Select Page

Decarbonization Avenue : Energy Efficient Industrial Equipment

India, one of the world's fastest-growing economies, faces a dual challenge: sustaining its economic growth while addressing environmental concerns. As the country continues to industrialize, energy consumption & energy efficiency is a crucial component of India's decarbonization strategy. By focusing on energy-efficient industrial equipment, India can achieve significant energy and monetary savings, contributing to its climate goals.

 

Energy Consumption in Indian Industries

Industries in India account for about 37% of the total energy consumption. Electric motors alone consume approximately 30% of industrial electricity, reflecting a substantial opportunity for energy savings. While these motors are relatively efficient (80-90%), even a minor improvement of 5% can lead to significant energy savings due to their widespread use in industrial applications.

  • Industrial Energy Use: In 2018, India's industrial sector consumed approximately 330 million tons of oil equivalent (Mtoe), which is projected to reach 550 Mtoe by 2030 if current trends continue.
  • Electric Motors: Improving the efficiency of electric motors by just 5% could save around 40 billion kWh annually, equivalent to the annual electricity consumption of around 5 million Indian households.
  • Energy Efficiency Potential: According to the Bureau of Energy Efficiency (BEE), energy efficiency improvements in Indian industries could save up to 15-20% of their total energy consumption, translating to savings of approximately 100-130 Mtoe by 2030.

 

Key Technology 

  • Smart Sensors and IoT Integration: Implementation of IoT-enabled sensors in cement plants has led to a 12% increase in operational efficiency, resulting in annual energy savings of approximately 50,000 MWh.
  • Advanced Insulation Materials: Upgrading insulation in industrial kilns and furnaces can reduce energy consumption by up to 10%, translating to savings of approximately 20,000 MWh per year for a typical large-scale steel plant.
  • Efficient Water Management Systems: Water management in efficient cooling towers, heat exchangers, and water recycling systems can lead to substantial energy and water savings. A textile manufacturing unit in Gujarat implemented advanced cooling tower technology, resulting in a 25% reduction in water usage and 15% energy savings.
  • Energy Service Companies (ESCOs): The ESCO market in India is projected to grow at a CAGR of 15% from 2020 to 2030, potentially facilitating investments worth USD 15 billion in energy efficiency projects.

 

Case Studies

  • Tata Steel's Energy Efficiency Initiatives: Tata Steel has implemented several energy efficiency measures, including the use of high-efficiency motors, variable frequency drives (VFDs), and waste heat recovery systems. These initiatives have resulted in a 15% reduction in energy consumption and significant cost savings.

  • Godrej & Boyce: This company has adopted energy-efficient practices across its manufacturing units, including the use of LED lighting, high-efficiency chillers, and energy management systems. These measures have reduced energy consumption by 20%, highlighting the potential of energy-efficient equipment in reducing industrial energy use.

  • National Aluminium Company Limited (NALCO): NALCO's efforts in implementing advanced energy-efficient technologies, such as energy-efficient pumps and compressors, have led to a 10% reduction in energy consumption in their operations.

Decarbonization potential

The decarbonization potential in India's industrial sector is substantial, with opportunities for significant CO2 emissions reductions through energy efficiency improvements, renewable energy integration, and fuel switching. The industrial sector is a major contributor to India's CO2 emissions, primarily through the consumption of electricity and thermal energy. Addressing the decarbonization potential in this sector is crucial for India to meet its climate goals.

 

Key Datapoints

  • As of 2023, the industrial sector accounts for approximately 40% of the country's total electricity consumption, which was around 1,600 TWh in 2022.
  • Industrial electric motors consume about 640 TWh annually. This results in approximately 320 million tons of CO2 emissions, given the carbon intensity of India's power generation, which is about 0.5 kg CO2 per kWh.
  • Industrial furnaces in India consume about 1,200 TWh of energy per year. This results in approximately 600 million tons of CO2 emissions annually.
  • High-efficiency motors and implementing advanced motor control technologies, energy consumption can be reduced by up to 20%, potentially saving around 128 TWh of electricity and reducing CO2 emissions by 64 million tons annually.
  • Upgrading to more efficient Furnace models, and adopting waste heat recovery systems can lead to energy savings of up to 25%, potentially saving 300 TWh of energy and reducing CO2 emissions by 150 million tons annually.
  • Expanding solar and wind energy capacity to replace a portion of the coal-based power can reduce CO2 emissions by up to 200 million tons annually by 2030.

Industries impacted

  • Aerospace & defense
  • Automobiles & auto components
  • Chemicals & petrochemicals
  • Electrical
  • Electronics & semiconductors
  • Engineering goods & machinery
  • Fertilizers
  • Food & beverages
  • Mining & metals
  • Oil & gas
  • Packaging & plastics
  • Pharmaceuticals
  • Power
  • Printing & publishing
  • Textile & apparel
  • Waste management
  • Water

Themes & Topics

  • Heating & cooling equipment

    • Furnaces

    • Kilns & ovens

    • Boilers

      • CHP boilers

    • Distillation

    • Cooling towers

    • Hot air generators

    • Heat exchangers

    • Chillers

    • Foundry & metal working

    • Autoclave applications

  • Electrical & electronics

    • Motors

    • Turbines

    • Generators

  • Mechanical & machine working equipment

    • Pumps

    • Bearings

    • Filtration & separation equipment

    • Drives & gears

    • Energy efficient metal working machinery & processes

    • Energy efficient mixers & grinders

    • Energy efficient blowers & compressors

    • Energy efficient logistics & conveyor equipment

  • ESCO models for industrial energy efficiency

  • Education/capacity building

  • Collaboration

  • Advanced materials for energy efficient equipment

  • Maintenance for energy efficiency

 

 

 

 

 

 

 

 

  • Use of IT & digital solutions in energy efficiency equipment

    • IoT & analytics

    • PLC

    • Energy monitoring

    • SCADA systems

  • Key sectors

    • Engineering & manufacturing

    • Construction & infrastructure

    • Process industries

    • Fabrication industries

    • OEMs/Product assembly

  • Energy efficient equipment for specific industries

    • Aerospace & defense

    • Automobiles & auto components

    • Chemicals & petrochemicals

    • Construction & real estate

    • Electrical

    • Electronics & semiconductors

    • Engineering goods & machinery

    • Fertilizers

    • Food & beverages

    • Mining & metals

    • Oil & gas

    • Packaging & plastics

    • Pharmaceuticals

    • Printing & publishing

    • Paper & forest products

    • Telecom

    • Textile & apparel

    • Waste management

    • Water

 

 

 

 

 

 

 

 



All Decarbonization Avenues @ EAI


Renewable Energy :

  • Utility Scale Solar PV |
  • Distributed Solar PV |
  • Solar Thermal |
  • Wind Power |
  • Biomass for Heating & Power |
  • Biofuels |
  • Hydro Power |
  • Geothermal Energy |

  • Energy Efficiency :

  • Industrial Waste Heat Recovery |
  • Low Carbon Thermal Power |
  • Energy Efficient Industrial Equipment |
  • Smart Grids |
  • Heat Pumps |
  • Digital for Decarbonization |
  • Energy Efficient Buildings |

  • Energy Storage :

  • Green hydrogen |
  • Thermal & Mechanical Storage |
  • Battery Storage |

  • Agriculture & Food :

  • Sustainable Forestry |
  • Regenerative Agriculture |
  • Smart Farming |
  • Low Carbon Food |
  • Agro Waste Management |

  • Waste Management :

  • Reducing Food Waste |
  • Solid Waste Management |

  • Materials :

  • Bio-based Materials |
  • Advanced Materials |
  • Product Use Efficiency |
  • Industrial Resource Efficiency |

  • Water :

  • Water Use Efficiency |

  • Decarbonizing Industries :

  • Low Carbon Metals |
  • Low Carbon Chemicals & Fertilizers |
  • Low Carbon Construction Materials |
  • Low Carbon Textiles & Fashion |
  • Corporate Carbon Management |
  • Decarbonizing Oil & Gas Sector |

  • Low Carbon Mobility :

  • Electric Mobility |
  • Low Carbon Trucking |
  • Low Carbon Marine Transport |
  • Low Carbon Aviation |
  • Low Carbon ICE Vehicles |
  • Mass Transit |

  • GHG Management :

  • C2V - CO2 to Value |
  • CO2 Capture & Storage |
  • Reducing Emissions from Livestock |
  • Reducing Non-CO2 Industrial & Agricultural Emissions |
  • Managing Large Carbon Sinks |

  • Communities :

  • Low Carbon Lifestyles |
  • Low Carbon Cities |

  • Finance :

  • Climate Finance |

  • Platforms :

  • Multi-stakeholder Collaboration |
  • Low Carbon Accelerators |

  • Moonshots :

  • Moonshots |