1 By Zenith Energy Services (P) Limited Hyderabad Presentation on Vapi Dyes and Chemical Industries Cluster Gujarat State

2 Zenith Energy Services Pvt. Ltd. started Energy use and Technology Audits in the Month of November Schedule of Implementation

3 No. of units Covered for Energy use and Technology Audit Total No. of units in Vapi Cluster are around 450 No. of units to be covered in the Cluster are 75 units

4 Products Manufactured Chemicals Dyes Intermediate Pigments Pharmaceuticals Bulk drugs etc

5 Main Energy Forms used Electricity Lignite Coal Imported coal Natural gas Biomass materials

6 Major Energy Consuming Process Equipments Reactors Dryer (Tray & Rotary) Steam Boilers Blenders. Ball Mills Refrigeration and A/c Plants Dust Collector Pulverizers Eccentric Vibrating Screen Rotary Screen

7 Energy Scenario Supply by State Electricity board: In Vapi total 5 grid (66 kv 3rd phase, 66 kv 4th phase, 66 kv GIDC SS, 66 kv Damanganga, 220 kv Balitha) each grid minimum 10 to 15 feeders & each fedder 11kv. Power available 24 hr. weekly one day power cut. Phase wise staggering is there. (Wednesday, Thursday, Friday & Saturday). Per unit Rs.5.80 Gas supply by Gujarat State Petroleum Corporation Ltd. (GSPC), per unit rate Rs /- basic price & vat 15% extra. They offer service wherein minimum consumption 100 units per month & maximum no limit. At present gas availability problem. Other fuel FO/ LDO/Coal/ Wood getting from local traders. ( Wood cost Rs. 3/- per kg.) Due to cheap cost maximum are using wood

8 Possible Identified Areas De-super-heaters for refrigeration plants for hot water generation required for the boiler and process hot water requirement Replace old and inefficient dryers with new dryers for optimizing steam consumption and fuel consumption Auto control system for water circulation pumping system with VFD’s and pressure transducers for optimising power consumption of pumps Efficient boilers in place of old boilers Improve the performance of the refrigeration system by various methods

9 Replace local make pumps with new energy efficient and optimized size pumps Improved design agitators with helical gear system and VFD’s Improved design ball mills and Pulverisers Efficient and Optimum sized blowers Install waste heat recovery system for boilers and natural gas generators Possible Identified Areas

10 Issues and concerns for Implementation Involves high investment for technology change of various equipments and low returns Interested to implement low cost measures Lack of interest in investing in energy efficiency measures and more concentration on production, quality and new products innovation Financial Issues

11 Technical Issues Lack of awareness on technologies available in the market Rely on local equipment suppliers and all equipments are locally fabricated Lack of awareness on energy saving either for the management or workers

12 Thank You