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By

Zenith Energy Services (P) LimitedHyderabad

Presentation on

Jagadhri Brass and Aluminum Industries Cluster

Jagadhri, Haryana State

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Zenith Energy Services Pvt. Ltd. started Energy use and Technology Audits in the Month of November 2009.

Schedule of Implementation

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No. of units Covered for Energy use and Technology Audit

• Total No. of units in Jagadhri Cluster are

around 200

• No. of units to be covered in the Cluster as out 60 units

• As on date, The Preliminary studies were completed in 6 units only

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Products Manufactured

• Brass sheets and utensils,

• Aluminum utensils &

• Stainless steel utensils

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Process Flow Diagram

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Main Energy Forms used

• Electricity

• Fuels

Wood Coal Furnace Oil HSD Oil

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Major Energy Consuming Process

Equipments• Melting furnaces (crucibles) • Heat treatment furnaces• Induction furnaces• Rolling machines• Shearing machines • Sizing machines• Embossing• Drawing machines

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Energy Scenario

• The average wood consumption is around 150 tons per annum and 100 tons of coal for a typical 2500 kgs/day production capacity.

• The electricity consumption is varies from 10,000 to 20,000 kWh/month depending on the production capacity of the plant and equipments installed

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Possible Areas of Energy Conservation

• Improved design of melting furnaces for aluminum and brass industries for reducing flue gas losses , radiation losses and reducing un-burnt coal quantity burning after completion of the melting process and waste heat recovery system.

• Improved design of wood fired annealing and re-heating furnace.

• Replacement of very old motors with new motors• Replacement of old inefficient transmission systems• Variable frequency drives for shearing, utensils making

tools to reduce the power consumption during un loading• Optimizing excess air supply to the furnaces• Use of efficient burners

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Issues and concerns for Implementation

• Lack of interest in investing new technologies as the operation of the units are continuing for more than 50 years

• Involves high investment for technology change

of various equipments

Financial Issues

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Technical Issues

• No successful stories of new technologies in the cluster.

• Some of the technologies adopted by selected SME’s were not successful and hence lack of interest

• Rely on local equipment suppliers

• There is no much technology development in the technologies used in the cluster since past so many years

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Other Issues

• Rely on the success stories of technologies adopted in the cluster by the SME owners or neighboring industries

• Lack of confidence on the technical consultants

and the technologies • Only 1 or 2 demonstration projects in the

cluster will have impact on the cluster owner

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• Dissemination Program : March/April 2010

• Energy use and Technology Audit will be completed by June 2010

• Cluster manual preparation by August 2010

• DPR Preparations from September 2010

• Local Service Providers Workshop November 2010

• Other programs as decided by BEE

Implementation Plan

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Thank You