compilation and analysis of energy-related data for the sectors, consultation workshops, and preparation of overview report of the above sectors, covering types, manufacturers, production, capacity utilisation, policy, energy consumption, etc. Through this study, CII suggested the sectors which can be included in subsequent phases of the PAT scheme, and suggested the threshold energy consumption for the new sectors.

Status: 2013-14

Thematic Area: Energy Efficiency and Analytics

Funded By: Shakti Sustainable Energy Foundation

Desk Study on Waste Heat Recovery Potential in Indian Cement Industry

Energy efficiency has taken top priority in the Indian cement industry, but Waste Heat Recovery (WHR) systems were not widely adopted. During the study period, it was found that out of 150 large cement kilns in the country, only five cement kilns adopted WHR systems.

CII undertook a desk review and presented a detailed finding on the WHR potential available in the country, and identified the barriers to implementation.

The study indicated that there was a potential of more 415 MW of WHR, and would create an investment opportunity of over USD 724 million.

Key Activities:
• Review of major WHR technologies implemented around the world.
• Identify potential of WHR considering the pyro section, mass flow, and temperature of the gases.
• Highlighting existing application of WHR in India - success and barriers.
• Mapping of WHR technologies to cement process, potential energy savings and power generation capacity.
• Studying the technical feasibility and financial viability of the projects.
• Recommending roles for major stakeholders to facilitate market uptake of WHR technologies in the country.

Partners: IFC

Status: Completed

PAT Baseline, Mandatory Energy Audits and M&V Studies

CII-Godrej GBC team was involved in the implementation of the BEEPAT Scheme. The team conducted baseline energy audits for 107 Designated Consumers (DCs), across all the eight sectors. CII-Godrej GBC team also conducted more than 50 mandatory energy audits and 19 Monitoring & Verification (M&V) studies.

CII-Godrej GBC was also associated with DCs and BEE in fixing up the baseline energy consumption levels, identifying energy saving opportunities to achieve targets, identifying factors beyond DC's control that affect their Gate to Gate Specific Energy Consumption, and assisting them in conveying the same to BEE.

Further, CII-Godrej GBC has been continuously working on PAT scheme by organising awareness programmes (workshops, conferences and publications), and developing sector-specific technology compendiums for assisting DCs to identify technologies that will help them in achieving PAT targets.

CII has also been frequently interacting with the industry and BEE on several key areas, such as the need and methodology for normalisation, and facilitating several industries achieve their PAT targets.

Partners: Associated with more than 150 Designated Consumers.

Status: Ongoing

Thematic Area: Energy Efficiency, Monitoring & Verification, Baseline Audits

Key Partner:

Sector Experience: Cement, Iron & Steel, Aluminium, Chlor-Alkali, Textile, Pulp & Paper, Thermal Power Plant, and Fertilizer

Foster GHG Emission Reduction Technologies in Indian Cement Industry - APP project

This project aimed at identifying and implementing measures that can bring down GHG emissions in the cement industry.

Key activities included offering services to facilitate companies achieve GHG reduction of more than 50,000 tonnes of CO2.

Based on the international missions and taskforce meetings, a 'Best Practices' manual was published, highlighting the GHG reduction potential.

Further, four workshops for sharing best practices and identifying replication potential opportunities were organised. The outcome of the project served as a background study to develop the Low Carbon Roadmap for the Indian cement industry.

Thematic Area: Energy Efficiency, Technology Implementation, GHG Mitigation

Duration: 2010

Funded By: Asia Pacific Partnership

Investors Manual for Energy Efficiency

CII was appointed by IREDA to prepare an investor's manual on energy efficiency for the energy-intensive sectors in India.

The objective was to prepare an Investor's Manual, covering energy saving potential for various industries, technologies available to improve energy efficiency, equipment suppliers, government policies/incentives available for the sector, terms of IREDA and other financial institutions extending support to such projects, etc.

The overall objective of the project was to facilitate market development for energy efficiency/conservation products & services. The whole effort focused on preparing a simplified and user-friendly manual based on inputs from various stakeholders in the energy efficiency sector.

Through this study, energy saving of INR 37,510 million was estimated, with investment of INR 82,575 million, for 16 energy-intensive sectors in India.

Partners: IREDA

Status: Completed

Thematic Area: Energy Efficiency, Technology Transfer, Financing, Capacity Building

Promoting Investment in Energy Efficiency & Environment Projects in Select Sectors

In 1999, this project was initiated to promote investments in energy efficiency and environment improvement, with respect to the following energy-intensive sectors: Cement, Pulp & Paper, Sugar, Glass & Ceramics, Textile Processing and Fertiliser (Urea).

Important activities carried out include:
Development of Manual on Energy Conservation at Design Stage
This manual includes all the energy saving aspects that can be incorporated at design stage for achieving energy efficiency. It covers six energy-intensive sectors (cement, paper, sugar, textile, fertilizer, glass & ceramics) and 10 commonly used equipment. More than 100 technical experts were involved in developing this manual.

Case study booklets on energy efficiency
Six case study booklets were published for six energy-intensive sectors, covering actual implemented case studies.

To widely disseminate information about the project and also about latest energy efficient technologies in different sectors, five technology seminars pertaining to Cement, Paper, Sugar, Ceramics and Textile industry were organised.

Facilitating Buyer-Seller Meetings
To bring both the buyer and seller on a common platform to facilitate interaction for resolving issues and enhance investment on energy saving devices, three buyer-seller meetings were organised.

Apart from the seminars and various promotional materials, a website was also hosted under the project to spread the benefits and results of the project, and provide access to information related to energy efficiency for industry personnel. The website was maintained during the course of the project. The website was hosted on March 1999, and it was maintained till March 2001.