1 By Zenith Energy Services (P) Limited Hyderabad Presentation on Solapur Textile Cluster Solapur, Maharashtra State

2 Zenith Energy Services Pvt. Ltd. started Energy use and Technology Audits in the Solapur Cluster during the first week of June Schedule of Implementation

3 No. of units Covered for Energy use and Technology Audit Total No. of units in Solapur Cluster are around 200 No. of units to be covered in the Cluster are 53 units As on date, The Energy use and Technology audit studies has been completed in 30 units

4 Products Manufactured Terry Towels Chaddars Bed Sheets Cotton yarn

5 Process Flow Diagram Contd.,

6

7 Main Energy Forms used Electricity Fuels  Wood,  Coal and  Biomass fuels

8 Major Energy Consuming Process Equipments Power looms Winding machines Doubling machines Warping machines Reeling machines Hang dyeing machine Hydro extractor

9 Major Energy Consuming Equipments - Utilities Boiler Blowers Thermopac Chulhas Small Pumps Air compressors Lighting etc.

10 Energy Scenario Energy cost: 6 to 8% of the total production cost and varies as per the products manufactured. The average electricity bill consumption per unit varies from 10,000 to 30,000 kWh depending on the no. of looms installed. Subsidized Electricity Tariff for these type of Industries is Rs.2.50 kWh per unit Fuel Consumption: (wood) is 50 to 200 tons per annum.

11 Present Hot water Generation System ( Chulha)

12 Wood Fired Thermic Fluid Heater

13 Possible Areas of Energy Conservation Installing variable frequency drives for Doubling machines, hydro extractor, hang dyeing machine, FD fan etc Light weight spindles, synthetic tapes for doubling machines and energy saver drive system developed by SITRA Install energy saver for power looms for reducing power consumption during idle operation Auto-looms for improved productivity and efficiency Replace old inefficient boilers/thermopac with new boilers or hot water generators Solar water systems for hot water

14 Suggested Wood fired Hot Water Generator

15 Suggested Solar Hot Water Generator

16 Issues and concerns for Implementation The payback period is high due to subsidized electricity cost Involves high investment for technology change of various equipments and low returns Financial Issues

17 Technical Issues Lack of awareness on technologies available in the market Rely on local equipment suppliers There is no much technology development in power looms sector for energy efficiency improvement rather than quality

18 Other Issues Lack of interest due to low electricity tariff Lack of space for implementing the measures

19 Case Study Rajashree Industries Pvt. Ltd. Products Manufactured Terry Towels Chaddars

20 Main Energy Forms used Electricity Wood

21 Annual Energy Bill Total: Rs lakhs

22 Measures Identified  Replace the inefficient hot water generation through thermic fluid heater system with new hot water generator with an insulated tank Reduces the wood consumption by 100 tons per annum The annual monetary benefit is estimated of 2.50 lakhs The investment required is Rs.3.00 lakhs Simple payback period is 15 months.

23  Install Variable frequency drives Reduces energy consumption about 10 to 15% which is equivalent to 100 kWh per day and kWh per annum Monetary savings of Rs lakhs The investment required is Rs lakhs for 5 drives of various capacities Simple payback period is 40 months

24  Install energy saver for power looms for reducing power consumption during idle running The estimated savings is 1.5 kWh for 12 hrs of operation and annual savings is 14,500 kWh Monetary savings of Rs per annum for 30 looms. The investment required is Rs lakhs for 30 looms Simple payback period is 29 months

25 Though there is potential for replacing the other equipments like Power looms, Doubling machines etc., The Return on Investment is low due to subsidized Electricity Cost. Energy Efficiency

26 Summary

27 Tentative Schedule for Completion Dissemination Program : December 2009 Energy use and Technology Audit will be completed by January 2010 Cluster manual preparation by January 2010 DPR Preparations from November 2009 Local Service Providers Workshop March 2010 Other programs as decided by BEE

28 Thank You