Industrial Sectors

Brief Overview of Tyre SectorThe tyre industry is pivotal in the automotive sector, driven by OEM and replacement segments. Current OEM demand aligns with new automobile production trends, while the replacement segment is linked to usage patterns. Presently, the replacement sector holds a significant market share, with a notable 133% surge in radial tyre adoption for passenger cars from April to August 2021. In contrast, only 60% of truck and bus tyres and 40% of LCV tyres have transitioned to radials.In the fiscal year 2019, the Indian tyre industry exceeded £7.41 billion, involving over 40 manufacturers in 60 production facilities. Employing over 2 million people directly and supporting over 1 million jobs indirectly, the industry is substantial.The top 10 players collectively dominate 90-95% of the market share, with the leading few in each segment controlling 70-80%. Major players like MRF, Apollo Tyres, and JK Tyres collectively capture around 60%. Despite intense segment-level competition, no single manufacturer holds dominant market share or significant pricing power, resulting in a moderately competitive industry overall (Source: Present Scenario of Tyre Industry in India, The Role and Relevance in Indian Economy).Manufacturing Process and Energy ConsumptionManufacturing tyres involves the conversion of raw materials into final products utilised in diverse vehicles. The tyre industry, characterised by specialisation, relies on advanced technology and machinery to produce resilient and top-quality tyres. Key raw materials in tyre manufacturing encompass natural and synthetic rubber, carbon black, and various chemicals. These materials undergo meticulous blending and processing to form distinct tyre components, such as treads, sidewalls, and inner liners. The tyre production process encompasses crucial stages like mixing and extrusion, calendaring, building, curing, and inspection and testing, all subject to rigorous quality control to ensure adherence to specifications and performance standards.In the initial step of mixing and extrusion, raw materials are blended in a sizable mixer and then heated and extruded through a machine, forming tyre components like treads, sidewalls, and inner liners. Following this, calendaring involves passing the extruded rubber through rollers to achieve uniform thickness and shape, with the rubber subsequently cut and marked as needed. The subsequent building stage involves the assembly of tyre components into a cohesive unit, including placing the inner liner, adding the tread and sidewall, and moulding the tyre into its final shape.Fig: Tyre Manufacturing Process (Source: Presentation of JK Tyre, Chennai)The total energy consumption at manufacturing sites showed a notable increase of 11% from 2009 to 2010. Following this, it remained relatively steady until 2018. In 2019, the overall energy consumption remained constant when compared to 2018 levels. However, in 2020, amid the COVID-19 pandemic, there was a significant decline in total energy consumption by ~12%, aligning with the production levels. During the period from 2019 to 2020, there was a 5% increase in energy intensity. This heightened intensity can be attributed to a comparatively smaller decrease in energy consumption compared to the reduction in production. Some production lines continued operations despite reduced activity, and certain machinery, such as heating equipment, remained in continuous operation (Source: Environmental Key Performance Indicators for Tire Manufacturing 2009-2020, Tire Industry Project 2021, World Business Council for Sustainable Development).PAT Scheme for Tyre SectorAs per notification from Ministry of Power dated 6th June 2023, Units of tyre manufacturer plants or establishments those are under manufacturing of tyres, having energy consumption of 7,000 metric tonne of oil equivalent per year and above will qualify as a Designated Consumer in Tyre Manufacturing Sector. This sector is yet to be covered in the PAT scheme.Best Practices Adopted by Tyre SectorTyre industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures:·  Recycling and Waste Management.·  Installation of (Variable Frequency Drive) VFDs.·  Use of energy though Renewable Resources.·  Replacing air blower fans to energy efficient fans.· Use of energy efficient (IE-3) motor in place of conventional motor.Details of Line Ministries·  Ministry of Commerce and IndustryDetails of Specialised Organization / Research Institute· Indian Tyre Technical Advisory Committee (ITTAC)Details of Industrial Associations· Automotive Tyre Manufacturers' Association (ATMA)List of Key Technologies· Use of Eco tyres (made up of compounds of different types of rubber and other materials that work together to decrease friction with the road to increase fuel efficiency).· Thermal Energy Management System (TEMS) technology. This can help to improve the efficiency of rubber manufacturing processes by reducing the amount of energy needed to heat and cool the process. This can lead to significant savings on energy costs.· Energy efficiency solutions and equipment upgrades.· Use of Carbon Nanotubes (CNT) in Tyres.

Brief Overview of Sugar SectorIndia ranks as the world's second-largest producer of sugar, with key states like Maharashtra, Gujarat, Bihar, Andhra Pradesh, Haryana, Karnataka, Punjab, Uttar Pradesh, and Tamil Nadu leading the production. This sector significantly impacts the lives of around 50 million sugarcane farmers and nearly 500,000 mill workers, generating employment across various associated sectors such as transportation, trade, machinery, and agricultural inputs. The annual output value of India's sugar industry stands at ₹80,000 crores.As of 2021, India has installed756 sugar factories, equipped with enough crushing capacity to yield approximately 350 lakh MT of sugar. This capacity is almost evenly split between privately-owned units and cooperative sector units. Most sugar mills typically have a crushing capacity ranging from 2500 TCD (Tons of Cane per Day) to 5000 TCD, but there's a growing trend of expansion, with some even surpassing 10000 TCD. Among the 756 installed sugar mills, 522 were operational during the 2021-22 sugar season.Ethanol, primarily derived from molasses, a by-product of the sugar industry, plays a crucial role, particularly during years of surplus sugarcane production. It aids the industry in managing timely payments to farmers. The Ethanol Blending Programme (EBP) aims to blend ethanol with motor fuel to reduce pollution, conserve foreign currency, and support the industry in settling payments to farmers.Manufacturing Process and Energy ConsumptionThe typical sugar production process includes these steps:Juice extraction:The juice extraction facility comprises cane handling, cane preparation, and milling segments. The extraction of juice from the prepared sugarcane involves two distinct methods. Around 95 to 97% of sugar factories utilize the milling process, while the diffusion process is employed by around 3 to 5% of these factories.Cane Handling: The arrival of cane at the mill involves a mechanical unloading process using a grab-type attachment. Occasionally, a truck tippler is installed to aid in unloading the cane, simplifying the transfer of sugar cane onto the cane carrier.Cane Preparation: The sugarcane undergoes levelling in the leveller prior to entering the cutter. This machine shreds the cane into smaller pieces, preparing it for the fibrizer, where the cane is transformed into a pulp-like substance.Milling: The processed sugarcane undergoes milling through a tandem of four to six three-roller mills. High-pressure squeezing in these rollers extracts the juice from the cane. To maximize extraction, the disintegrated cane is thoroughly washed with weak juice and makeup water in a counter-current system. The resulting fibrous residue, known as bagasse, left after milling, serves as fuel for steam generation.Diffusion: The diffusion process involves a methodical washing of cane or bagasse through a continuous counter-current system using imbibition water. Water is introduced at the conveyor's discharge end, filtering through the bed of bagasse and the perforated slats of the conveyor. This water facilitates the dissolution of sugar within the bagasse, resulting in a thin juice collected in a hopper. Through pumping, this juice progresses through stages until it reaches peak concentration at the diffuser's input end. The diffuser can be configured for either a single-flow or parallel-flows circulation of juice.Juice Clarification:The process of juice purification includes several steps: (a) heating the juice, (b) applying sulphitation, (c) clarification, and (d) filtration. Initially, the mixed juice from the mills undergoes heating in raw juice heaters. Chemical treatment follows, causing the precipitation of various dissolved impurities in the heated juice. These precipitates are then separated to achieve clear and pristine juice in clarifiers. Subsequently, the clear juice undergoes another round of heating to reach a temperature of approximately 105°C.Evaporation:The juice undergoes concentration from 15 Brix to ~ 60 Brix using a multiple-effect evaporator. Vapours extracted from these evaporators are utilized for heating the juice in different heat exchangers and for boiling the massecuite (a blend of molten liquid and crystals) in vacuum pans. This process stands as the primary steam-consuming segment within the facility.Crystallisation:Crystallisation, referred to as Pan boiling within the sugar industry, stands as a vital unit operation. Most sugar mills conduct a significant portion of the crystallisation process using batch-type vacuum pans. Following this stage, the massecuite is moved to crystallisers, where the process concludes through the cooling of the mass under stirred conditions.Centrifuging:The massecuite derived from the vacuum pans undergoes separation of sugar crystals from molasses within the centrifuges. These centrifugal devices can be categorized as batch or continuous types and are specifically designed for different massecuite types—'A', 'B', and 'C'. The extracted molasses from this process serves as a valuable by-product, widely regarded as an excellent raw material for distilleries.Drying, Grading and Packing: The moist crystals acquired from centrifugal machines typically hold around 15-20% surface moisture. These crystals undergo drying in conventional dryers, are sorted based on their sizes, and are subsequently packaged into bags.Sugar production in India had been cyclic in nature. Every 2-3 years of high sugar production were followed by low sugar production. However, from the sugar season 2017-18 and onwards, the country has produced surplus sugar than the domestic requirement of about 250-265 Lakh Metric Tonnes. The season-wise production of sugar from 2011-12 and onwards is as belowSugar Season (October – September)Production of Sugar (Qty. in lakh tonne)2011-122632012-132522013-142452014-152842015-162512016-172022017-183222018-193322019-202742020-213102021-223592022-23 (As on 21.03.2023)288 Fig: Sugar Manufacturing Process (Source)Sugar mills, recognized as energy-intensive sectors as per the ‘Energy Conservation Act, 2001’, necessitate substantial energy inputs. The energy usage within these mills is shaped by several factors including capacity, steam generation parameters, equipment age, and the specific machinery employed.Typically, electricity consumption per tonne of sugar produced ranges from 200 to 500 kWh depending on the production year. The average energy consumption in an Indian sugar mill stands at ~ 26 to 40 kWh per tonne of cane (Source: TERI Energy Audit Reports). For a standard sugar mill with a crushing capacity of 3400 TCD, the total power requirement is around 4.0 MW. Steam consumption varies between 30% and 50% per tonne of cane based on factors like capacity, evaporator vapor bleeding arrangement, and equipment age. PAT Scheme for Sugar SectorAs per notification from Ministry of Power dated 6th June 2023, Units of sugar plants or establishment those are under production of sugar and its variants such as white sugar, brown sugar, and liquid sugar, having energy consumption of 10,000 metric tonne of oil equivalent per year or above will qualify as a Designated Consumer in Sugar Sector. This sector is yet to be covered in the PAT scheme.Best Practices Adopted by Sugar SectorSugar industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures: Use of high yielding varietiesDrip IrrigationSoil health improvementDetails of Line MinistriesMinistry of Consumer Affairs, Food & Public DistributionDetails of Specialised Organization / Research Institute  Indian Institute of Sugarcane Research National Sugar Institute Sugarcane Breeding InstituteDetails of Industrial AssociationsIndian Sugar Mills Association (ISMA) List of Key Technologies  Soil Moisture Indicator Sugarcane Sett treatment device Information and Communication Technology in Sugarcane Agriculture  Irrigation Management to Enhance Water Availability Bio-intensive Nutrient Management 

Brief Overview of Pulp & Paper SectorThe Indian paper industry accounts for about 3.7% of the world’s production of paper. The industry employs more than 0.5 million people directly, and 1.5 million people indirectly. Most paper mills have been in operation for a long time, with their technology spectrum ranging from the oldest to the most modern equipment. Indian paper industry is a de-licensed sector and 100% FDI inflow is allowed on the automatic route. The sector attracted 54.93 million US dollar FDI investment in FY 2019. The industry structure comprises of more than 861 paper units, with an installed capacity of nearly 27.15 million tonnes out of which 4.72 million tonnes are lying idle. As of date, around 526 mills are in operation with a total operating capacity of around 87%. Total production for the year of 2019-20 stood at 20.614 exhibiting an increase of 6.4% on YoY basis.The paper industry is broadly classified into three segments namely Writing & Printing (W&P), Newsprint and Paperboard & Industrial Packaging (Paperboard). Paperboard is the largest segment, accounting for 45% of total domestic paper demand, followed by W &P (35%) and Newsprint (20%). The mills use a variety of raw materials, viz., wood, bamboo, recycled Fiber, bagasse, wheat straw, rice husk, etc. Presently, in the total production, the share of wood, agro and wastepaper-based mills stand at 20%, 8% and 72%, respectively. During the year 2019-20, a total of 2.192 million tons of paper and paperboard was imported.In India, per capita consumption of paper is about 15.75 kg, which is far lower than the world average (57 kg. in 2019).Manufacturing Process & Energy Consumption:The pulp and paper industry converts fibrous raw materials into pulp, paper, and paperboard products. Pulp mills manufacture only pulp, which is then sold and transported to paper and paperboard mills. A paper and paperboard mill may purchase pulp or manufacture its own pulp in house; in the latter case, such mills are referred to as integrated mills. The major processes employed in the pulp and paper industry include raw materials preparation, pulping (chemical, semi-chemical, mechanical, and wastepaper), bleaching, chemical recovery, pulp drying, and paper making.Currently, about 31% of the raw material requirement is met from forest product including wood and bamboo. Logs typically arrive at the mill on trucks. Debarkers are used to remove bark from logs prior to chipping, since bark is a contaminant in the pulping process. After debarking, the logs are sent to a chipping machine (most commonly a radial chipper). Agro/Agro-waste based mills use varieties of raw vmaterials including stalks, straw and sticks. Cutters/shearing machines are used for the preparation of such materials for pulping. Increasingly, most of the mills are also using some secondary fibre in the production of pulp. Wastepaper is currently the major source for secondary fibre.The primary goals of pulping are to free fibres in wood from the lignin that binds these fibres together, and then to suspend the fibres in water into a slurry suitable for paper making. The three main processes for producing wood pulp are mechanical pulping (includes thermo-mechanical process), chemical pulping (includes kraft and sulfite pulping also), and semi-chemical pulping.Mechanical pulping is the oldest form of pulping. The process employs mechanical energy to weaken and separate fibres from wood and waste paper feedstock via a grinding action. The advantage to mechanical pulping is that it produces much higher yields than chemical pulping processes (up to 95%). However, because this process does not dissolve lignin, the fibre strength and age resistance of the resulting pulp are low. The weakness of the resulting pulp is compounded by the fact that the mechanical grinding process also produces shorter fibres.In the thermo mechanical pulping (TMP) process, wood chips are first steamed to soften them before being ground in the same manner as the RMP process. The TMP process generates the highest grade mechanical pulp but is also a high energy intensity process due to its steam use. Chemo-thermo-mechanical pulping (CTMP) involves the application of chemicals to wood chips prior to refiner pulping. The process begins with an impregnation of sodium sulphite and chelating agents. The mixture is then preheated to 120-130 ºC and ground in the refiner.Raw pulp can range in color from brown to crème due to the remaining lignin that was not removed during the pulping process. For paper products for which brightness and resistance to color reversion are important, such as office and printing paper, the pulp must be whitened by a bleaching process prior to the paper making phase.The papermaking process can be divided into three basic stages: (1) stock preparation, (2) “wet end” processing where sheet formation occurs, and (3) “dry end” processing where sheets are dried and finished.Fig.: Process diagram of a typical Pulp & Paper Plant(Source)Pulp and paper production is highly energy intensive with 60 to 80% of the energy requirement being used as process heat and 20 to 40% as electrical power. The share of thermal and electrical energy depends upon variable factors such as raw materials and finished products. Energy consumption for pulping and digesting, for example, is lower if wastepaper is used instead of wood chips or agricultural residue. In general, the use of wastepaper requires about 2.5 times less energy than a similar production process based on other inputs mainly because of less intensive pulping needs for wastepaper.The ratio of steam to power makes the industry ideally suitable for deployment of cogeneration technology, simultaneous generation and power and steam, bleeding medium and low pressure steam from power turbine to meet the process demand.Most of the energy is used in form of heat within the pulping process (digester, evaporator and washing) when raw materials have to be cooked and mechanically or chemically treated for further use in the production chain. Furthermore, paper making requires considerable amounts of energy in form of both heat and electricity for forming, pressing and drying of the paper.Pulp and paper making processes account for over 70% of the total energy used in the manufacturing operation. Balance 30% is consumed mostly for various utilities and support systems. Typical fuel mix of Pulp and Paper manufacturing process is presented below: Types of Fuels%Coal80.00Oil5.00Gas0.00Grid Electricity15.00PAT Scheme for Pulp & Paper SectorThere are more than 550 Pulp and paper plants in India, comprising wood based, agro based, and recycled fibres, producing various kinds of papers such as writing-printing, newsprint, packaging paper, speciality paper, etc. These paper plants are spread across India and categorised into large, small and medium enterprises. However, most of the paper plants are smaller plants and either fall under SME or use biomass as fuels and do not cross the threshold defined under PAT. The plants covered under the PAT cover almost 30% of the sector- both capacity wise and production wise. PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Pulp and paper Sector are presented below: CyclesNo. of DCsTotal Energy Consumption (Million TOE)Energy Saving Targets (Million TOE)PAT Cycle I312.090.29PAT Cycle II292.680.146PAT Cycle III10.0570.003PAT Cycle IV20.1640.0098PAT Cycle V80.28370.0169PAT Cycle VI20.0550.003PAT Cycle VII242.210.081PAT Cycle VIII70.19990.01178Energy Savings Achievement in the Pulp & Paper Sector under PAT Cycle I and PAT Cycle II are 0.29 Million TOE and 0.25 Million TOE respectively.Best Practices Adopted by Pulp & Paper SectorPulp & Paper industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures:Super Batch Cooking.Two-Stage Oxygen Delignification – OxyTrac.BCTMP Process (bleached chemi-thermomechanical pulp).Super Batch Cooking.Ultra-Low Intensity Refining.Opti Batch Process.Biogas firing in rotary lime kiln (Replacement of Furnace Oil).Boiler Conversion: Fluidised bubbling to Spouted bed.Solar Energy Utilization for Process Heating at Low and Intermediate temperature (Replacement of LP Steam) i.e., 50°C to 250°C.Oxyfuel burning in lime kiln and black liquor boilers.Installation of Extended Delignification System for cooking of wood (to reduce steamconsumption). Details of Line Ministries Department for Promotion of Industry and Internal Trade (DPIIT) Details of Specialised Organization / Research InstituteCentral Pulp and Paper Research Institute (CPPRI), Saharanpur, UPDetails of Industrial Associations Indian Agro & Recycled Paper Mills AssociationIndian Pulp & Paper Technical AssociationList of Key TechnologiesBiogas firing in rotary lime kiln (Replacement of Furnace Oil).Boiler Conversion: Fluidised bubbling to Spouted bed i.e., Hybrid Nozzle (FBC & AFBC Boilers).Installation Of Extended Delignification System for Cooking of Wood (To Reduce Steam Consumption).Innovative technology “Bio-Refinery” for Utilization of Paddy Straw as a source of bio energy, cellulosic pulp, paper, and value-added products.Precipitation and acidification to isolate lignin.Regasification of black liquor and Black liquor solids concentration.Continuous digester.Substitution of pneumatic conveyors with belt conveyors.Bio-methanation for agro-based plants.Oxy-fuel combustion in lime kiln & black liquor boilers.Caustic concentration unit for recover caustic soda from waste liquor.Bleach recovery from bleach plant effluent.Novel technology developed in laboratory that can directly convert Green Liquor to Caustic without lime addition.Concentrating Solar Power (CSP) Technologies for heating applications.

Brief Overview of Textile Sector Indian textile and apparel industry contributes ~2% to the national GDP and 7% of industry output in value terms. India accounts for ~4% of the global trade in textiles and apparel. In 2020-21, textiles, apparel & handicrafts together accounted for ~11.5% of India’s total exports. The domestic textiles & apparel industry stood at GBP 130 bn in 2021. Indian textiles and apparel industry employs 45 million people directly and 100 million people in allied industries, making it the 2nd largest industry by manpower. The textile industry in India includes a wide range of segments – from traditional handloom & handicrafts to cotton, wool & silk, and the ‘organized textile industry’. The organized textile industry is marked by its use of capital-intensive technology for mass production and includes apparel manufacturing, spinning, weaving, processing, etc.Cotton production in India is projected to reach 7.2 million tonnes (~43 million bales of 170 kg each) by 2030 driven by increasing demand from consumers. Thehandicraft exports from India too are expected to rise YoY due to increased participation from industry players to boost handicraft products in the global market.Manufacturing Process & Energy ConsumptionThere are broadly three manufacturing processes, spinning, weaving and processing. A particular unit can be either composite covering all the three processes or a unit just covering one process such as spinning.Spinning Process: In the spinning process, raw cotton is converted into yarns in several steps which includes blow room, carding, drawing, rowing, spinning, sizing and weaving, desizing, scouring, bleaching, calendaring, dyeing and printing. Weaving Process: Weaving is the process of making fabric or cloth using the yarns. In it, two distinct sets of yarns called the warp and the filling or weft are interlaced with each other to form a fabric. Yarn is a long continuous length of interlocked fibres. The lengthwise yarns which run from the back to the front of the loom are called the warp. The crosswise yarns are the filling or weft. A loom is a device for holding the warp threads in place while the filling threads are woven through them. The sub-processes which are usually involved in weaving include warping, sizing, reeding, weft prim winding, weaving, shearing, folding, and packing. Processing: It covers all processes in a textile unit that involve some form of wet or chemical treatment. The wet processing process can be divided into three phases: preparation, coloration, and finishing. It uses different types of technologies depending on the type of yarn or fabric that are dyed. Jigger, winch padding, mangle and jet-dyeing are some of the important dyeing machines. Similarly, there are different types of printing: direct printing, warp printing, discharge printing, resist printing, jet printing, Rotary printing etc.Energy use in a textile mill depends upon the deployed process. For spinning and weaving mills, electricity is the main source of energy whereas for process houses, both electrical and thermal energy are needed, thermal constituting the major source. In an integrated mill, almost 80% of the total energy need is thermal. Typical break up of electricity and thermal energy consumption for an integrated mill is shown in below table:  Electricity ConsumptionThermal ConsumptionAreas%Areas%Spinning Preparatory13Boiler Loss25Ring frame28Steam Distribution Loss10Weaving18Bleaching & Finishing35Humidification19Dying and Printing15Processing10Humidification & Sizing15Others12  Energy consumption in a spinning mill is primarily electricity used in the production machineries and auxiliaries. In weaving process, energy is used for operating machines, air conditioning and illuminating the area where fabrics are manufactured. In addition to these, compressors, which provide compressed air to the weaving line, use energy. Electricity is used for machines, air conditioning, illumination and compressors, while thermal energy is consumed by processes such as sizing and sometimes by air conditioning. PAT Scheme for Textile Sector The Textile sector is one of the designated sectors covered under the BEE’s Perform, Achieve and Trade scheme. The Textile industry in India can be classified into organized and decentralized/ rural sectors. The organized sector comprises mills which include both spinning mills and composite mills. The decentralized power-loom/ hosiery and knitting sector form the textile industry's largest section.In the Indian textile sector, a unit with an annual consumption of over 3,000 tonnes of oil equivalent (TOE) is notified as a designated consumer (DC) under the Energy Conservation Act, 2001. PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Textile Sector are presented below:CyclesNo. of DCsTotal Energy Consumption (Million TOE)Energy Saving Targets (Million TOE)PAT Cycle I901.20.13PAT Cycle II991.480.088PAT Cycle III340.6680.04PAT Cycle IV70.3420.0204PAT Cycle V160.22670.0135PAT Cycle VI70.1120.007PAT Cycle VII1201.920.099PAT Cycle VIII380.56180.0334Energy Savings Achievement in the Textile Sector under PAT Cycle I and PAT Cycle II are 0.13 Million TOE and 0.136 Million TOE respectively.Best Practices Adopted by Textile SectorTextile industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures:Waste heat recovery from PV motex stenter.Installation of a Low-pressure Air compressor with a Heat Recovery unit.Installation of Flash jet recovery system.Installation of VFD in Weaving chiller Cooling tower Fan.High-pressure mist spray system at AWT.Use of Removable reusable insulation.Pulser dyeing technique. Microbial fuel cells technology to generate electricity from textile wastewater treatment. Energy recovery from H-plant exhaust air by providing a special turbine which generates electricity to be used for lighting purpose.  Details of Line Ministries Ministry of Textiles Details of Specialised Organization / Research Institute Ahmedabad Textile Industry’s Research Association (ATIRA), Gujarat Bombay Textile Research Association (BTRA), MumbaiSouth India Textile Research Association (SITRA), CoimbatoreMan-made Textile Research Association (MANTRA), GujaratNorthern India Textile Research Association (NITRA), GhaziabadIndian Jute Industries Research Association (IJIRA), KolkataWool Research Association, ThaneDetails of Industrial Associations Textile Association of IndiaConfederation of Indian Textile IndustryList of Key Technologies Various Dyeing processes such as Pulser Dyeing Technique, Airflow Dyeing Technology, Digital Dyeing, and Supercritical CO2 Dyeing Technique.Technological processes such as Ultrasonic Assisted Wet Processing, and Closed condensate recovery pump.Wind recovery turbine from humidification exhaust Microbial fuel cells technology to generate electricity from Textile wastewater treatment.Energy Recovery from H-Plant exhaust air by providing a special turbine which generates grid-connected electricity to be used for lighting purposes.Clean-tech digital textile manufacturing solutions.Ultrasonic Assisted Wet ProcessingSupercritical CO2 Dyeing Technique

REFINERY SECTOR IN INDIA The oil and gas sector is among the eight core industries in India, thus holding an influential position in the decision-making processes at the top government level that affect all other important sectors of the Indian economy. With a massive capacity 247.571 MMTPA, the Indian Refinery sector is next only to the US and China in global volumes. Within the country, the sector is the second-largest energy consumer. Of the total refining capacity, more than half comes from public sector refineries. India’s economic growth and demand for energy are strongly interlinked, and hence the forecast for growth in the refinery sector remains positive for several years in the future.PAT SCHEME FOR THE REFINERY SECTOR There are around 23 Petroleum refineries plants in India. Out of this PAT has covered 20 plants. However, these plants are the large plants which has the maximum energy consumption and has the maximum share in India’s total production. It is evident that the large producers which are also the large energy consumers in the sector has been covered under PAT as 87% of the plants the PAT scheme produces more than 94% of the total production in country.PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Refinery Sector are presented below:CyclesNo. of DCsTotal Energy Consumption (Million TOE)Energy Saving Targets (Million TOE)PAT Cycle I---PAT Cycle II1818.501.098PAT Cycle III---PAT Cycle IV---PAT Cycle V---PAT Cycle VI2021.3041.169PAT Cycle VII--- BEST PRACTICES ADOPTED BY THE REFINERY SECTOR Commissioning of heat integrated, energy efficient crude distillation unit (CDU).Implementation of Advance process control (APC) in CCR.Replacement of third stage ejector system by Liquid ring vacuum pump (LRVP) in vacuum distillation unit (VDU).Furnace efficiency improvement of CDU heater.Process parameters and APC optimization.“indeDiesel Technology” - DHDT Hydrotreatment for Euro-IV & V diesel (S < 50 & 10 ppm, CN > 51).“indeHex Technology”- Food Grade Hexane Hydrotreatment of hexane for benzene removal (< 100 ppm).“indJet Technology” - ATF Hydrotreating - Selective Removal of Mercaptan Sulfur in ATF / desulphurisation of kerosene.NDMAX Technologies- A novel technology to produce high yield of light olefins / LPG and high octane gasoline from various petroleum fractions.Innovative methodology for prediction of Refining Characteristics of Oil (BPMARRK).indSelectG Technology- Selective desulphurization of full range FCC & other cracked gasoline streams to meet BS-VI S spec with minimum loss of RON (~3 units).One Divided wall column in place of 2 columns in FCC Naphtha splitter.LP steam superheating with MP steam in shell and tube exchanger in place of direct mixing.Energy real time optimizer (ERTO software).Substituting N2 blanketing in place Fuel gas in Naphtha splitter receiver. 

Brief Overview of Fertilizer SectorThree decades of planning and development of the fertilizer industry has brought India to the frontline of a fertilizer-producing country. The Indian fertilizer industry has made good progress in the case of Nitrogen-based fertilizers. India is the 2nd largest consumer of Urea fertilizers after China. India also ranks 2nd in the production of nitrogenous fertilizers and 3rd in phosphatic fertilizers. As far as Potassic (K) fertilizers is concerned, there is no indigenous capacity. The requirements are met entirely through imports. India meets its 80 % requirement of Urea (N), while it is heavily dependent on Imports for its potassium (K) and phosphorus (P) fertilizer requirements. The fertilizer industry of India is developed both under the Public and Private sectors.The actual production of all the Fertilizers during the year 2018-19 was 41.485 million tonne. The estimated Production of all the Fertilizers during the year 2019-20 is expected to be 46.215 million tonne showing an increase of more than 11.40% in comparison of the previous year. As of now, the country has achieved 80% self-sufficiency in production capacity of Urea. As a result, India could manage its substantial requirement of nitrogenous fertilizers through the indigenous industry besides imports. Similarly, 50% indigenous capacity has been developed in respect of phosphatic fertilizers to meet domestic requirements. Manufacturing Process & Energy ConsumptionThe urea manufacturing process comprises two major sub-processes such as production of ammonia through reformation/partial oxidation of primary fuel and urea through reaction of ammonia and carbon di-oxide. Specific energy consumption is least for gas based plant followed by fuel oil and coal based plants respectively. Electrical energy is used all the production processes whereas thermal energy is required for decomposition, drying and concentration.As in case of cement, fertiliser sector in India too has achieved global benchmark in energy efficiency. In fact, the average specific energy consumption of the gas based plants in India is better than the global average. Apart from the feedstock, process technology and capacity utilisation are the two other major factors, which impact the SEC in urea manufacture. India has been in the forefront in adopting new technology as would be seen from the rapid stride made in reducing the SEC over the last 25 years. Typical fuel mix of Fertiliser manufacturing process is presented below:Types of Fuels%Coal8Grid Electricity2.0Gas90In addition to technology up gradation, maintaining high productivity has also contributed in improving the energy performance of the sector.PAT Scheme for Fertilizer SectorThe Fertiliser sector is one of the designated sectors covered under the BEE’s Perform, Achieve and Trade scheme. At present, there are 32 large size urea plants in the country manufacturing urea, 19 units producing DAP & complex fertilizers and 2 units manufacturing Ammonium Sulphate as a by-product. In Fertilizer Sector in PAT Scheme covers 30 Urea plants, 1 ammonia plant and 6 complex fertilizer plants.PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Fertilizer Sector are presented below: CyclesNo. of DCsTotal Energy Consumption (Million TOE)Energy Saving Targets (Million TOE)PAT Cycle I298.20.78PAT Cycle II378.260.447PAT Cycle III---PAT Cycle IV---PAT Cycle V---PAT Cycle VI---PAT Cycle VII---Energy Savings Achievement in the Fertilizer Sector under PAT Cycle I and PAT Cycle II are0.78 Million TOE and 0.383 Million TOE.Best Practices Adopted by Fertiliser SectorFertiliser industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures:CO2 as feed for urea production.Changeover of feedstock from FO to NG, Naphtha to NG, Coal to NG.CO2 Recovery unit.Details of Line MinistriesDepartment of Fertilisers under Ministry of Chemicals & Fertiliser (https://www.fert.nic.in/home-page)Details of Industrial AssociationsThe Department of Fertiliser Association of India (https://www.faidelhi.org/)List of Key TechnologiesZirconium CoatingInstallation of Secondary Reformer Heat ExchangerInstallation of VAM for chilling of gas at suction of Ammonia Synthesis gas compressor, process air compressor, CO2 compressor & air compressor for Gas turbine.Coal fired boiler are being substituted with gas-based turbo-generator and associated HRSG.Utilization of green hydrogen can be explored in ammonia production for additional emission reduction. 

Brief Overview of Iron & Steel SectorIndia is currently the world’s second-largest steel producer, and second-largest steel consumer (WSA, 2020a). As with any industrializing economy, the steel sector is of vital importance to India, contributing around 2% to the country’s GDP and employing around 2.5 million people in the steel and related sectors (MoS, 2020a). The Indian Iron and Steel segment offers a product mix that includes hot rolled parallel flange beams, columns rails, plates, coils, wire rods, and continuously cast products such as billets, blooms, beams, blanks, rounds, slabs, metallic, and ferroalloys. In FY 2018, India’s crude steel production crossed 100 MT for the first time, reaching 106.5 MT and registering a 4.5% year-on-year growth rate, and becoming the 2nd largest producer of steel in the world after China. India was also the largest producer of Sponge Iron (Direct Reduce Iron or DRI) in the world in 2020.In 2017, the Ministry of Steel (MoS) launched the National Steel Policy (NSP), which laid down the broad roadmap for encouraging long term growth for the Indian Steel Industry, both on demand and supply sides, by 2030-31 including to increase India’s teel making capacity to 300 Mt by 2030. This policy also encompasses targets to reduce energy consumption per tonne of steel, through adopting the latest energy efficiency measures.India is also among the largest iron ore producers in the world, ranking 4th globally. Iron ore is a key input product for manufacturing steel and primary iron. More than 85% of the iron ore reserves in the country are of medium or high-grade and are directly used in blast furnace and Direct Reduced Iron (DRI) plants, in the form of sized lumps, sinters, or pellets.Manufacturing Process & Energy ConsumptionThe basic process of manufacturing of iron & steel is carried out in two stages, sponge and pir iron through the reduction followed by production of crude steel. Secondary process involves production of merchant products from the crude steel. The steel industry in India is relatively heterogeneous compared to other countries, with a wide range of different sized facilities in the primary and secondary steelmaking sectors. There are also several different technologies currently being used, including the Blast Furnace – Basic Oxygen Furnace (BF-BOF), coal-based Direct Reduction (DR), gas-based DR, Electric Induction Furnace (EIF) and Electric Arc Furnace (EAF). BOF technology dominates a growing share of steel production (45%), being the preferred technology for most new capacity, with EAF (28%) and EIF (27%) taking an almost equal share of the remainder of the market.BF-BOF process is primarily used by integrated steel plants. After the BF-BOF process, molten steel is controlled to a target composition and temperature and is then cast by continuous casting machine to produce slabs and billets. These castings are rolled to the required dimensions by the rolling mill to produce the steel products. Sponge iron is produced by DRI process. Originally, natural gas based reformation technology used to be used in the DRI process. However, technology for using coal has since been developed and most of the Indian sponge iron units use coal both as fuel and reducing agent. Direct reduced iron along with steel scrap is then melted in an electric arc furnace (EAF) to produce molten steel and subsequent products.Fig: Process diagram of a typical Integrated Steel Plant(Source) The energy used in steel making is classified under primary and secondary sources. Energy purchased from outside such as coal, coke, electricity, gas etc. is classified as primary resource whereas recovered energy such as blast furnace and coke oven gas, waste heat from furnaces is classified as secondary resources. From the energy conservation perspective, major emphasis has always been increased use of secondary resources, such as recent spur in investment in WHR based power plants in large number of sponge iron making plants. Iron making by far the most energy intensive process accounting for close to 60 to 70% of total energy consumption. Typical fuel mix involves a) Coal (83.5%) b) Oil (2%) c) Gas (1.5%) d) Grid Electricity (13%). (Source)PAT Scheme for Iron & Steel SectorThe Iron & Steel sector is one of the designated sectors covered under the BEE’s PAT scheme. The modified threshold limit for the Iron & Steel Sector is 20,000 metric tonnes of oil equivalent of energy consumption per annum.PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Iron and Steel Sector are presented below:CyclesNo. of DCsTotal Energy Consumption (Million TOE)Energy Saving Targets (Million TOE)PAT Cycle I6725.322.1PAT Cycle II7140.442.283PAT Cycle III297.6480.457PAT Cycle IV353.3340.1934PAT Cycle V232.82550.1687PAT Cycle VI50.5150.031PAT Cycle VII13460.062.729PAT Cycle VIII663.710.2438Energy Savings Achievement in the Iron & Steel Sector under PAT Cycle I and PAT Cycle II are 2.1Million TOE and 2.921 Million TOE respectivelyBest Practices Adopted by Iron & Steel SectorIron & Steel industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measuresInstallation of Top Recovery Turbine and Pulverized Coal Injection in Blast Furnace.Commissioning of LD Gas Recovery Plant in Steel melting shop.Use of Hydrogen in steel making reheating furnaces.Use of Plastics to replace PCI in Blast Furnaces.Direct rolling in mini steel plants.Hot charging of DRI in EAF.Details of Line MinistriesMinistry of SteelDetails of Specialised Organization / Research InstituteResearch & Development Centre for Iron & Steel (RDCIS) SAIL, RanchiSteel Research & Technology Mission of India (SRTMI), New DelhiCentre of Excellence in Steel Technology (COEST), IIT MumbaiNational Institute of Secondary Steel Technology (NISST), PunjabDetails of Industrial AssociationsIndian Steel AssociationList of Key Technologies100% electrolytic hydrogen based DRI.Waste Heat Recovery in Sinter Plat/ DRI.Hydrogen enrichment.Hisarna with 80-90% capture CCS.Increasing share of production from the secondary sector through scrap recycling.Installation of Top Recovery Turbine.Pulverized Coal Injection in Blast Furnace.Coke Dry QuenchingRegenerative/recuperative burner for reheating furnace

Brief Overview of Chlor-Alkali SectorThe Chlor-Alkali industry in India produces about 69% of the basic chemicals in India, making it an important sector in manufacturing. Caustic soda, Chlorine, Hydrogen and Hydrochloric Acid are the main components of the Chlor-Alkali industry. These chemicals find their applications in a number of industries such as textiles, chemicals paper, PVC, water treatment, alumina, soaps & detergents, glass, chlorinated paraffin wax, among others. There are 32 plants in the country, with 56% of capacity in Western India alone. India constituted to 4% of global Chlor-Alkali capacity with installed capacity and production of 4.38 million TPA and 4.54 million TPA respectively.Alkali chemicals production rose by 4.32% in FY 2017-18, with growth being steady over the years.With a capacity of 2 million tonnes, Gujarat is the largest State for the manufacturing of Caustic Soda. Gujarat also accounts for about half of India’s annual Caustic Soda production, pegged at 35.39 Lakh MT for 2018-19.Among the 32 plants of the Chlor-Alkali industry in the country, most are merchant units, with an average plant size of about 150 tonnes per day (TPD).Manufacturing Process & Energy ConsumptionThe Chlor-alkali process is so called due to simultaneous production of caustic soda and chlorine. The production process involves electrolysis of brine followed by other processes as shown in the following picture.  Electrolytic cell is the core of the process. Three cell technologies; Mercury, Diaphragm and Membrane are used for the electrolysis. Now Membrane technology is widely used in the Chlor-Alkali Plants. Energy consumption is highest in the mercury cell process but it does not require steam for concentration of caustic soda. Membrane cell is most energy efficient but requires some steam for evaporation to concentrate the liquor of about 32-33% concentration to about 50%, the standard market product. Apart from higher level of energy consumption, mercury cells are also polluting and as such have been almost totally phased out in India.Electricity is the primary source of energy for the Chlor-alkali manufacturing process; though some small amount of thermal energy is needed for increasing the concentration of cell liquor produced in diaphragm and membrane cells. The electrolysis energy need in the membrane cell process is close to 90% of the total energy, balance 10% being almost equally shared by auxiliary and thermal energy consumption. In the overall context, typical distribution of energy usage in different sub-processes is shown below: Sub- Processes% of Total Energy Consumption (Equivalent to AC kWh/T CL2)Electrolysis89Auxiliary5Thermal6Further, most of the plants have their coal based captive power plants meeting practically the entire power demand of the manufacturing process. Typical fuel mix of Chlor-Alkali manufacturing process is presented below:  Types of Fuels%Coal75Oil2Gas13Grid Electricity10PAT Scheme for Chlor- Alkali SectorThe Chlor-Alkali Sector is a designated sector covered under the Bureau of Energy Efficiency’s flagship Perform, Achieve and Trade (PAT) scheme for large energy-intensive industrial sectors. PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Chlor-Alkali Sector are presented below: CyclesNo. of DCsTotal Energy Consumption (Million TOE)Energy Saving Targets (Million TOE)PAT Cycle I220.890.09PAT Cycle II241.770.102PAT Cycle III---PAT Cycle IV20.050.003PAT Cycle V20.02820.0017PAT Cycle VI---PAT Cycle VII242.480.097PAT Cycle VIII10.1350.00810Energy Savings Achievement in the Chlor-AlkaliSector under PAT Cycle I and PAT Cycle II are 0.09 Million TOE and 0.136 Million TOE.Best Practices Adopted by Chlor-Alkali SectorChlor-Alkali industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures:Technology upgradation to Zero-gap technology.Installation of micro-turbine.Feeding of 48% hot Caustic Soda Lye direct to flaker plant.Changeover of fuel from Furnace Oil (FO) to Hydrogen in process heating/steam requirement.Utilizing Hydrogen in Captive Power Plant.PEM Fuel Cell Technology using Hydrogen.Hydrogen Compressed Natural Gas (HCNG) (Hydrogen blending with CNG).Details of Line MinistriesDepartment of Chemicals and Petrochemicals (https://chemicals.gov.in/)Details of Specialised Organization / Research InstituteIndian Institute of Chemical Technology, HyderabadNational Chemical LaboratoryIndian Institute of Chemical EngineersDetails of Industrial Associations Alkali Manufacturers Association of India (AMAI)List of Key TechnologiesZero Gap ElectrolyserOxygen-Depolarised Cathodes (ODCs)Hydrogen Fuel Cell for Electrolysis in Caustic Soda Production 

Brief Overview of Aluminium SectorThe Indian Aluminium Industry is the second-largest producer of aluminium globally, with a share of ~5.3% of the global output. In FY21, India produced ~4 million tonnes (MT) of aluminium. The industry is highly concentrated with most of the country’s aluminium being produced by the top five companies. The aluminium industry in India is thriving at an enviable growth rate of 7% per annum, which is one of the highest in the world. Demand for aluminium has grown over the years from various sectors such as construction, electrical, automobile, packaging, etc. The export of primary Aluminium from India has witnessed a rapid rise over the years and the share of exports in aggregate production has risen to 54% in FY20 from 46% in FY16. India's primary Aluminium exports increased by approximately 50% during the first quarter of FY21.In FY21, India's per capital aluminium consumption stood at 2.5 kg as against the worldwide average of 11 kg and 24 kg of China. According to a NITI (National Institution for Transforming India) Aayog study, enhancing India’s per capita aluminium consumption to the global average would require an annual increase of 16 MT in consumption. The major aluminium-consuming sectors include power (~44%), construction (17%), and consumer durables & transportation (10-12%).Manufacturing Process & Energy ConsumptionThe Aluminium manufacturing process comprises of two primary sub-processes; bauxite refining for production of alumina and smelting for productions of aluminium metal and secondary process for conversion to merchant products.Although considerable energy is also used in anode production, this is often accounted for under raw materials. In the overall context, typical distribution of energy usage in different sub-processes is shown below:Sub- Processes% of Total Energy ConsumptionAlumina Refining12Anode Production9Smelting72Casting7In the refining and anode making process primarily thermal energy is used, for digestion and calcination for the former and baking for the later. However, if the energy content of the coke is also considered, it adds 30% more to the overall energy consumption. Electricity is used for the smelting process. For the secondary process, both thermal and electrical energy are used, thermal energy for die casting, pre-heating and stress relieving whereas electrical energy for rolling and extrusion. Further, all the plants in India have their coal based captive power plants meeting practically the entire power demand of the manufacturing process. Typical fuel mix of Aluminium manufacturing process involves a) Coal (94%) b) Oil (4.5%) c) Gas (0.5%) d) Electricity (1%)In addition to the basic technology, operation and maintenance also play very important role in maintaining the energy usage. Some of the critical areas of operational control include control of alumina feed rate, cell temperature, current densities, anode management, management of product extraction. Similarly, maintenance includes proper insulation levels and thermal balance, conductivity of various bus bar connections and joints etc. Flow Process Diagram of one Typical Aluminium PlantBirdeye of a Typical Smelter Potline of an Aluminium PlantPAT Scheme for Aluminium Sector The Aluminium sector is one of the designated sectors covered under the BEE’s Perform, Achieve and Trade scheme. The Aluminium sector has been categorized based on its process in to four subsectors: refinery, smelter, integrated and cold sheet mills. The Aluminium industry, with an annual consumption of over 7,500 tonnes of oil equivalent (toe), is notified as a Designated Consumer (DC) under the PAT scheme. 1. PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Aluminium Sector are presented below: CyclesNo. of DCsTotal Energy ConsumptionEnergy Saving TargetsPAT Cycle I312.090.29PAT Cycle II292.680.146PAT Cycle III10.0570.003PAT Cycle IV20.1640.0098PAT Cycle V80.28370.0169PAT Cycle VI20.0550.003PAT Cycle VII242.210.081 PAT Cycle VIII10.12670.00744 Energy savings achieved by DCs of Aluminium sector under PAT Cycle I and PAT Cycle II are 0.73 MTOE and 0.573 MTTOE respectively. Best Practices Adopted by Aluminium Sector Aluminium industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures:100% graphitized cathode installation. Improvement of conversion efficiency of rectifier systems. Graphitized pots current efficiency improvement and average voltage reduction.  Silicate-based anode coating technique applied in reducing the top oxidation which has a major impact on Net Carbon Consumption. AC to DC conversion efficiency improvement.  Use of RUC (Ready to use Cathode) copper inserted collector bar for pot cathode. Reducing the dead pot residual voltage to zero by a shorter current path having a higher cross-section and lower current density.Fitch fuel catalyst used in the Bake oven and cast house to save HFO consumption and to reduce emissions in the Bake Oven and cast house (around 5% of fuel saving).Biomass Co-firing in boilers. Energy Analytic Platform using Power BI with AI and energy saving using copper insert.  Digital smelter solution (first in India), deployed at an aluminium smelter in Jharsuguda, Odisha - uses digital twin technology for human-less monitoring, and operational control thus enhancing energy & resource efficiency through a remote advisory system. OSIsoft PI (Process Information) System, an industrial IoT solution, implemented inJharsuguda uses machine learning to boost operational efficiency and productivity. Details of Line Ministries Ministry of MinesDepartment for Promotion of Industry and Internal Trade (DPIIT)Details of Specialised Organization / Research Institute Jawaharlal Nehru Aluminium Research Development and Design Centre (JNARDDC) under the Ministry of MinesDetails of Industrial Associations Aluminium Association of IndiaAluminium Secondary Manufacturers Association (India)List of Key Technologies Drained cell technology with wet table cathodesZero Gap Electrolyser Calciner main burner nozzle replacement.Use of Cold sealing paste for pot relining.Corro-coat coating of the pump to increase its efficiency.Solar heating system for hot mill emulsion.Hot water generator to replace the steam boiler in Tension Leveller process.Inert Anode Technology.Wetted Cathode TechnologyMultipolar Cell Technology. Renewable Energy based Smelter PlantList of EE and Decarbonisation Technologies and Solutions (National& International)  Reports  Pathways for Energy Efficiency and Decarbonisation in the Indian Aluminium Industry     

 Brief Overview of Cement Sector In a rapidly developing nation such as India, there is no dearth of demand for new infrastructure. Indian Cement industry, the second largest producer of cement after China, produces 7% of the global cement production and completed 100 years of its service to the Nation in October 2014 with the first plant coming up in 1914. It is one of the fastest-growing sectors and is also humungous in its volume of production as compared to volumes worldwide. With a total of 206 large integrated cement plants and about 350 mini cement plants making up a total capacity of 539 million tonnes per annum in 2018-19, the Indian cement sector is a formidable giant. Indian cement consumption is around 235 kg per capita against the global average of 520 kg per capita. There is no foreseeable reason for any slowdown in the juggernaut of the cement industry in India. As per ICRA, in FY22, the cement production in India is expected to increase by ~12%YoY, driven by rural housing demand and government’s strong focus on Infrastructure Development. As per CRISIL Ratings, the Indian Cement Industry is likely to add ~80 million Tons (MY) capacity by FY24, the highest since the last 10 years, driven by increasing spending on housing and Infrastructure activities.Indian cement plants are comparable with the best in the world in respect of production facilities, technology, and energy efficiency. The sector has achieved the best specific energy consumption levels achieved i.e., 670 kcal/kg of clinker and around 68 kWh per tonne of cement, which are comparable with the best-achieved levels in the world.Manufacturing Process & Energy Consumption: Generally, cement manufacturing process involves the following stages: Crushing Pre-homogenization and raw meal grindingPre-heatingPre-calciningClinker production in the rotary kilnCooling and storingBlending Cement grindingStoring in the cement siloMostly dry processes is deployed in the raw material preparation and clinkerisation sub-processes. In the dry process, crushed raw materials are dried in a cylindrical rotary drier, mixed at per predetermined ratio, further ground and conveyed in different storage tanks. The prepared materials are further mixed as per pre-determined ratio and fed into rotary kiln for clinkerisation. Depending upon the usage of clinker and other materials in the final product, marketed cement product is classified under three different categories such as Ordinary Portland Cement (OPC), Portland Pozzolana Cement (PPC) & Portland Slag Cement (PSC). Clinker constitutes about 95% in OPC, Gypsum contributing for the rest. In PPC, 15 to 20% of the clinker is substituted by pozzolonic material such as fly ash whereas in PSC about 50% clinker is substituted by blast furnace slag, Gypsum contribution in both the cases remaining at the same level of about 5%. With increased availability of fly ash and its favorable contribution in improving the strength of concrete and reduction in cost of energy, share of PPC production has been continuously increasing all over the world, more so in India. Fig: Process diagram of a typical Dry type Integrated Cement Plant(Source)The cement plant consumes two types of primary energy: thermal energy and electricity. The material transport, crushing and milling mainly consumes electricity whereas thermal energy is used for calcination. The secondary energy sources used in cement production are kiln exhaust gas and hot air from clinker cooler. The secondary heat contained in the hot kiln exhaust gas is utilized primarily in pre-drying and preheating the raw materials before their introduction into the kiln and raw mill. The waste heat contained in the exhaust air from the clinker cooler serves to preheat combustion air and also to dry and preheat the raw materials before they enter the raw mill and kiln. Electricity is majorly consumed in the clinker grinding, raw material processing and clinker production. Typical distribution of energy usages in different processes is shown below:Sub-Processes% of Total Electricity ConsumptionRaw-material Preparation30%Clinker Production25%Clinker Grinding40%Others05%Electricity and Coal have been the sources of energy for most of the plants. Cost of both the energy resources have been sharply increasing putting pressure on the profitability margin even for the energy efficient units. With a view to remaining globally competitive, Indian Cement Industry has made major strides by undertaking innovative measures for managing the energy cost. These include:Investment in energy efficient technologiesHigh efficiency captive power generation including based on waste heat recovery.Use of non-conventional fuel like biomass, RDF (Municipal solid waste derived fuel), old tyres etc.Off-site renewable energy generation and wheeling through open access.Typical fuel mix of Cement manufacturing process includes a) Coal (97%) b) Oil (1%) c) Grid Electricity (2%). PAT Scheme for Cement Sector In the Cement Sector, to become a designated consumer, the notified threshold limit is 30,000 metric tonnes of oil equivalent of energy consumption per annum. PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Cement Sector are presented below:CyclesNo. of DCsTotal Energy Consumption (Million TOE)Energy Saving Targets (Million TOE)PAT Cycle I8515.011.48PAT Cycle II11121.431.117PAT Cycle III141.7430.096PAT Cycle IV10.0740.004PAT Cycle V121.60.087PAT Cycle VI371.2420.063PAT Cycle VII12025.560.896PAT Cycle VIII250.6280.0323Energy Savings Achievement in the Cement Sector under PAT Cycle I and PAT Cycle II are 1.48 Million TOE and 1.56 Million TOE respectively. Best Practices Adopted by Cement Sector Cement industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures:Increase in AFR utilisation.Waste Heat Recovery from the pre-heater outlet. Adopting Renewable Energy.Calcium looping as Carbon Capture technology. Installation of Kiln Shell radiation recovery system in Kiln for CPP makes up water heating. Reduction of Clinker Factor in Pozzolana Portland Cement. Details of Line MinistriesDepartment for Promotion of Industry and Internal Trade (DPIIT) under Ministry of Commerce and IndustryNational Council of Cement and Building Materials (NCCBM) under Ministry of Commerce and IndustryDetails of Specialised Organization / Research InstituteNational Council of Cement and Building Materials (NCCBM) under Ministry of Commerce and IndustryDetails of Industrial AssociationsCement Manufacturers Association List of Key Technologies Increase in usage of AF from 2% to 10%.Waste heat recovery from the cooler and preheater outlet. Adoption of a Vertical roller mill for grinding.Installation of Kiln Shell radiation recovery system in kiln.Reduction in Clinker factor in Pozollana Portland Cement.Oxy-fuel combustion technologyManufacturing of polymer cement from waste of iron sludge