UNIDO Regional Office in India Promoting Energy Efficiency and Renewable Energy In selected MSME Clusters In India A Joint Initiative of GEF, UNIDO and BEE Niranjan Rao Deevela National Technology Coordinator, UNIDO 16 th SAMEEEKSHA Workshop, Rajkot 14 September, 2019 1
UNIDO Regional Office in India About the Project • Objective: Introduce energy efficiency and enhance Sectors & Clusters: use of renewable energy technologies in process Foundry applications in the 12 selected energy-intensive Coimbatore MSME clusters in India Belgaum Indore • Project Value: GEF Grant 7.17 million US$/Co- Brass financing 26.2 million US$ Jamnagar Ceramic • Project Partners: Khurja Thangadh Morbi Hand Tools • Cluster Partners: Nagaur Jalandhar Dairy Gujarat Sikkim Kerala 2 2
UNIDO Regional Office in India Project Presence in 12 clusters Sikkim Jalandhar Nagaur Khurja Morbi Indore Thangadh Jamnagar Gujarat Belgaum Foundry Clusters Coimbatore Ceramic Clusters Kerala Hand Tools Clusters Brass Cluster Dairy Clusters 3 3
UNIDO Regional Office in India Scaling up in 11 new clusters Punjab Haryana Madhya Pradesh Howarha Odisha Maharashtra Telangana Himmatnagar Andhra Pradesh Ahmedabad Tamil Nadu Foundry Clusters Ceramic Clusters Virudhachalam Dairy Clusters 4 4
UNIDO Regional Office in India Component 1 Increased capacity of • Owners, Managers and Operators • Suppliers of EE & RE products • Service providers • Finance providers Components Increasing the Component 4 Project Component 2 level of end-use Strengthening demand and policy, institutional implementation and decision- of EE and RE making technologies and frameworks practices by . MSMEs Scaling up of the project to national level Component 3 5 5
UNIDO Regional Office in India 6 6
UNIDO Regional Office in India Participants attended EE & RE Measures Implemented 523 2650 Workshops MSME Units Benefited 335 Energy Savings Achieved 9894 (TOE/Year) 95 Workshops Organized Monetary Savings Achieved 5062 (Lakhs/year) 275 Case Studies Prepared Co-financing on EE & RE 6659 Investments (Lakhs) 232 Carbon Emissions Avoided DPRs Developed 54896 (Tonnes/year) Cumulative Carbon Emissions 27 Pilot Projects Sanctioned Will be Avoided in 15 years (million 0.62 tonnes) 7 7
UNIDO Regional Office in India EE and RE projects Implemented Energy CO 2 Reduction Monetary Investment Cluster Name Small Savings (Tonnes/year) Savings (Lakh ₹) Scale (TOE/year) (Lakh ₹ /year ) Projects Jalandhar 58 247 1892 179 119 115 Coimbatore 50 190 1843 227 160 Nagaur 48 24 235 25 8 technologies Jamnagar 38 113 667 137 270 have been Khurja 9 383 1495 75 28 identified and some of them Indore 20 130 821 71 52 replicated multiple times Gujarat 110 5799 32484 2935 4047 Belgaum 83 393 3079 272 349 Thangadh 90 1967 10414 1046 1547 Morbi 14 564 1739 71 49 Kerala 3 84 227 24 30 Total 523 9894 54896 5062 6659 8 8
UNIDO Regional Office in India Project interventions in MSME Clusters in Saurashtra 9 9
UNIDO Regional Office in India Thangadh Ceramic Cluster Batch preparation (clay, quartz and feldspar) • Located near Rajkot and there are about 225 ceramic units in the cluster Wet milling (ball mill) fall under three distinct types based on Homogenizing their primary products: pottery, insulators, and sanitary ware. Casting / Moulding • The project activities initiated in the Drying Thangadh cluster in 2014. Glazing Firing Sorting and packaging Production process 10 10
UNIDO Regional Office in India Roof Top Solar Photovoltaic Project • Till date, 23 industries have installed grid connected roof-top solar photovoltaic systems • The capacity of the system is varying from 11 kWp to 99 kWp • Commutatively, 1.1 MWp solar rooftop PV system was installed with an investment of around 4.29 crores • Total five service providers have supplied the systems 42 to 60 • All are polycrystalline silica plants with panel warrantee of 20 years and inverter warrantee for Months 5 years Simple payback period • Average per unit cost of electricity from the Grid is about Rs. 7/kWh 11 11
UNIDO Regional Office in India Roof Top Solar PV Installations and Investment 120 40 36 35 100 29 30 Total Investment (Lakh Rs.) Installed Capacity (kWp 80 24 24 25 20 20 20 20 20 20 20 20 20 20 18 18 60 20 14.5 14.5 99 12.5 15 12 11.5 81 11 40 67.5 10 50 50 50 50 50 50 50 40 30 40 50 50 50 50 50 50 20 4 31 30 5 25 11 0 0 12 12
UNIDO Regional Office in India Installed Capacity and Average kWp cost of each Supplier 60000 340 48000 50000 290 41428 40000 Insytalled Capacity (kWp) 36365 36148 40000 Investment (Rs./kWp) 240 30000 190 20000 140 10000 90 325 357.5 230 142 50 40 0 Tata solar Rajkot Raison solar Gujrat solar energy. J.J.solar Rajkot Venture solar Rajkot Ahmedabad Ahmedabad Installed Capacity (kWp) Cost of the System (Rs./kWp) 13 13
UNIDO Regional Office in India Energy Efficient 28W BLDC Ceiling Fans Pre reli limin inary ry con onsultatio ion • The moulds have to be completely dried in 24 hours so that the Repor ort on on Su Sustain inable le mo models ls for or cum m – feasibilit ility y stud tudy shaped ware can be cast the following day. EMC’s in the MSME clusters • Typically, one ceiling fan is required for every four moulds, and each unit has about 400 – 800 fans which run for almost 20 hours a day (depending on ambient weather conditions). • Energy audits showed that the conventional fans consuming 70 – 66% 75W at full speed and the performance was poor due to age • Typically, a unit incurred monthly expenditure of 5000 – 8000 rupees Energy Efficient on maintenance and repair of fans. 3 year • More than 120 sanitary ware units are already replaced about 16000 conventional fans with 28W energy efficient BLDC fans Warranty • A total investment of about 3.52 crore rupees, against which they 45 Lakh are saving an estimated 3.15 crore rupees annually in energy cost. This measure is saving over 4.51 million kWh of electricity and avoiding 3700 tonnes of CO 2 emissions each year. kWh Annual Demand Aggregation Model Savings 14 14
UNIDO Regional Office in India Other Energy Conservation Interventions Pre reli limin inary ry con onsultatio ion Repor ort on on Su Sustain inable le mo models ls for or Energy Conservation Measure Implemented Estimated Annual cum m – feasibilit ility y stud tudy EMC’s in the MSME clusters units Energy Savings 15 43200 SCM of PNG Low thermal mass car in tunnel kiln High alumina media /lining in glaze ball mill in 20 22 Lakh kWh place of natural lining VFD screw air compressor system in place of 35 3.86 Lakh kWh fixed motor compressor (30 HP and 20 HP systems) Modification in existing tunnel kiln design — 3 810000 SCM of PNG double deck system and shortening of firing zone Replacing old compressed air pipeline with 10 7000 kWh seamless (joint-less) pipe line to avoid air leakages 4 15960 SCM of PNG Waste heat recovery from exit flue gas 15 15
UNIDO Regional Office in India Jamnagar Brass Cluster • In Jamnagar brass cluster, about 100 brass units are targeted under the project. • 38 EE/RE projects implemented like IGBT billet heater, EE furnace, EE pumps, EE fans , EE Compressors & lighting systems • Overall achieved a energy saving of 113 toe per year and avoided 667 tonnes of Carbon dioxide emissions per year 16 16
UNIDO Regional Office in India Morbi Ceramic Cluster • In Morbi Ceramic Cluster, about 200 units are targeted under the project. • 14 EE/RE projects implemented like EE motors, VFD for ball mill, EE fans etc.. • Overall achieved a energy saving of 564 toe per year and avoided 1739 tonnes of Carbon dioxide emissions per year 17 17
UNIDO Regional Office in India Gujarat Dairy ry Clu luster Concentrated Solar MBR+ICR technology 250 TR Freon Thermal Steam in effluent treatment package chiller Generation system plant More than 110 EE/RE measures were implemented and resulted annual energy savings of 5799 toe which in turn reduced 32484 tonnes of carbon dioxide emissions 18 18
UNIDO Regional Office in India • Premium Efficiency Air Gujarat Dairy ry Clu luster Compressors • Variable Frequency Drives for • Replace of evaporator various applications condensing system with PHE • Condensate Recovery system • Waste Heat Recovery from • Ring-main system for Boilers and Powder Plant compressor air distribution • Energy Efficient Lighting system • Solar PV and Thermal • Replaced spray pond type Applications cooling tower system with • Installation of High Efficiency Induced draft cooling tower for Screw Compressors Chilling Centre • Heat Pump • Replaced existing condensing • Back Pressure Turbine system with new condensing • Methane capture from dairy chiller system (Falling Film effluent Chiller) • De-superheaters at Refrigeration • Installation of Biomass fired systems boilers • Energy Efficient Bulk Milk Coolers • Energy Efficiency Motors, Fans 19 19 and Pumps
UNIDO Regional Office in India Other Project Activities 20 20
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