Manual for Training Energy Professionals in Limekiln Sector

Bureau of Energy Efficiency

Ministry of Power, Government of India

Prepared By

Zenith Energy Services Private Limited

10-5-6/B, My Home Plaza, Masabtank, Hyderabad – 500 028

Ph.No. (040) 2337 6630/ 31: 2331 5810/12: Fax (040) 2332 2517

Email: [email protected], web: www.zenithenergy.com

Manual for Training Energy

Professionals in Limekiln Sector

ii

Acknowledgement

Zenith Energy Services Private Limited (ZESPL) places on record its gratitude to the

Bureau of Energy Efficiency (BEE), Government of India, for entrusting us with this

prestigious assignment of “Training of Energy professionals in Limekiln Sector” which is

part of the Global Environmental Facility (GEF) Programmatic Framework (2010-14) for

Energy Efficiency in India with an objective to increase demand for energy efficiency

investments in targeted MSMEs clusters

Zenith Energy Services Private Limited sincerely thanks Dr Ajay Mathur, Director

General, Shri S Lahiri, Procurement Specialist, and Shri Vishal Aggarwal, Energy &

Environment Specialist of BEE for their support, guidance, and valuable inputs to the

project.

We sincerely appreciate the interest and support of Mr Mariappan, President and Mr

Gomath Nayagam, Treasurer of Tirunelveli Lime Manufacturers Welfare Association,

Tirunelveli and Mr Asharam Dhoot, President and Sharad Jain, Secretary of Rajasthan

Lime Manufacturers Association, Jodhpur. We further express our gratitude to limekiln

unit owners at Tirunelveli and Jodhpur cluster and M/s Kaycee Chemicals, Tuticorin for

their cooperation in sharing valuable information and details for the completion of the

manual.

We gracefully acknowledge the diligent efforts and commitments of all those who have

contributed in preparation of the manual.

Zenith Energy Services Private Limited

Hyderabad

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Contents

Chapter 1: Introduction

1.1 About the project

1.2 Objective Of the project

1.3 Technical Approach & Methodology

1.4 Expected outcome of the project

1.5 Energy Conservation Act 2001 & its amendments

1.6 Lime industry Association

Chapter 2: Technological status and energy consumption scenario

2.1 Overview of Targetted Limekiln clusters

2.1.1 Targeted Limekiln Cluster

2.1.2 Products Manufactured

2.1.3 Classification of units

2.1.4 Raw Material used

2.2 Energy consumption scenario

2.2.1 Fuel Used and price

2.2.2 Energy consumption

2.2.3 Specific Energy Consumption

2.2.4 Energy Cost

2.3 Manufacturing Process

2.4 Major Barriers for implementation of Energy Efficiency Measures

Chapter 3: Energy Audit and Technology Assessment Study

3.1 Technology Assessment Study

3.1.1 Technology Employed in the Targeted Cluster

3.2 Methodology Adopted

3.2.1 Preliminary Energy Audit and Findings

3.2.2 Detailed Energy Audit and Finding

3.3 Energy Efficiency Measures Recommended for Tirunelveli Cluster

3.3.1 New Energy efficient vertical shaft limekilns

3.3.2 Retrofitting of the existing kilns

3.3.3 Use of Refractory for reducing Surface Radiation Loss

3.3.4 Use Biomass as Supplementary/ main fuel in limekiln

3.3.5 Better Operating Practices

iv

3.3.6 Instrumentation for Process Optimization

3.3.7 Better Housekeeping Practices

3.4 Energy Efficiency Measures Recommended for Jodhpuri Cluster

3.4.1 Use of Better Quality Insulation

3.4.2 Energy Efficient Motors

3.4.3 Installation of Automatic Power Factor Controller to Maintain Unity PF

3.4.4 Improve Coke Storage


Chapter 4: Cross Cluster Learning and Technologies Suitable for Lime Burning

4.1 Technology Adoption for Lime Burning

4.2 Technology Gap Assessment

• Evolution kiln designs in India

• Natural draft based limestone burning kiln

Chapter 5: Training Needs Assessment Survey

5.1 Needs Assessment

5.2 Tirunelveli Limekiln Cluster

5.2.1 Issues Facing

5.2.2 Capacity Building Needs Assessment

5.3 Jodhpur Limekiln Cluster

6.3.1 Issues Facing the Jodhpur Cluster


6.2 Capacity Building Needs Assessment

Chapter 6: Case Studies/ Best Practices

6.1 Case Study 1: Replacement of Conventional Kiln with Vertical Shaft Kiln Coupled

with Biomass Gasifier

6.2 Case Study 2: Replacement of Conventional Kiln with Forced Draft Vertical Shaft

Kiln with Sheet Steel

6.3 Best Practices: Replacement of Re-winded/Old Motors with EE Motors

Chapter 7: EE Financing Scheme

7.1 Back ground

7.2 Lending Scheme/ Financial Schemes/ Credit Facility/ EE Schemes of SIDBI

7.3 Small industrial development bank of India (SIDBI)

7.4 Other Banks/ Financial Institutions

7.5 Central Government Schemes

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Annexure

Annexure 1: List of Members associated with Tirunelveli Lime Manufacturers Welfare

Association

Annexure 2: List of Members associated with Rajasthan Lime Manufacturers

Association

Annexure 3: Equipment Suppliers and Service Providers in Tirunelveli Limekiln Cluster

Annexure 4: Equipment Suppliers and Service Providers in Jodhpur Limekiln Cluster

Annexure 5: List of Energy Managers & Energy Auditors in Tirunelveli District

Annexure 6: List of Energy Managers & Energy Auditors in Jodhpur District

Annexure 7 List of units Where Preliminary Energy Audit conducted in Limekiln Sector

Annexure 8: Comparison of various technologies in Jodhpur limekiln cluster

1

Chapter 1

Introduction

1.1 About the Project

The project “Financing Energy Efficiency at MSMEs” is part of the Global Environmental

Facility (GEF) Programmatic Framework (2010-14) for Energy Efficiency in India with an

objective to increase demand for energy efficiency investments in targeted MSMEs

clusters and to build their capacity to access commercial finance. The GEF

implementation agency for this project is the World Bank. Bureau of Energy Efficiency

(BEE), Ministry of Power, Govt. of India and the Small Industries Development Bank of

India (SIDBI) are executing agencies for the project

1.2 Objectives of Project

The overall objective of the project is to provide training to energy professionals (energy

auditors, energy managers, other energy specialists and plant managers of limekiln

units) with specific focus on MSMEs to augment the skills of the energy professionals in

energy auditing, preparation of bankable DPRs, and for accessing commercial finance

by MSMEs for energy efficiency investments.

1.3 Technical Approach and Methodology

The technical approach and methodology adopted by Zenith Energy Services Private

Limited (ZESPL) for implementation of the project activity was based on successful

approaches adopted by ZESPL in training and capacity building of various stakeholders

for MSME sector (energy auditors, managers, associations, owners, bankers, LSPS,

other stakeholders in MSME clusters) and technical assistance for a number of projects

in the past and at present funded by various agencies such as BEE, NREDCAP, ADB,

GIZ, APIIC, etc. The lessons learnt from these projects and feedback analysis of similar

training programs have been taken into consideration for successful implementation of

the project. The Tirunelveli and Jodhpur limekiln cluster were identified for implementing

the project “Training of Energy Professionals in Limekiln Sector”.

A well planned methodology was adopted to execute various activities such as needs

assessment survey, cluster break up study, walk through energy audit, preparation of

international case studies and best practices, collection of energy professionals and

local service providers in the cluster and EE financing schemes for the MSME sector to

achieve the desired project objectives.

1.3.1 Needs Assessment Survey

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Interviews were conducted with key stakeholders of the targeted clusters such as MSME

owners, industry associations, financial institutions, local suppliers & service providers,

business development service providers and other active institutes in the cluster. These

interviews were conducted by administering structured questionnaires to identify the

needs of the various stakeholders of the cluster for accelerating energy efficiency

promotional activities in the cluster units.

1.3.2 Cluster Break up study

Field visits and survey were carried out in the targeted limekiln cluster in terms of

emergence of the cluster, technology status & gaps, energy consumption scenario,

technology upgradation, and barriers and constraints faced by MSME units in the

cluster. Targeted limekiln cluster units were classified based on technology adopted,

production capacity and energy consumption for thorough understanding of the cluster.

1.3.3 Walk Through Energy Audit

Major steps which followed during the walk through energy audit were mentioned below:

• Data Collection

• Measurements

• Compilation and Analysis

• Technical discussion with unit owners/supervisors

The primary objective of the energy audits is to quantify the existing thermal and

electricity consumption through measurements and discussions with unit owners. The

key points targeted through energy audits were determination of specific fuel

consumption, various losses and operating practices. ZESPL team has collected

information such as limekiln dimensions, raw material specifation, pulvariser load, pet

coke & raw material ratio, and petcoke & electricity consumption with respect to

production and undertaken measurements with involvement of unit owners during field

visit. The instrument such as load Manager, anemometer, temperature meters, Infrared

Thermometer, Lux meter were used during the study. At the end of field visit, ZESPL

team briefed observations made during audit, which may effect reduction in fuels and

electricity consumption to unit owners.

1.3.4 Identification of service providers and vendors for EE technologies

The details of local services providers, equipment suppliers, and vendors in the

respective cluster who could design, supply, install and provide maintenance of EE

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technologies/ equipments applicable for limekiln sector have been collected, analyzed,

compiled. The required information was gathered through discussions with the industry

association and compiled the list of local service providers/suppliers of EE equipment.

1.3.5 Documentation of lending / Financing/ EE schemes of SIDBI

ZESPL team interacted with financial institutions such as Small Inustries Development

Bank of India (SIDBI) for obtaining the information on EE loan products and credit

facilities. The information was also collected from various financial institution websites

for various lending schemes available and guidelines for availing the loans.

1.3.6 Identification of Energy Professionals in the cluster

ZESPL was identified energy professionals such as energy auditors, managers, MSME

unit owners and unit supervisors in the targeted clusters, who are involved or working in

energy sector in industries and others. The list was compiled from web searches (BEE,

Energy Manager Training and Society for Energy Managers & Energy Auditors) and

from interactions with the respective State Designated Agencies for energy efficiency

activities in the state and with National Productivity Council (NPC).

1.3.7 Preparation of Training Manual for Limekiln Sector

ZESPL was prepared training manual based on various studies conducted in the

targeted clusters and wide consultations with various stakeholders of the project such as

unit owners, energy professionals, industrial association, MSME–DI, DIC, technology

providers and equipment suppliers. The training manual contains information such as

cluster scenario, technology used, sources of energy and its consumption pattern,

preliminary energy audit observations and recommendation for targeted cluster units,

case studies and EE financing schemes & subsidies available applicable for MSME

sector.

1.3.8 Training of energy professionals in limekiln cluster

The two training programs were conducted at Tirunelveli and Jodhpur limekiln clusters

and participants were from individual units (owners and supervisors), energy managers

and energy auditors in the area. The training program was conducted at respective

clusters with the objective of augmenting their knowledge on EE technologies,

preparation of detailed project report, dissemination of EE Financing schemes and

subsidies applicable for MSME.

1.4 Expected Outcome of the project

4

The primary outcome of the project is to provide in-depth training to energy professionals

(energy auditors, energy managers, and other energy efficiency specialists) in the

targeted limekiln clusters. The training programmes intend to:

a) Augment the knowledge and experience of certified energy auditors/energy

managers/, energy efficiency experts, private consultants, and energy practitioners

pertaining to the specific needs of MSMEs;

b) Information dissemination of the latest technologies available and best practices for

improving energy efficiency in limekiln cluster units

c) Facilitate energy experts in preparing bankable Detailed Project Reports (DPRs),

and assist MSMEs in accessing commercial finance for energy efficiency

investments in their respective units.

1.5 Energy Conservation Act 2001 & its Amendments

i) The Energy Conservation Act, 2001 & its Features Policy Framework – Energy Conservation Act – 2001

With the background of high energy saving potential and its benefits, bridging the gap

between demand and supply, reducing environmental emissions through energy saving,

and to effectively overcome the barrier, the Government of India enacted the Energy

Conservation Act, 2001. The Act provides the much-needed legal framework and

institutional arrangement for embarking on an energy efficiency drive.

Under the provisions of the Act, Bureau of Energy Efficiency established with effect from

1st March 2002 by merging erstwhile Energy Management Centre of Ministry of Power.

The Bureau would be responsible for implementation of policy programmes and

coordination of implementation of energy conservation activities.

ii) Important Features of Energy Conservation Act are:

Standards and Labeling

Standards and Labeling (S & L) identified as a key activity for energy efficiency

improvement. The S & L program, when in place would ensure that only energy efficient

equipment and appliance would be made available to the consumers.

The main provision of EC act on Standards and Labeling are:

� Evolve minimum energy consumption and performance standards for notified

equipment and appliances.

5

� Prohibit manufacture, sale and import of such equipment, which does not

conform to the standards.

� Introduce a mandatory labeling scheme for notified equipment appliances to

enable consumers to make informed choices

� Disseminate information on the benefits to consumers

Designated Consumers

The main provisions of the EC Act on designated consumers are:

� The government would notify energy intensive industries and other

establishments as designated consumers;

� Schedule to the Act provides list of designated consumers which covered

basically energy intensive industries, Railways, Port Trust, Transport Sector,

Power Stations, Transmission & Distribution Companies and Commercial

buildings or establishments;

� The designated consumer to get an energy audit conducted by an accredited

energy auditor;

� Energy managers with prescribed qualification are required to be appointed or

designated by the designated consumers;

� Designated consumers would comply with norms and standards of energy

consumption as prescribed by the central government.

Certification of Energy Managers and Accreditation of Energy Auditing Firms

The main activities in this regard as envisaged in the Act are:

A cadre of professionally qualified energy managers and auditors with expertise in policy

analysis, project management, financing and implementation of energy efficiency

projects would be developed through Certification and Accreditation programme. BEE

needs to design training modules and conduct a National level examination for

certification of energy managers and energy auditors.

Energy Conservation Building Codes:

The main provisions of the EC Act on Energy Conservation Building Codes are:

� The BEE would prepare guidelines for Energy Conservation Building Codes

(ECBC);

� These would be notified to suit local climate conditions or other compelling

factors by the respective states for commercial buildings erected after the rules

6

relating to energy conservation building codes have been notified. In addition,

these buildings should have a connected load of 500 kW or contract demand of

600 kVA and above and are intended to be used for commercial purposes;

� Energy audit of specific designated commercial building consumers would also

be prescribed.

Central Energy Conservation Fund:

The EC Act provisions in this case are:

� The fund would be set up at the centre to develop the delivery mechanism for

large-scale adoption of energy efficiency services such as performance

contracting and promotion of energy service companies. The fund is expected to

give a thrust to R & D and demonstration in order to boost market penetration of

� Efficient equipment and appliances. It would support the creation of facilities for

testing and development and to promote consumer awareness.

Bureau of Energy Efficiency (BEE):

� The mission of Bureau of Energy Efficiency is to institutionalize energy efficiency

services, enable delivery mechanisms in the country and provide leadership to

energy efficiency in all sectors of economy. The primary objective would be to

reduce energy intensity in the Indian Economy.

� The general superintendence, directions and management of the affairs of the

Bureau is vested in the Governing Council with 26 members. The Council is

headed by Union Minister of Power and consists of members represented by

Secretaries of various line Ministries, the CEOs of technical agencies under the

Ministries, members representing equipment and appliance manufacturers,

industry, architects, consumers and five power regions representing the states.

The Director General of the Bureau shall be the ex-officio member-secretary of

the Council.

� The BEE will be initially supported by the Central Government by way of grants

through budget, it will, however, in a period of 5-7 years become self-sufficient. It

would be authorized to collect appropriate fee in discharge of its functions

assigned to it. The BEE will also use the Central Energy Conservation Fund and

other funds raised from various sources for innovative financing of energy

efficiency projects in order to promote energy efficient investment.

Role of Bureau of Energy Efficiency

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The role of BEE would be to prepare standards and labels of appliances and equipment,

develop a list of designated consumers, specify certification and accreditation procedure,

prepare building codes, maintain Central EC fund and undertake promotional activities in

co-ordination with center and state level agencies. The role would include development

of Energy service companies (ESCOs), transforming the market for energy efficiency

and create awareness through measures including clearing house.

Role of Central and State Governments:

The following role of Central and State Government is envisaged in the Act

� Central - to notify rules and regulations under various provisions of the Act, provide

initial financial assistance to BEE and EC fund, Coordinate with various State

Governments for notification, enforcement, penalties and adjudication.

� State - to amend energy conservation building codes to suit the regional and local

climatic condition, to designate state level agency to coordinate, regulate and

enforce provisions of the Act and constitute a State Energy Conservation Fund for

promotion of energy efficiency.

Enforcement through Self-Regulation:

E.C. Act would require inspection of only two items. The following procedure of self-

regulation is proposed to be adopted for verifying areas that require inspection of only

two items that require inspection.

� The certification of energy consumption norms and standards of production

process by the Accredited Energy Auditors is a way to enforce effective energy

efficiency in Designated Consumers.

� For energy performance and standards, manufacturer’s declared values would

be checked in Accredited Laboratories by drawing sample from market. Any

manufacturer or consumer or consumer association can challenge the values of

the other manufacturer and bring to the notice of BEE. BEE can recognize for

challenge testing in disputed cases as a measure for self-regulation.

Penalties and Adjudication:

� Penalty for each offence under the Act would be in monetary terms i.e.

Rs.10,000 for each offence and Rs.1,000 for each day for continued non

Compliance.

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� The initial phase of 5 years would be promotional and creating infrastructure for

implementation of Act. No penalties would be effective during this phase.

� The power to adjudicate has been vested with state Electricity Regulatory

Commission which shall appoint any one of its member to be an adjudicating

officer for holding an enquiry in connection with the penalty imposed.

iii) The Energy Conservation (Amendment) Bill was introduced in the Lok Sabha on March 8, 2010. It amends the Energy Conservation Act, 2001

� The Energy Conservation Act empowers the government to specify norms and

standards of energy efficiency to be followed by different industries (who are

specified in a schedule to the Act) in their use of power. Norms and standards of

energy efficiency and conservation are also to be set for appliances and

equipment, and the construction of buildings. The Act empowers state

governments to enforce its various provisions.

� The Act also establishes the Bureau of Energy Efficiency under the central

government to specify qualifications and certification procedures for energy

auditors and managers who shall audit the use of energy by industries.

� The Bill expands the scope of energy conservation norms for buildings and

tightens the applicability of energy efficiency norms for appliances and

equipment. It provides a framework within which savings on energy use can be

traded between those industries who are energy efficient and those whose

consumption of energy is more than the maximum set by the government. The

Bill increases penalties for offences and provides for appeals to be heard by the

Electricity Appellate Tribunal set up under the Electricity Act, 2003.

� Under the Act, the government could specify energy conservation building codes

for commercial buildings with a connected load of more than 500 kW or contract

demand of 600 kVA. The Bill broadens the range of commercial buildings to

which such building codes apply to those with a connected load of more than 100

kW, or contracted demand of more than 120 kVA.

� Under the Bill, the central government can issue energy savings certificates to

those industries whose energy consumption is less than the maximum allowed.

Such certificates can be sold to other consumers whose consumption is more

than the maximum allowable.

� The Act empowers the government to specify energy consumption norms for

equipment or appliances. The government can also prohibit the manufacture,

9

sale, purchase or import of notified equipment unless they conform to such

norms. However, this prohibition can only be issued two years after the norms

have been specified. The Bill reduces this time frame to six months, extendable

by a further six months.

� The Bill increases the penalty specified for offences committed under the Act.

Each offence shall attract a penalty of Rs 10 lakh (Rs 10,000 earlier), with an

additional penalty of Rs 10,000 for each day that the offence remains (Rs 1000

earlier). The additional penalty, for those industries who consume energy in

excess of norms, will be the value of the excess energy consumed.

� The Act provided for the setting up of an Appellate Tribunal for Energy

Conservation, which would hear appeals against orders of the central or state

government. The Bill does away with this provision and provides for appeals

against such orders to be heard by the appellate tribunal established under the

Electricity Act, 2003.

� The Bill increases the term of office of the Director General of the Bureau of

Energy Efficiency from three to five years. It provides for the Bureau, rather than

the Central Government, to appoint its officers and staff.

1.6 Lime Industry Association

Tirunelveli limekiln cluster

The Tirunelveli Lime Manufacturers’ Welfare Association is the local association

representing the limekiln units and has been working actively for the development of

limekiln units located at Rasta, Rajapalayam, and Shankar Nagar in Tirunelveli.

Presently, the association has 42 members/units registered with the association and the

list is enclosed as Annexure 1. The present office bearers of the association are:

• Mr. Arasu Mariappan- President

• Mr. Gomathi Nayagam- Treasurer

• Mr. Mohammed Hanifa Secretary

Jodhpur limekiln cluster

The Rajasthan Lime Manufacturers Association is representing the limekiln units located

in three districts namely, Pali, Nagore, and Jodhpur in Rajasthan. Presently, the

association has 102 members/units registered with the association and the list is

enclosed as Annexure 2. Presently, Mr. Asharam Dhoot is the President of Rajasthan

Lime Manufacturers Association, Jodhpur.

11

Chapter 2

TTeecchhnnoollooggyy SSttaattuuss aanndd EEnneerrggyy CCoonnssuummppttiioonn PPaatttteerrnn

2.1 Overview of Targeted Clusters

2.1.1 Targeted Limekiln Cluster


Small-scale limekilns in Tirunelveli district in Tamil Nadu are primarily concentrated in

Sankarnagar, Rasta, Rajapalayam, and Sankaran Koil. There are about 94 units

engaged in lime burning and each unit has two to eight kilns. Nearly 50% of the units are

registered with the local industry association, namely Tirunelveli Lime Manufacturers’

Welfare Association. Almost all the units of the cluster are operational and produce

hydrated lime from two different types of raw material, viz. dolomite and calcite

limestone. The total actual production of the cluster is estimated to be 520 tons of

hydrated lime per day.


There are 250 limekiln units in the cluster and these

units are having total of 400 limekilns engaged in

lime (hydrated & quick lime) production spread

across three districts of Rajasthan namely Jodhpur,

Nagaur and Pali. These limekiln units are located at

Sojath in Pali district, Borunda, Pipad city, Ran

sigaon & Khejedla in Jodhpur district and Gotan,

Medta, Manakpur & Khimsar in Nagaur District. The

mines which are supplying limestone to these

units are located close by in a radius of 10 kms

from the cluster. Most of the units, material handling is non-mechanized in nature and

operating in single shift. Firewood & Pet coke are the main fuels used in the cluster.

2.1.2 Products Manufactured


Two grades of lime are produced, namely (i) Cem Grade (II) Chemical Grade in the

cluster. Cem grade lime meant for white washing applications and chemical grade lime

for industrial applications in sugar, pulp & paper, textiles and chemical industries. For

Cem grade lime, dolomite limestone is used whereas for chemical grade lime which

needs high CaO content, the limestone containing high CaCO3 (calcite) is used. The

Cem grade lime produced is sold entirely in the domestic market for white washing of

Figure 2.1: Vertical shaft kiln at Jodhpur

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Figure 2.2: Classification of units based on production capacity

4, 13%

18, 56%

10, 31%

Upto 5 tonnes/day

5 to 15 tonnes/day

>15 tonnes/day

buildings/ houses and chemical grade lime is supplied to paper mills, textiles, and

chemical industries. The cluster produces approximately 520 tons per day of hydrated

lime.


Natural draft based vertical shaft kiln of capacities various from 12-15 tons of quick lime

output per day used in the cluster. Thus produced quicklime is slaked with water

resulting hydrated lime depending upon market. The quicklime is highly reactive product

which is essential to many industrial applications.

2.1.3 Classification of units


The cluster units can be broadly classified based on production capacity, no. of kilns per

unit, and energy consumption as described below:

CLASSIFICATION BASED ON PRODUCTION

The production capacity of each unit is in the range of 2 to 40 tons per day and the

categorization based on production capacity is as follows:

� Above 15 tons/ day

� 5- 15 tons/ day

� Up to 5 tons/ day

Out of 32 units for which data is available, 10 units (31%) are large, 18 units (56%) are

medium, and the remaining four (13%) are small units. The classification of the units

based on installed capacity is furnished in Figure 2.2.

CLASSIFICATION BASED ON NO. OF KILNS INSTALLED

The number of kilns installed in a unit is in the range of 2 to 8 and the categorization of

the cluster units based on number of kilns is as follows:

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Figure 2.3: Classification of units based on no. of kilns installed per unit

5, 16%

22, 68%

5, 16%

Upto 2 kilns

2 - 5 kilns

>5 Kilns

i) Above 5 kilns per unit

ii) Above 2 up to 5 kilns per unit

iii) Upto 2 kilns per unit

As can be seen from Figure 2.3, out of 32 units, 5 units (16%) have more than five kilns

per unit, 22 units (68%) are having more than 2 upto 5 kilns per unit, and the remaining 5

units (16%) have upto 2 kilns per unit.


There are 250 units in the cluster engaged in production quicklime and hydrated lime.

Among 250 units, 150 units manufactures only quicklime and out of the balance 100

units, 50 units producing only hydrated lime and the rest of the units are producing both

quicklime & hydrated lime. These units are broadly classified with respect to production

capacity of quicklime.

1) Large Scale Units

2) Medium Scale Units

3) Small Scale Units

Large Scale Units

Units which are having annual quicklime production above 15000 tonnes can be

categorized as large scale units. These units are having more than 10 kilns, each of

more than 15 TPD and around 10 of such large capacity in the cluster.

Medium Scale Units

Units with a capacity range of 3000-15000 Metric Tonnes/annum can be categorized as

medium scale units. These units are having no. of kilns in the range of 5-6 and around

35 units fall under this category.

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Small Scale Units

These are units with capacity less than 5000 Metric Tonnes per annum and having less

than 5 no. of kilns. There are 200 limekiln units in the cluster fall under this category

2.1.4 Raw Material used

Limestone deposits are found in all states, only a small portion is pure enough for

industrial lime manufacturing and is used in many industries such as cement, steel,

paper, chemical, constructions, and etc., To be classified as limestone, the rock must

contain at least 50 percent Calcium Carbonate. When the rock contains 30 to 45 percent

magnesium carbonate, it is referred to as dolomite, or dolomite limestone.

Limestone is abundantly available in and around the districts of Tirunelveli and Jodhpur.

The typical composition of limestone available in Tirunelveli limekiln cluster is 50-55%

CaCO3, 20-25% MgCO3, 8% SiO3, 2% FeO, and O.5% Al2O3 and lime produced by

dolomite limestone is mainly used for production of white cem, which is sold in domestic

market. The landed cost of dolomite and calcite limestone on-site is in the range of

Rs.500- 600 per ton

The typical composition of limestone available in Jodhpur limekiln cluster is 90-95%

CaCO3, 1-4.5% MgCO3, 1% SiO3, 0.2% FeO, and 0.1% Al2O3. The landed cost of lime

stone is in the range of Rs 450-550 per ton

2.2 Energy Consumption Scenario

2.2.1 Fuel Used and price

Tirunelveli Cluster

In Tirunelveli cluster units, charcoal and electricity are used as fuel for calcination of

limestone. Charcoal is mixed with limestone in required proportion and varies with

quality of limestone and calorific value of the charcoal. The charcoal price varies from

Rs.11,000 to Rs.16,000 per ton.

Jodhpur Cluster

Pet coke is used as fuel for calcination of limestone in cluster units. The quantity of pet

coke used for calcinations of limestone varies with quality of limestone, calorific value of

the coke. The pet coke price is varied in the range of Rs.8,000 - 9,000 per ton

2.2.2 Energy consumption

The process of manufacturing hydrated lime from limestone is energy intensive and

requires thermal and electrical energy. Thermal energy accounts for major share of total

energy consumption.

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Tirunelveli Cluster

These cluster units consumes approximately 200 kg of charcoal per ton of burnt lime in

the cluster is required. The charcoal consumption for typical unit of production of

capacity of 10 TPD is 2 tons per day in the cluster.

Electrical energy is used for driving prime movers of such as blowers, crushers,

pulverizers, and mechanical handling system. The specific electricity consumption is

varies from 50 – 55 kWh / ton of hydrated lime. A typical unit in the cluster having 3 No.

of kilns and capacity of 10 TPD has connected load of 75 HP.

Jodhpur Cluster

Pet coke is the fuel used in the cluster and the alternative layer of limestone and pet

coke are laid in the kiln for burning of limestone. The average pet coke consumption per

day is 15 tons for the production capacity of 100 TPD.

Few units in the cluster are involving in hydration of quicklime where in electricity is used

as fuel. The typical unit having hydration facility has contract demand of 150 KVA to

meet hydration load.

2.2.3 Specific Energy Consumption

Tirunelveli Limekiln Cluster

The specific fuel and electricity consumption for the cluster is 200kg charcoal /ton of

quicklime and 50 – 55 kWh / ton of hydrated lime respectively.


The specific fuel and electricity consumption for the cluster is 170-180 kg/ ton of quick

lime and 14-15 kWh/ton of hydrated lime respectively. Fuel & electricity consumption for

a typical unit of production capacity 20 TPD is shown below:

Table 2.1 Petcoke Consumption for typical unit

Type of kiln Vertical Shaft Kiln

Type of fuel used Petcoke , and wood

Running hours /day 24

Production capacity

(tn/day)

20 tonne of quicklime

Fuel Consumption 3.2 - 3.5 tonne of pet coke

Specific Energy

Consumption per tonne of

quicklime

170-180 kg of pet coke

16

Table 2.2 Electricity consumption for crushing & hydration for typical unit

Type of kiln Vertical Shaft Kiln

Type of fuel used Petcoke and wood

Running hours /day 24

Production capacity

(tn/day)

20 tonne of quicklime output

Electricity Consumption 280-300 kWh/day

Specific energy

consumption per tonne of

hydrated lime

14-15 kWh of electricity

2.2.4 Energy Cost

The energy cost for production of quicklime is approximately Rs.2000 per ton and

Rs.1600 per ton at Tirunelveli and Jodhpur limekiln cluster respectively. Similarly,

percentage of energy cost in quick lime production cost is 58% and 49% at Tirunelveli

and Jodhpur limekiln cluster respectively. From the above, it is clearly understood that

units located in Tirunelveli are inefficient and energy cost is more than Jodhpur cluster

units. The composition of the limestone available in the Tirunelveli is also affecting the

fule consumption. The break-up for production cost for the two clusters is provided in

Table 2.3 and 2.4 below:

Table 2.3: Cost of production of lime at Tirunelveli

Item Cost, Rs./ ton

Production Cost 3;900

Charcoal 2,000

Electricity 300

% energy cost of total production cost

58%

Table 2.4: Cost of production of quicklime at Jodhpur

Item Cost, Rs./

ton

Production cost 3500

Fuel cost 1600

Electricity 100

% energy cost of total production cost

49%

17

Figure2.5: Limestone lumps

2.3 Manufacturing Process

Tirunelveli Cluster

The hydrated lime production process followed by the

cluster units is similar and detail process description is

provided below and process flow chart in figure 2.7:

� Limestone size varies from 4 to 12 inches. It is

crushed to the required size of two to four inches

in crushers. After crushing, the powder is

separated from the lumps. The

limestone is mixed with charcoal in

required proportions and fed to the kiln. Figure 2.5 shows quicklime discharged

from the kiln. The limestone to charcoal ratios varies from kiln to kiln in the range

of 4:1 to 6:1 depending on the quality of limestone, capacity of the kiln, and

operational practices followed. Figure 2.6 shows the limestone charcoal bed

preparation.

� The process takes about 16 hours and the quicklime (burnt lime) is discharged

from the kiln after cooling of the product through blower or natural cooling

� The product (quicklime) discharged from the kiln is allowed to cool to ambient

temperature and segregated into quicklime (lumps). The under burnt lime is

recycled.

Figure 2.4: Limestone crusher & screening

Figure2.6: Limestone charcoal bed preparation

18

� All the kiln operations including sizing of limestone, charging of feed, removal of

product from the kiln, grading, and packing is done manually.

Figure 2.7 Process flow chart for Tirunelveli Limekiln cluster

Jodhpur Cluster

Natural draft based vertical shaft kilns are used in

the cluster for calcinations of limestone

(quicklime). Lime stone from mines received at 6-

12 inches which is crushed into required size 3-4

inches before feeding into kiln. These kilns are

continuous type kiln where raw material is fed

from top side and finished product (quick lime) is

drawn out from the bottom after 72 hours of

limestone fed to kiln. The kiln has three zone

namely, preheating zone, combustion zone,

cooling zone of kiln where different temperatures are maintained. About 950-1000

degree temperature is maintained in combustion zone for calcinations of limestone.

Quicklime discharged from the bottom of the kiln is allowed to cool ambient temperature

and material movement in the kiln is by gravity.

Few units in the cluster are manufacturing hydrated lime where quicklime is reacted

(slaked) with water to form hydrated lime. The basic processes in the production of lime

are;

Figure 2.8: Vertical shaft kiln at Jodhpur

19

(1) Quarrying raw limestone, (2) crushing & sizing of lime stone (3) Calcination of

limestone in the kiln (4) Processing the lime further by hydrating and pulvarising (5)

Storage and Packing

Figure 2.9 :- Hydrated Lime Production Process

2.4 Major Barriers for Implementation of Energy Efficiency Measures

Tirunelveli Cluster

Technological Barrier

• Lack of awareness and information among cluster owners on the losses, EE

technologies and energy efficiency. A few demonstration projects may motivate

MSME owners to take up the EE projects

• Though local service providers are available in the cluster, the LSP’s don’t have

technical strengths for supply of EE equipments

Financial Barrier

• There is lack of cost effective energy efficient technology in Kiln.

• The units in the cluster are not having good financial strength to implement the

various energy efficiency measures available in the market.

• Lack of interest of investing on the new technologies, as these industries getting

profits with the existing technologies

20

• There is need to develop attractive financing mechanism in order to create

interest among industry for technology adoption.

Manpower

Majority of the operators and helpers deployed in the cluster units are non technical and

illiterates and their knowledge is based on the past experience. They do not have

technical skills and knowledge on energy conservation. This is one of the important

factors for inefficiency of the process and energy losses.

Jodhpur Cluster

Financial Barrier

• There is lack of cost effective energy efficient technology in Kiln.

• Lack of interest of investing on the new technologies, as these industries getting

profits with the existing technologies

• There is need to develop attractive financing mechanism in order to create

interest among industry for technology adoption.

Manpower

Most of the operators and helpers deployed in the cluster units are non technical and

illiterates and their knowledge is based on the past experience. They do not have

technical skills and knowledge on energy conservation which results in inefficiency in the

process and also energy losses.

21

CChhaapptteerr 33

EEnneerrggyy AAuuddiitt aanndd TTeecchhnnoollooggyy AAsssseessssmmeenntt SSttuuddyy

3.1 Technology Assessment Study

3.1.1 Technology Employed in the Targeted Cluster


The lime burning technology used in the cluster is that of a conical kiln ending with a

steam less funnel type section and designed to handle mixed feed. Typically these kilns

have an open top and the kilns are constructed with local materials (brick and mortar, in

some cases lined with fire bricks). Various equipments employed in this process are

given below:

1) Jaw Crusher

2) Kiln

3) Air Blower

4) Pulvariser

Jaw Crusher

A jaw crusher is installed in raw material storage area and is used for material size

reduction. Jaw crushers are used as primary crushers, or the first step in the process of

reducing lime stone to required size. They crush primarily by using compression. The

limestone as received from mines is dropped between two rigid pieces of metal, one of

which then moves inwards towards the limestone, and the limestone is crushed because

it has a lower breaking point than the opposing metal piece. Jaw crushercan crush large-

sized limestone, and the range of size that can be handled by the crusher is 9-12”. The

crushers are operated intermittently depending on the kiln charging plan.

Kiln

These country kilns are cylindrical and vary in size and dimensions for 2 TPD kiln are as

follows: height above surface is 8-9m, & diameter: 2.5 to 3 meters. Near the bottom on

the conical section, there is a single inlet for air supply. A blower (2-3HP Motor) supplies

air from bottom of the kiln to enable calcination. The kiln is constructed with low cost

local materials like clay bricks, boulders etc. and with mud as mortar. Limestone (12 to

19 mm size) and fuel are mixed manually and fed in to the kiln and firing is started. The

cycle time for a single batch is 12-14 hours. Quick lime powder is removed from outlet at

the bottom of the kiln.

22

Prior to charge, raw material received is crushed in a jaw crusher (50 HP Motor). The

range of stone size that can be handled by the crusher is 9”-12”. Slaked lime is

pulverized and then packaged. Pulverization process helps in removing rejected and

unburnt material (typically 20-25%).

Air Blower

A blower installed in the kiln and is used for supplying the combustion air. Centrifugal

fans or blowers normally mounted in a fan or blower housing. The air enters the housing

inlet, is turned 90 degrees and is exhausted out of the housing discharge. Each kiln has

a blower operating approximately 12-14 hours per day.

Pulvariser

It is installed in the packaging area and is used for pulverizing the slaked lime to 300 to

325 mesh size. The Pulveriser operates by impact action and will pulverize most dry,

free-flowing materials. Material fed into the hammer mill from the top falls into the

grinding chamber. The material is contacted by a series of hardened steel hammers

rotating at high speed. The material is ground by repeated contact with these hammers,

contact with the walls of the grinding chamber, and particle to particle contact. The

material remains in the hammer mill grinding chamber until particles become small

enough to escape by passing through the perforated screen that covers the bottom half

of the grinding chamber. Interchangeable hammer mill screens are available with hole

diameters from 1/64" to 2", to allow for fine or coarse grinding of most products. Size

reduction is caused by impact between the rotating hammers, particles and deflector

liner mounted in the mill housing cover. The desired fineness can be influenced by the

type of hammer, rotor speed and the size of the screen opening.

Jodhpur Limekiln Cluster

The limestone received from mines sized into required size and transferred to loading

section. The sized limestone fed into kiln through conveyor/ manually to kiln which as

three zones namely, preheating zone, combustion zone and cooling zone. Alternative

layer limestone and pet coke is laid in the kiln for burning of limestone and material

movement in the kiln is by gravity. The output material from kiln goes to the hammer mill

& lime is crushed in to small pieces. These fine lime particles are further divided by

classifiers according to that different grade of lime. Finally lime is packed in bags of

20/40/60 kgs and sold/ supplied to different places across the world. Various equipments

employed in this process are given below:

1) Kiln

2) Manual Hammer

23

4) Hydration unit

4) Pulvariser

5) Classifier

3.2 Methodology Adopted

3.2.1 Preliminary Energy Audit and Its Findings

The following methodology adopted for preliminary energy audit study:

• Collection of past energy consumption details and energy bill

• Establish specific energy consumption

• List out major energy consuming areas of the plant

• Level of technologies adopted and equipments used

• Status of instruments installed in the plant and necessary instrumentation required for the detailed study

• Understanding in detail the manufacturing process with energy and material balance

• Identify areas for detailed study for implementing energy efficiency measures

ZESPL has adopted above methodology and conducted preliminary energy audit studies

in the selected 10 units each in targeted clusters for data collection, measurement,

monitoring and discussions with unit owners. The details of the units visited provided in

Annexure 7. The following observations were made pertaining to energy saving

measures:


� Batch kilns employed in the unit are outdated and highly in-efficient characterized

by high fuel consumption.

� The kilns have no fire brick or refractory lining and the kilns are provided with

only clay brick resulting in high radiation and convective losses. The surface

temperature during field study found that 120-130 deg C during combustion time

and 60 deg C during cooling time.

� Combustion air supplied to kiln was not uniformly distributed to entire kiln which

results under burnt/over burnt of quicklime

� The cost of energy for lime production is high and accounts for major share (over

60%) of cost of production. This is attributed again to outdated kiln technology

and high cost of fuel.

24

� Power factor measured in the cluster units is in the range of 0.90 to 0.94 and it

could be improved almost unity to get rebate by installing capacitor bank along

with APFC.

� The power supply is unreliable and erratic in the region. The cluster faces 4 to 8

hours of load shedding on daily basis which results poor quality of quicklime.


� There is no major EE interventions were undertaken in the cluster in kiln

retrofitting/ redesign since 1990.

� Power Factor measurements carried out the in the cluster shows that there is

potential to improve PF to almost unity from exiting 0.93 level.

� 45% alumina bricks were used as insulation throughout the kiln. Zenith Energy

suggests providing 60% alumina insulation at combustion zone and 45% alumina

at rest of the zones.

� Old and inefficient motors were used in cluster which lead to increase in power

consumption, which can be reduced by installing energy efficient motors

3.2.2 Detailed Energy Audit

The following methodology has been adopted for conducting detailed energy audit in the

targeted clusters:

• Monitoring of energy related parameters of various equipment/ machines using

portable instruments

• Collection of operating data from various measuring instruments

• Collection of past operating/ historical data from log books and data registers

• Compilation of design data / name plate details of various equipment from design

manuals and brochures

• Discussions with concerned plant personnel to take note of operating practices

and shop-floor practices being followed in the plant and to identify specific

problem areas and bottlenecks if any with respect to energy consumption

• Critically analyzed the data collected / monitored during the site visit

• Information gathering pertaining to lime burning technology and equipments

installed

• Identification of energy wastage areas and quantification of energy losses

• Identification of suitable measures for reducing energy wastages and areas for

reuse and recycle

25

3.2.3 Observation Made During Detailed Energy Audit

Energy audit team made many observations during visit to the units in the areas of Kiln,

material handling process, technology or equipment employed, energy availability, utility

energy consumption in both the clusters which are listed below:

1. Energy Consumption profile


The majority units of the cluster use electricity and charcoal fuel for burning of limestone.

The charcoal consumption in cluster units varies from 190-200 kg per tone of quicklime

depending on production capacity and quality of limestone.

The specific electricity consumption of three typical units visited is furnished in the below

table 3.1:

Table 3.1 specific electricity consumption of three typical units visited at Jodhpur cluster

Details Value Unit -1 Unit -2 Unit -3

Char Coal tons 400 570 750

Electricity kWh 120 165 275

Final production per day tons 2 3 5

Specific Electricity consumption kWh/tn of

product

60 55 55

Specific charcoal consumption Kg/tn of

product

200 190 190


Energy consumption profile varies from starting to end of process. Highest energy

consuming equipments are kiln followed by Hammer mill, Pulverisor, Classifier &

hydrator. Pet coke as fuel is used in kiln.

There are four types of technologies found in Jodhpur limekiln cluster which is presented

below along with sources of energy, pet coke consumption and specific energy

consumption:

2. Capacity Utilization

Most of the units operate through out in a day and 250-300 days per annum depending

on market requirement of lime in the targeted clusters. The pet coke consumption is

almost uniform through out the production where as the load on the motors vary with

plant production. Most of units, pulvariser are operated about 60% to the rated capacity.

26

3. House Keeping Practices

There are no specific procedures followed in any of the units in both the clusters for the

operation and maintenance of the various equipments/utilities. The workers don’t have

the knowledge on energy conservation and efficiency. There is no monitoring of

consumption of fuels or electricity on daily basis in any of the units surveyed. Some of

the observation made with respective to house-keeping practices in limekiln units is

presented below:


• Not maintain uniform air distribution through out the kiln results in over and under

burnt quicklime

• Temperature indicators are not installed in the cluster units

• Charging and discharging time not monitored

• Idle running of equipments also observed in the cluster units


• Uniform distribution of limestone and pet coke not maintained during charging

into the kiln results over and under burnt quick lime.

• Charging and discharging time in not monitored in the cluster units

• No storage yard for peat coke results unwanted carpet losses.

• Temperature indicators are not installed in the cluster units

3.3 Energy Efficiency Measures Recommended for Tirunelveli Sector

3.3.1 New Energy efficient vertical shaft limekilns

The existing inefficient limekilns can be replaced by

energy efficient limekilns, which are successfully

working with low specific energy consumption in other

countries.. There are two types of efficient kiln types,

the details of which are provided below:

• Single shaft counter flow heating kiln; and

• Multiple shaft parallel flow heating kiln.

The standard PFR-Kiln is a two-shaft kiln (see Figure

below defined by alternating burning and non-burning

shaft operation. There are two distinguishing features

of the PFR-Kiln:

27

• The parallel flow of hot gases and stone in the burning zone, and

• The regenerative preheating of combustion air in the process.

The PFR type of kiln is ideally suited to produce soft burned, high reactive lime and

dolomite lime because of two reasons:

• The conditions created by the parallel flow of the stone and the combustion

gases in the burning shaft.

• Additionally, the regenerative process provides the lowest heat consumption of

all modern kilns available today.

• As the amount of cooling air is not sufficient for complete combustion of the fuel

additional air has to be introduced via lateral burners. As in this type of kiln, the

fuel is introduced at the lower end of the burning zone - where the material is

already calcined - the temperature in this area is significantly higher than

required for the production of high reactive lime. In parallel flow kilns the fuel is

introduced at the upper end of the burning zone and the combustion gases travel

parallel to the material. As the fuel is injected at the upper end of the burning

zone where the material can absorb most of the heat released by the fuel, the

temperature in the burning zone is typically as low as 950º C (on average).

Because of this, parallel flow heating is the best solution for the production of soft

burned, reactive lime and dolomitic lime as required in most applications.

• The second important characteristic of the PFR-Kiln is the regenerative

preheating of the combustion air. In kilns with counter flow heating, the

combustion air is preheated in the cooling zone by the sensible heat contained in

the calcined lime. The amount of preheating is limited by enthalpy of the lime. In

the counter flow heating process there is a surplus of usable sensible heat

contained in the exhaust gas that is not recovered prior to being exhausted. As a

consequence some single shaft kiln designs have incorporated recuperators in

an effort to recover this waste heat, but such heat exchangers are susceptible to

operating problems caused by dust contained in the hot exhaust gases.

• In the twin shaft parallel flow regenerative kiln the combustion air is preheated in

an optimal way. The regenerative process requires two connected kiln shafts.

Each shaft is subject to two distinct modes of operation, burning and non-

burning. One shaft operates in the burning mode and simultaneously the second

shaft operates in the non-burning or exhaust mode. Each shaft spends an equal

amount of time in both the burning and non-burning modes of operation. In the

burning mode a shaft is characterized by the parallel flow of combustion gases

and raw stone whereas in non-burning mode a shaft is characterized by the

28

counter-current flow of exhaust gases and raw stone. The combustion gases exit

the burning shaft through a crossover channel into the non-burning shaft. The

alternating burning / non-burning shaft sequence serves as a regenerative

preheating process. Heat is transferred to the raw stone from the exhaust gases

during the non-burning mode and then reclaimed by the combustion air from the

raw stone during the burning mode. The preheating zone acts as a regenerator

with the stone charge as checkers. This kind of regenerator is completely

insensitive to dust-laden or corroding gases and, at the same time, shows

excellent heat transfer characteristics.

• The regenerative preheating of the combustion air makes the thermal efficiency

of the kiln practically independent from the excess combustion air factor. This

considerably simplifies the setting of the correct flame length required to achieve

the desired degree of lime reactivity. A large quantity of excess air produces a

shorter flame and less excess air produces a longer flame. The length of the

flame is one of the key factors to control the reactivity of burned lime. Generally

shorter and hotter flames reduce the reactivity of the burned product.

• The excellent thermal design of the PFR-Kiln can be satisfactorily proven by

means of the heat balance. The sum of effective heat, i.e. the heat required for

dissociation, and of the various heat losses provides the thermal requirement of

the kiln.

The heat losses consist of:

• The loss through the kiln walls equal to approx. 170 kJ 40 kca1)/kg of lime.

• The sensible heat of the discharged burned lime equal to approx. 80 kJ (20

kcal)/kg of lime at a discharge temperature of 100 'C, and

• The sensible heat contained in the exhaust gases equal to approx. 290 kJ (70

kca1)/kg of lime at a discharge temperature of 100 'c.

• Considering the above figures for heat losses of the kiln and when producing

lime with 96% CaO the total thermal requirement is approx. 3520 kJ (840

kca1)/kg or 3.02 mi11ion Btu per ton of burned lime.

The conventional and radiation loss in conventional kiln are high compared to the above

energy efficient kiln.

3.3.2 Retrofitting of the existing kilns

The guiding factor for energy efficiency and effective heat recovery in conventional kiln is

the diameter to height ratio. The higher the ratio better is the thermal efficiency.

However, the existing kilns in the unit have ratio in the range of 1:1 to 1:4, which is small

29

and leads to large quantity of heat losses and poor thermal efficiency. It is recommended

to modify the existing kilns in such a way that the shaft height is at least six times the

diameter, and preferably nearer nine times for greatest efficiency. Ensuring optimum

height to diameter ratio ensures reduction in fuel consumption by at least 20 to 25%.

3.3.3 Provide refractory and insulation for reducing surface radiation loss

The choice of refractory and insulating material is important as heat loss from the walls

of a kiln has to be kept to a minimum for energy efficient and economic operation. The

refractory bricks are not used in the cluster kilns to contain the thermal energy with in

kiln. Most of the units were used only insulating bricks and also leaving an air gap

between the kiln's inner surface and the casing which reduce heat loss to some degree.

The possible insulation material are such as insulation bricks, rockwool (industrial or

mineral wool) and ceramic fiber which tends to be expensive, but is an excellent

insulator and easy to install.

3.3.4 Use biomass as supplementary/main fuel in limekilns

The high-cost of energy for lime production coupled with the availability of biomass fuels

could be the main drivers to try biomass as supplementary fuel along with coal. The

biomass utilization trials in limekilns had been unsuccessful due to a variety of technical

and operational problems like inadequate fuel preparation, improper mixing with

limestone, incomplete combustion, poor quality product, etc. The use of biomass

briquettes or biomass producer gas helps in reducing the energy costs of production by

20 to 25%. The cost of machinery for gasification or briquetting can be paid back in less

than 18 months time. Since the kiln sizes and production capacities vary widely across

the clusters, the sizing of the gasifiers or briquetting machines also vary widely.

However, the cost of the gasifier varies in the range of Rs.10,00,000 to Rs.15,00,000

depending on the requirements.

3.3.5 Better operating practices

All the kiln operations including sizing of limestone, charging of feed, withdrawal of

product, grading, and packing are manual in the unit. It recommended installing

mechanical material handling system for feed the raw material and discharge the

product and automatic hydration system

Monitoring of fuel consumption, process parameters, production, instrumentation for

various equipments are not practiced and these may be due to lack of awareness.

Hence, it recommends maintaining log book (1) temperature maintained in the kiln on

30

hourly basis (2) raw material, char coal, electricity consumption and production on daily

basis.

3.3.6 Instrumentation for process optimization

The cluster units have conventional kiln for burning of limestone and calcinations occurs

around 900ºC-1000ºC. The low efficiency of kiln is due to lack of instrumentation for

monitoring the kiln temperature. It is recommended to install thermocouples for kiln for

time to time temperature monitoring which results in fuel consumption optimization.

3.3.7 Better Housekeeping

By improving the operational practices in these units, efficiency will improve by around 2-

5%. Some of the suggested house-keeping practices in limekiln units are presented

below:

• Maintain uniform air distribution through out the kiln to minimize the over and

under burnt quicklime

• Maintaining proper combustion air pressure in the kiln

• Regulate combustion air blower opening proportion to load on the kiln

• Fuel storage should be done in accordance with the available guidelines for

storing that particular kind of fuel.

• Installation of digital temperature indicators in place of human monitoring reduces

the chances of overheating of limestone and subsequent energy& material loss

• Monitor charging time in Kiln

• Idle running of equipments should be avoided

3.4 Energy Efficiency Measures Recommended for Jodhpur Cluster

The Energy audit team found that the natural draft vertical shaft kiln technology used in

the cluster is energy efficient and it consumes 1200 kcal per tone of quicklime. The

following measures improves specific energy consumption of the unit further.

3.4.1 Use of better quality insulation

The choice of insulating material is important as heat loss from the walls of a kiln has to

be kept to a minimum for energy efficient and economic operation. Most good insulating

materials contain a high percentage of air. In fact, merely leaving an air gap between the

kiln's inner shaft and the casing will prevent heat loss to some degree. However, it is

better if the air is contained in a matrix of some solid material as this further reduces

losses. Obviously, you need to choose a material which will not catch fire at

temperatures which might approach 1000°C. The possibilities include insulation bricks,

rockwool (industrial or mineral wool) and ceramic fiber - which tends to be expensive,

31

but is an excellent insulator and easy to install. There are also alternatives such as rice

husk ash or other ashes. Insulation should always be placed in the cavity between the

inner shaft and the kiln casing or added to the outside of the kiln. This type of insulation

can be planned the kiln design.

3.4.2 Energy efficient motors

It was observed that the maximum of motors are re-winded more than 5 times which

leads to approx 2.5 times more power consumption and lower operating efficiency.

These motors must be replaced by the Energy Efficient Motors which leads to higher

working efficiency up to 4 % for the same working condition. Energy-efficient motors

(EEM) are the ones in which, design improvements are incorporated specifically to

increase operating efficiency over motors of standard design. Design improvements

focus on reducing intrinsic motor losses.

Improvements include the use of lower-loss silicon steel, a longer core (to increase

active material), thicker wires (to reduce resistance), thinner laminations, smaller air gap

between stator and rotor, copper instead of aluminum bars in the rotor, superior bearings

and a smaller fan, etc. Energy-efficient motors now available in India operate with

efficiencies that are typically 3 to 4 percentage points higher than standard motors. In

keeping with the stipulations of the BIS, energy-efficient motors are designed to operate

without loss in efficiency at loads between 75 % and 100 % of rated capacity. This may

result in major benefits in varying load applications. The power factor is about the same

or may be higher than for standard motors.

3.4.3 Installation of Automatic Power Factor Controller to maintain unity power

factor

An automatic power factor correction unit has to be used to improve power factor. A

power factor correction unit usually consists of a number of capacitors that are switched

by means of contactors. These contactors are controlled by a regulator that measures

power factor in an electrical network. To be able to measure power factor, the regulator

uses a current transformer to measure the current in one phase. Depending on the load

and power factor of the network, the power factor controller will switch the necessary

blocks of capacitors in steps to make sure the power factor stays above a selected

value.

Benefits

� Reduction in I2R losses

� Improved voltage regulation

32

� Decrease in kVA loading

� Reduction in energy kWh consumption

� Rebate on electricity bill

� Reduction in Maximum demand

� Longer life of electrical distribution components such as switch gears,

transformers, cables etc

3.4.4 Improve coke storage

Storage of pet coke includes oxidation, wind and

carpet loss. A 1% oxidation of coke has the same

effect as 1% ash in coke, wind losses may account

for nearly 0.5 – 1.0% of the total loss. The main goal

of good coke storage is to minimize carpet loss and

the loss due to spontaneous combustion. Formation

of a soft carpet, comprising of coke dust and soil

causes carpet loss. On the other hand, gradual

temperature builds up in a coke heap, on account of oxidation may lead to spontaneous

combustion of coke in storage. Action need to be taken for maintaining quality of fuel.

The measures that would help in reducing the carpet loses are as follows:

1. Preparing a hard ground for petcoke to be stacked upon.

2. Preparing standard storage bays out of concrete and brick. In process Industry,

modes of petcoke handling range from manual to conveyor systems. It would be

advisable to minimize the handling of coke so that further generation of fines and

segregation effects are reduced.


By improving the operational practices in these units, efficiency will improve by around 2-

5%. Some of the suggested house-keeping practices in limekiln units are presented

below:

• Uniform distribution of limestone and pet coke during charging into the kiln

results good quality of quick lime.

• Maintain uniform air distribution through out the kiln to minimize the over and

under burnt of quick lime

• Monitor charging time in Kiln

• Idle running of equipments should be avoided

33

• There is need to create sufficient space & process for storage of raw material,

coke. Also proper flouring & covering of the coal storage yard is required which

can reduce unwanted dust & carpet losses.

• Unwanted stone, other residues get mixed in pet coke, which consume the

additional heat during the combustion which results in non uniform heating of

lime stones & increased fuel consumption for same production

• Fuel storage should be done in accordance with the available guidelines for

storing that particular kind of fuel.

• Installation of digital temperature indicators in place of human monitoring reduces

the chances of overheating of limestone and subsequent energy& material loss

34

Chapter 4

CCrroossss CClluusstteerr LLeeaarrnniinngg aanndd TTeecchhnnoollooggiieess SSuuiittaabbllee FFoorr LLiimmee BBuurrnniinngg

4.1 Technology Adopted for Lime Burning

Lime produced primarily in traditionally evolved kilns over the years in India. As per the

Comprehensive Industry Document on Lime Kilns published by the Central Pollution

Control Board (CPCB), there were around 30,000 operational kilns in 1992, but the

recent preliminary discussions with the regulatory agencies and the industry

associations reveal that units are are reduced to around 6,000 limekilns due to lack of

white washing market. These clusters of limekilns came into existence near the

limestone deposit areas. The major clusters are located in Andhra Pradesh, Karnataka,

Tamil Nadu, Madhya Pradesh, Himachal Pradesh, Uttaranchal, Uttar Pradesh,

Rajasthan, and Maharashtra. The types of kilns employed for lime production varies

from batch type country kiln, natural & forced draft vertical shaft kiln across different

clusters, with vertical shaft kilns being the most widely used. These clusters also differ in

physical and chemical properties of limestone processed, fuels employed, grades of lime

produced, kiln size and design parameters, mechanization levels, operational practices,

etc.

4.2 Technology Gap Assessment

Among the technologies adopted in India for lime burning, vertical shaft kilns are energy

efficient, tall cylindrical kilns of varying designs and

length/diameter ratios. These are refractory lined with

provisions to discharge the burnt lime at the bottom. In mixed

feed kilns, the discharge doors are provided at the bottom for

discharging lime. The air drawn at the bottom helps to supply

the preheated air to the kiln for the combustion of the

coal/coke either by natural or forced draft. When the fuel is

oil or gas, separate burners are located at suitable positions

around the circumference of the kilns to provide heat for the

calcination to take place. Properly designed kilns have

definite zones for preheating, calcining and cooling.

The calcination occurs in the kiln due to the action of hot gases of combustion on the kiln

charge consisting of pieces of limestone and permeable to gases which move

downwards under the action of gravity.

A vertical shaft kiln is divided into pre-heating, burning (calcination) and cooling zones.

In the pre-heating zone the incoming raw material (feed) comes into contact with

ascending gases from burning zone at a sufficiently high temperature thereby getting

35

pre-heated before entering burning zone. Calcination takes place in burning zone and in

the cooling zone the calcinated lime gets cooled by the incoming draught facilitating hot

air to burning zone for efficient combustion. The calcinated lime is removed through

discharge doors. The air for combustion is drawn through discharge doors located at the

bottom of vertical kiln.

The combustion air is normally pre-heated in the cooling zone in counter current by the

sensible heat present in the lime after calcination. The quantity of heat introduced with

combustion air depends on the efficiency of heat recovery in cooling the lime. The ratio

of heat requirement of the burning zone to heat supplied to pre-heating zone depends on

CaCO3 content of limestone.

The decomposition behavior is determined by heat transfer to the material, heat

conduction inside the material, chemical kinetics, diffusion of the CO2 through the porous

oxide layer and mass transfer. The heat transfer is the temperature difference between

surroundings and the reaction front while the mass transfer is the difference between

equilibrium pressure and ambient partial pressure. The dissociation temperature of stone

is directly proportional to dissociation of various carbonates present in it.

The thermal efficiency of a lime kiln is the ratio of total heat supplied by the fuel to that

required to decompose stone completely under ideal condition. The limit of heat

consumption is dictated by the heat of reaction needed for the decomposition of CaCO3

into CaO and CO2.

The efficiency of kiln depends on:

• The way in which fuel is introduced into the kiln.

• The efficiency of combustion and quantity of air in excess of the theoretical

requirement. Distribution of heat in the hottest part of the kiln.

• Utilization of heat available with escaping gases.

• The amount of heat left in the lime drawn from cooling zone

• The quantity of heat lost by radiation and in other ways.

Evolution of designs in India

36

1

7

8

9

2

3

4

5

6

The All India Khadi and Village Industries Commission (KVIC) assisted the villages

where lime stone deposits were available with improved kiln design with a production

capacity of 2 to 10 tons of lime per day. Since the kiln is small, batch-type and operated

only in fair weather, it did not work out to be cost-effective. The lime produced in these

kilns is sold in villages for mortar and plasterwork, and also for use in refining sugarcane

juice in village Khandsari, Uttarakhand.

Although some of the country kilns are of the

mixed feed vertical shaft type, the operational

principles for these kilns are often neglected by the

people running them. For almost 15 to 20 years,

the lime industry continued in its infancy as far as

technology was concerned.

The Central Building Research Institute (CBRI),

Roorkee had gauged the importance of

standardized good quality lime in the 1970s. They

introduced an improved design-a partially

mechanized vertical shaft kiln lined with refractory Figure 4 1: KVIC Limekiln

Figure 4.2 CBRI Limekiln

37

Figure 4.3: CBRI Improved Limekiln

Figure 4.4: Shell high capacity mixed feed vertical shaft lime kiln

bricks, together with a check on the size of

limestone and coal for 10 to 15 tons of lime

production per day. Studies indicate that

these kilns are thermally more efficient, and

able to produce lime of good quality.

At the same time, the Bureau of Indian

Standards brought out codes of practice for

production of limes (IS 1849 and IS 1861)

and several other very good specifications.

The changes in the design of the kiln and IS

specifications brought about improvement in

the production of quality lime. Dyers Stone

Lime Co. Pvt. Ltd developed the design for a

kiln in Sataun, Himachal Pradesh, followed by

kilns for the Madhya Pradesh government.

The CBRI kiln, as well as this kiln with the capacity to produce 50 tonnes of lime per day,

provided a network of rings and columns on the outer periphery of the shaft for proper

strengthening and reinforcement. The kiln had expansion joints provided in the walls to

obviate the thermal stresses. Later, in1982, Dyers introduced a modern, mechanized

steel shell kiln with refractory lining. This kiln could produce up to 100 tonnes of lime

per day .

The technology that was used in the country

kilns and in the KVIC, CBRI, and Dyers kilns,

was initially the open-top, single shaft nd mixed

feed type. The ratio of limestone and coal was

determined on the basis of the quality of

limestone, its physical and chemical constitution

and the quality of coal which usually had high

ash content and low calorific value. A significant

quantity of heat escaped from the top of the

kilns, rendering them poor in thermal efficiency

(25 to 50 per cent). The modern, single shaft kiln

provides better thermal efficiency, if the fuel is

coke, petcoke, fuel oil or natural gas. The twin

shaft kiln technology, which was first introduced

in Europe, is based on the intensive study of

wastage of heat in both lime drawn, as well as on

the gases going out at temperatures higher than

38

100°C. The type of kiln design, capacity of production of lime, heat requirement and

thermal efficiency are listed in Table 4, in order of priority.

Table 4.1: Types of kilns and thermal efficiency

S. No. Type of kiln

Capacity of

production

Heat

requirement

Thermal

efficiency

(Tons/day) (Kcal/kg lime) (%)

1. Vertical shaft (Single shaft) 10-20 1,100-1,200 60-65

2. Open top large 30-50 1,800-2,000 40-45

3. Small intermittent 2-10 1,600-2,000 40-45

Natural and Forced Draft Based Limestone Burning Kiln

In these kilns, steel shells are provided on the outer structure instead of concrete

structure. Mica is used as insulating material in addition to firebrick and clay brick. The

advantage of steel kilns over concrete kilns is the increased life and high resale value as

claimed by the entrepreneurs. However, there is no significant fuel savings envisaged in

steel kilns when compared to concrete kilns. Steel kilns are typically 34 to 35 feet in

height, 10.5 feet inner diameter and 3.3 feet wall thickness. The average output of these

kilns is in the range of 18 to 20 tonnes per day. To improve the energy efficiency feature

and throughput in these kilns, forced draft with mechanized conveying was introduced

and it is explained below:

Forced draft is employed to increase the throughput of the finished product and reduce

the fuel consumption. There is kiln with forced draft and mechanized conveying in

Piduguralla and Jodhpur limekiln cluster which is operating at higher energy efficiency

over old vertical shaft kilns. The combustion air is supplied by a blower to an air header,

which in turn distributes the air and supplies to the kiln through different ports of four-

inch diameter. The kiln has also a provision to operate on natural draft. During forced

draft operation the air inlet holes for natural draft operation are closed down. The kiln is

also provided with mechanized conveying system with separate hoppers for limestone

and coal to maintain the feed and fuel ratio. In this technology, limestone and fuel such

coal/peat coke are fed into the kiln on layer by layer of different thickness depending

upon the caloric value of the fuel.

39

Chapter 5

TTrraaiinniinngg NNeeeeddss AAsssseessssmmeenntt SSuurrvveeyy

5.1 Needs Assessment

The specific objective of this activity is to assess and document the capacity building

needs assessment for energy professionals such as energy managers & auditors,

limekiln unit owners, supervisor and plant managers in limekiln sector at Tirunelveli and

Jodhpur cluster. ZESPL team has conducted capacity building needs assessment study

in targeted limekiln clusters. As a first step, ZESPL team visited selected units for

detailed interaction to identify the major technology and knowledge gaps encountered by

the limekiln cluster. In addition, detailed discussions were held with the local limekiln

association to gain understanding on major issues and challenges being faced by the

cluster units. Further, ZESPL interacted with other key stakeholders of the cluster such

as energy professionals in the cluster, District Industries Centre (DIC), Micro, Small &

Medium Enterprises- Development Institute (MSME-DI), financial institutions, local

service providers (LSPs), vendors & suppliers of EE equipment, and technical

institutions to identify the capacity building needs of the targeted clusters.

5.2 Tirunelveli limekiln cluster

5.2.1 Issues Facing

The limekiln units located in Tirunelveli facing many challenges and few are described

below:

• The units suffer from lack of technical skills. The cluster units employs batch type

kilns which produces low quality products, poor yields and high fuel consumption.

There is also limited innovation and competitiveness in the cluster caused by lack

of technical and managerial skill.

• There is very limited information/ knowledge/ awareness of unit owners on EE

technologies/ equipment for lime production, energy conservation potential,

opportunities, and benefits. The unit owners prefer to invest in capacity

expansion rather than in energy saving projects due to lack of information &

awareness and due to perceived risks of investing in energy saving technologies.

• The cluster units only cater to low end markets due to poor quality of product

from batch kilns. As a result, the units are deprived to supply to better high

paying markets

• There is increasing threat and competition from other clusters such as

Piduguralla and Jodhpur for the finished product due to high cost of lime

production in Tirunelveli

40

• The units suffer from lack of information/ awareness on various financial

schemes/ subsidies from banks/ FIs/ governments for EE projects. There is also

lack of technical capacity of units for identifying and implementing EE projects.

• The units have limited credit worthiness for raising loans from banks for

technology upgradation projects. Also, there is lack of interest of banks/ FIs in the

district to lend for technology upgradation projects.

• One of the biggest problems of the cluster is lack of readily available of-the-shelf

energy efficient technologies suitable for burning the locally available limestone.

No demonstration/ pilot projects have been conducted in the cluster so far for

demonstrating energy efficient technologies. This is one of the major reasons for

no presence of energy saving kilns in the cluster.


The capacity building needs identified in close interaction with various stakeholders of

the projects and are described as below:

Awareness raising and training of unit owners and supervisors on energy

conservation & technical aspects

The major barrier that prevented the implementation of EE measures in limekiln sector is

lack of awareness of unit owners on energy & monetary losses due to the existing

technologies & practices, EE technologies suitable for the cluster such as EE motors/

pumps/ crushers/ pulverizers, mechanical handling systems, etc. There is very limited

information, knowledge, and awareness in the cluster on energy conservation potential

in limekilns, opportunities, and benefits. As a result, the unit owners prefer to invest in

capacity expansion rather than in EE projects and due to perceived risks of investing in

EE technologies.

In order to address this first and foremost barrier, there is need to raise awareness of

units on energy efficiency by conducting periodic training/ awareness programs in the

cluster targeting the MSME owners. The training programs should highlight technologies

in use, energy consumption profile of the units, energy losses due to the old/ in-efficient

technologies used in the cluster, consequent monetary losses, technology gaps, EE

technologies suitable for the cluster, fuel and electricity savings potential, monetary

benefits, indirect/ co-benefits, availability of the technologies, vendors supplying the EE

technologies, how to monitor energy consumption and assess the energy savings, etc.

There are 94 units located in Tirunelveli and near by districts with radius 30 km from

Tirunelveli, it is recommended to conduct a program at Tirunelveli.

The vendors/ suppliers of EE technologies (EE motors, pumps, crushers, etc) in the said

clusters should be actively engaged in the training programs. As a first step, the vendors

41

of EE equipment/ technologies should be registered with the association and the

registered vendors should be engaged actively to make presentations on EE

technologies applicable for limekiln cluster, energy saving potential, monetary benefits,

other co-benefits, etc. and government incentives applicable if any for the specific EE

technologies. Successful case studies should be presented by the vendors. This will

pave the way for networking of EE technology suppliers with the cluster units for future

replications.

Awareness raising and training on financing schemes

The promoters are not aware of financial schemes, lending schemes of different

commercial banks and FIs for EE projects and subsidies available from the central/ state

government.

There are attractive lending/ financing schemes available from SIDBI, FIs, and

commercial banks for investing in EE/ cleaner production technologies. There are also

central government incentives/ subsidies/ programs such as TEQUP, CLCSS and

REGP, which the cluster units can avail and benefit from. There is need to create

awareness among the promoters through focused training programs on availability of

financing/ lending schemes at lower interest rates, the benefits to the industry, the terms

and conditions & financial parameters of these schemes, how to apply, eligibility criteria,

etc. The beneficiary units of such schemes should be invited to the training programs to

share their experience and benefits of availing such schemes. Representatives of

banks/FIs may be invited to explain the lending schemes of their respective banks.

Capacity building of local service providers

The promoters do not have adequate technical expertise and knowledge on energy

efficiency and are totally dependent on local technology suppliers or service companies,

which normally rely on established and commonly used technology. It is observed that

due to lack of awareness to the promoters as also due to lower capital cost, vendors/

suppliers of equipment continue to supply inefficient equipment to the cluster units.

Therefore, there is need to build the capacity of vendors of motors, pumps, crushers,

pulverizers, etc in limekiln cluster to encourage them to sell energy efficient equipment to

the cluster by explaining the benefits of EE technologies. Training of vendors and

suppliers is therefore critical for sustainable investments in technology upgradation.

The BEE certified energy auditors shall be actively engaged in training programs as they

play catalytic role in technology upgradation in the cluster. The auditors help the

individual units in conducting energy audits and DPRs for identified/ potential EE

technologies and in the process raise the overall awareness of the cluster on EE. The

auditors can also facilitate handholding support for implementation of EE measures.

42

Training of operators

The operators of all the limekiln units in the cluster are unskilled workers and operate

equipment based on their experience and judgment rather than technical knowledge.

This often leads to suboptimal performance of the plant equipment, ultimately resulting in

poor product quality and yield. Hence, supervisors, operators, and managers of the

limekiln units are included in training program

5.3 Jodhpur limekiln cluster

5.3.1 Issues facing

About 250 units engaged in lime production which includes hydrated & quick lime spread

across three districts of Rajasthan namely Jodhpur, Nagaur and Pali District. Jodhpur

limekiln cluster is facing various problems and these are presented below:

• The vertical shaft kilns employed in the cluster are 20 years old technology

designed by CPRI & KVIC and no major innovation has done on limekiln

technology/design in recent years

• The cost of energy for lime production is high and accounts for major share 40 -

45% of cost of production.

• The petcoke price is very high and increased from Rs 7500 to Rs.9500 per ton in

the last three years.

• There is increasing threat and competition from Middle East to supply quicklime

to process industries located in coastal line like Mumbai since Jodhpur is far

away from coastal line


The capacity building needs identified in close interaction with the key players are

described as below:

Awareness raising and training on financing schemes

The promoters limited knowledge on lending schemes of different commercial banks and

FIs for EE projects and subsidies available from the central/ state government.

There are attractive lending/ financing schemes available from SIDBI, and commercial

banks for investing in EE/ cleaner production technologies. There are also central

government incentives/ subsidies/ programs such as TEQUP, CLCSS and REGP, which

the cluster units can avail and benefit from. There is need to create awareness among

the promoters through training programs on availability of financing/ lending schemes at

43

lower interest rates, the benefits to the industry, the terms and conditions & financial

parameters of these schemes, how to apply, eligibility criteria, etc.

Training of operators

The operators of all the limekiln units in the cluster are unskilled workers and operate

equipment based on their experience and judgment rather than technical knowledge.

This often leads to suboptimal performance of the plant equipment, ultimately resulting in

poor product quality &yield and higher energy consumption. Hence, supervisors,

operators, and managers of limekiln unit owners are also be involved in training program

so that energy conservation measures identified in the cluster will not continued in the

cluster units after the training program.

44

Chapter 6

CCaassee SSttuuddiieess// BBeesstt PPrraaccttiicceess

6.1 Case Study 1: Replacement of Conventional Kiln with Vertical Shaft

Kiln Coupled with Biomass Gasifier

i) Overview of the Tirunelveli Cluster

Limekilns located at Tirunelveli district in Tamil Nadu burning limestone to produce

quicklime/ hydrated lime and these kilns are primarily concentrated in Sankarnagar,

Rasta, Rajapalayam, and Sankaran Koil. Approximately 94 units engaged in quicklime

production in the cluster and each unit comprises two to eight kilns. Almost all the units

of the cluster are operational and produce hydrated lime from two different types of raw

material, viz. dolomite and calcite limestone. The technology status of Tirunelveli limekiln

cluster is discussed in detail in the Chapter 2.

ii) Energy Consumption for the Prevailing Technology

The average %CaCO3 in the limestone available in Tirunelveli limekiln cluster and

quantity of limestone rejection from the kiln would be 58% and 15% respectively. The

charcoal required per tonne quick lime is 200 Kg and its calorific value is 6500 kCal/kg.

The production capacity of the kiln is assumed to be 4.2 tonnes/day. Hence, quantity of

raw material and char coal are calculated as follows:

Quantity of limestone required = 4.2/ (0.58*0.85)

= 8.5 tonnes

Quantity of charcoal required = 4.2*200 kg

= 840 Kg

So, 840 kg charcoal is required to burn 8.5 tons limestone.

Energy required/ kg of quicklime = (Qty. of charcoal * Calorific Value) / Qty. of Quicklime

= 840* 6500/ 4200

=1300 Kcal

(a) Char Coal Cost per ton of quick lime = 200 x 14 = Rs.2800 / ton quicklime

Amount of electricity required per ton of quicklime = 55 kWh

(b) Electricity cost per ton of quicklime = 55* Rs 5/ kWh

= Rs 275/ ton quick lime

Total energy cost = Rs.3075/ per ton of quicklime

45

iii) Proposed energy efficient 20 TPD vertical shaft kiln coupled with biomass

gasifier

Energy requirement for the proposed Vertical shaft kiln = 1200Kcal/Kg of quicklime

Calorific value of the biomass (firewood) = 3500 Kcal/kg

Biomass (firewood) required for same output = 1200 / 3500

= 0.342 Kg/kg of quick lime

= 0.342*4200

= 1440 Kg of biomass

Assuming efficiency of biomass gasifier of 70%,

Biomass required for 4.2 ton of quick lime = 1440/0.70

= 2057 Kg of biomass

Quantity of limestone required = 4.2/ (0.58*0.95)

= 7.6 tons of limestone

(a) Biomass cost per tone of quicklime = 2057* Rs 3.5/Kg/ (4.2)

= Rs 1715 / tone of quick lime

(b) Electricity cost per ton of quicklime = 100* Rs 5/ kWh

= Rs 500/ ton quick lime

Total energy cost = Rs.2215/ per ton of quicklime

Difference in fuel cost between prevailing and proposed technology

= Rs (3075-2215)/ ton of quicklime

= Rs 860 / ton of quicklime

For 20TPD kiln saving per day on fuel = 860 x 20

= Rs.17,200 per day.

Considering 300 days operation in a year,

Annual saving on energy cost for 20 TPD = Rs.17,200 *300 days

=Rs 51.60 Lakhs.

Project cost including biomass gasifier of 20 TPD = Rs.122 lacs

46

Simple payback period = 2.36 years

v) Demerits of conventional kiln

• All the activities such as material feeding, preparation fuel – limestone and

product discharge are manual.

• Conventional kilns leads to air pollution and particulate emission which could be

control to some extent only.

vi) Advantages of Vertical shaft kiln coupled with biomass gasifier

• Charging of limestone and discharge of quicklime is automated.

• Minimum pollution would be anticipated which would be during crushing and

initial burning of limestone.

• Provision for Instrumentation to measure process data such as temperature,

pressure and level.

• Consistent product with good quality results sale price at least 20% higher.

• Although skilled labor will be at higher cost for the technology, overall labor cost

would be reduced.

6.2 Case Study 2: Replacement of Conventional Kiln with Forced Draft

Vertical Shaft Kiln with Sheet Steel

i) Overview of the existing technology

In the country kiln used in the Tirunelveli cluster, charcoal and electricity are used to

produce quicklime. The quantity of char coal and electricity required to produce lime of

one ton is 200 Kg and 55 kWh respectively. The calorific value of the char coal used in

the cluster is 6500 kCal/Kg. The cost of quicklime production is approximately Rs.3,900

per ton and energy cost accounts for over 60% cost of production at Tirunelveli limekiln

cluster. Energy consumption calculation is explained below:

Amount of char coal required per ton of quick lime = 200 Kg

Cost of char coal = Rs 14/kg

Fuel cost per ton of quicklime = Rs 2800

Electricity cost per ton of quicklime = 55 * 5 = Rs 275

Total energy cost per ton of quick lime = Rs 3075

ii) Proposed Vertical Shaft Kiln with steel shell

47

In these kilns, steel shells are provided on the outer structure instead of concrete

structure. Mica is used as insulating material in addition to firebrick and clay brick. The

advantage of steel kilns over concrete kilns is the increased life and high resale value as

claimed by the entrepreneurs. However, there is no significant fuel savings envisaged in

steel kilns when compared to concrete kilns. Steel kilns are typically 34 to 35 feet in

height, 10.5 feet inner diameter and 3.3 feet wall thickness. The average output of these

kilns is in the range of 18 to 20 tonnes per day. To improve the energy efficiency feature

and throughput in these kilns, forced draft with mechanized conveying was introduced

and it is explained below:

Forced draft is employed to increase the throughput of the finished product and reduce

the fuel consumption. There is kiln with forced draft and mechanized conveying in

Piduguralla and Jodhpur limekiln cluster which is operating at higher energy efficiency

over old vertical shaft kilns. The combustion air is supplied by a blower to an air header,

which in turn distributes the air and supplies to the kiln through different ports of four-

inch diameter. The kiln has also a provision to operate on natural draft. During forced

draft operation the air inlet holes for natural draft operation are closed down. The kiln is

also provided with mechanized conveying system with separate hoppers for limestone

and coal to maintain the feed and fuel ratio. In this technology, limestone and fuel such

coal/peat coke are fed into the kiln on layer by layer of different thickness depending

upon the caloric value of the fuel.

The project cost of setting up of a quicklime cum hydration facility unit at Jodhpur

limekiln cluster are approximately Rs 145 lakhs. The project cost covers cost of land,

construction of kiln, electrical items, mechanized conveying, office building, and yard.

The breakup of project cost is given in Table 1 below:

Table 6.1: Project cost of a quicklime cum hydration facility

Item Capital Cost, Rs

50 TPD

Kiln 40,00,000

Land (10000 sq.m) 70,00,000

Electrical Transformer, cabling and

accessories

10,00,000

Crusher 2,00,000

Working shed, yard, building for

hydration facility and office building

23,00,000

Total cost (approx.) 1,45,00,000

48

Quantity of peat coke and electricity required for quicklime production of one ton is 160

kg and 15 kWh respectively. The energy cost accounts for 30% of cost of production at

Jodhpur limekiln cluster.

iii) Energy saving Calculations:

Amount of peat coke required per ton of quicklime = 160 Kg

Cost of peat coke = Rs 10/Kg

Fuel cost per ton of quicklime = 160*10 = Rs 1600

Electricity consumption per ton of quicklime = 15 kWh

Electricity cost per ton of quicklime = 15*5 = Rs 75

Total energy cost per ton of quick lime = Rs 1675

Difference in energy cost between prevailing and proposed technology per ton of

quicklime = Rs (3075- 1675) = Rs 1400

Considering kiln capacity of 20 TPD and 300 days of operation,

Energy saving per day = 1400*20

= Rs 28000

Annual energy savings over conventional kiln = Rs.28000*300

= Rs 84 lacs

Simple payback period considering unit with hydration facility = 1.73 years

6.3 Best Practices: Replacement of Re-winded/Old Motors with Energy

Efficient Motors

Background

During the walk through energy audit it was observed that motors had re-winded more

than 5 times or age of motors more than 10 years were replaced with star rated energy

efficiency motors by unit owners.

Energy efficient motors leads to higher working efficiency up to 4 % for the same

working condition. Design improvements were incorporated specifically to increase

operating efficiency over motors of standard design in EE motors. Design improvements

focus on reducing intrinsic motor losses including the use of lower-loss silicon steel, a

49

longer core (to increase active material), thicker wires (to reduce resistance), thinner

laminations, smaller air gap between stator and rotor, copper instead of aluminum bars

in the rotor, superior bearings and a smaller fan, etc. In keeping with the stipulations of

the BIS, energy-efficient motors were designed to operate without loss in efficiency at

loads between 75 % and 100 % of rated capacity which may result in major benefits in

varying load applications. The power factor is about the same or may be higher than for

standard motors.

Benefits

� Reduced power consumption

� Higher efficiency through reduction no load loss and ohmic loss

� Good efficiency with wide range of load

Energy Saving Analysis

Installation of Energy efficient motors in place of re-winded motors would have saved the

power consumption as energy efficient motors have 4-5 % efficiency higher than

standard motor. A typical unit in Tirunelveli limekiln cluster replaced 32 kW standard

motor with EE motor of 30 kW. The details of savings are provided below:

Standard / Rewinded Motor = 32 kW

Energy efficient motor = 30 kW

Saving potential = 2 kW

Running Hours = 7000 hrs/year

Energy Saving = 2 kW/Motor x 7000 hrs/yr x Rs. 4.8 / kWh

= Rs. 0.67 Lakh/ year

Cost of Implementing

The typical unit spent around Rs. 1.2 Lakhs for purchasing of 30 kW energy efficient

motor and the same unit returned the investment in 2 years

50

Chapter 7

EEEE FFiinnaanncciinngg SScchheemmeess

7.1 Background

The primary objective of this activity is to identify, compile, and document the lending

schemes / financial schemes/ credit facility/ EE schemes of SIDBI for EE investment in

the cluster and present the same to energy professionals in the targeted limekiln cluster

during the capacity building programs/ workshops proposed to be organized by BEE/

ZESPL.

7.2 Lending Schemes/ Financial Schemes/ Credit Facility/ EE Schemes of SIDBI

ZESPL team interacted with financial institutions such as Small Industries Development

Bank of India (SIDBI) for obtaining the information on EE loan products and credit

facilities. The information was also collected from various financial institution websites

for various lending schemes available and guidelines for availing the loans. The financial

schemes/ lending schemes of various FIs/ banks and the central government schemes/

subsidies on EE loan products are listed below and described in detail in the following

sections:

Small Industries Development Bank of India (SIDBI)

(A) JICA-SIDBI Financing Scheme for Energy Saving Projects in MSME sector

(B) KfW- SIDBI Financing Energy Efficiency Projects in the MSME Sector

(C) KfW- SIDBI Financing Cleaner Production Measures in the MSME Sector and

Cluster

(D) Credit Guarantee Scheme for Micro and Small Enterprises (CGMSE)

(E) TIFAC-SIDBI Revolving Fund for Technology Innovation

Other Banks/ Financial Institutions

(F) Scheme for Financing Energy Efficiency Projects, Bank of Baroda

51

Central Government Scheme

(G) Technology and Quality Up-Gradation (TEQUP) support to Micro, Small and

Medium Enterprises

(H) Credit linked capital Subsidy scheme (CLCSS)

(I) Rural Employment Generation Programme (REGP)

7.3 SIDBI – (Small Industries Development Bank of India)

A) JICA-SIDBI Financing Scheme for Energy Saving Projects in

MSME sector

The Japan International Cooperation Agency (JICA) has extended the second Line of

Credit to Small Industries Development Bank of India (SIDBI) under the Phase II of the

Micro, Small and Medium Enterprises (MSMEs) Energy Saving Project for financing

Energy Efficiency (EE) opportunities in MSMEs. Phase I of the Project gained immense

popularity among the MSMEs across the different industrial sectors, where more than

3500 energy efficient projects were installed in MSME units. The project is aimed at

sustaining the efforts of MSME Energy Saving Project – Phase I and encourage MSME

units to undertake energy saving investments in plant and machinery to reduce energy

consumption, enhance energy efficiency, reduce CO2 emissions, and improve the

profitability of the units in the long run.

i ) Financial Parameters

The financial parameters for appraising the projects are:

Parameter Norms

Minimum Rs.10 lakh

Min. Promoters

Contribution

25% for existing units

33% for new units

Debt Equity Ratio Maximum 2.5 :1

Interest Rate As per credit rating and 1% below the normal lending rate

Upfront Fee Non refundable upfront fee of 1% of sanctioned loan plus applicable

service tax

Security First charge over assets acquired under the scheme; first/second

charge over existing assets and collateral security as may be

deemed necessary

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Asset Coverage Minimum Asset Coverage should be 1.4 :1 for new units and 1.3 :1

for existing units

Repayment

Period

Need based. Normally, the repayment period does not extend beyond

7 years. However, longer repayment period of more than 7 years

may be considered under the Line if considered necessary

(Source:http://www.sidbi.com/?q=financing-schemes-sustainable-development-

including-energy-efficiency-and-cleaner-production-msmes)

The financial assistance to MSMEs will be provided through SIDBI, as well as through

refinance to Banks/ State Finance Corporations (SFCs) and Non Banking Financial

Companies (NBFCs). The project also seeks to provide technical assistance to these

financial institutions and MSME units for successful implementation of this Scheme

resulting in Energy Saving in MSME Sector and thereby contributing to environmental

improvement and socio-economic development in the country and address the climate

change concerns.

i i ) Eligible Sub-Projects / Energy Saving Equipment List

The energy saving sub-project under this initiative means:

• Acquisition (including lease and rental) of energy saving equipments/facilities,

including newly installing, remodeling and upgrading of those existing

• Replacement of obsolete industrial furnaces and/or boilers or burners or

introduction of additional equipment which improve performance comparable

to those of replacement.

• Installation or improvement or adoption of such manufacturing machinery and

equipment that meet the specific requirements for energy performance

standard provided by the related energy conservation act/code in India (e.g.

Top Runner Equipment, Energy Labels etc.)

• Installation of building envelopes, equipments, heating systems, lighting and

electrical power/ motors in compliance with energy performance standard

provided in the Energy Conservation Building Code (ECBC)

• Introduction of the equipments that utilize alternative energy sources which

can reduce GHG emissions such as natural gas, renewable energy, biogas

etc. instead of fossil fuel such as oil and coal

• Clean Development Mechanism (CDM) projects involving clusters level

intervention by a change in the process and technologies for the cluster as

a whole duly supported by technical consultancy, will be eligible for coverage

53

The list of equipment eligible for financing under this initiative is available in SIDBI

offices. The equipment list is being continuously revised and updated by the Consultants

– InsPIRE Development Services appointed by JICA. The List shall be used for

screening the sub- projects for deciding their eligibility for coverage under the JICA Line

of Credit and the List would be the primary criteria for the sub-projects. Please contact

the nearest SIDBI Branch Office or refer to SIDBI website (www.sidbi.in) or JICA Project

website (http://jica.org.in ) for the updated List.

i i i ) Eligibil ity Criteria for Units (Direct Assistance)

• New / existing MSME units, as per the definition of the Micro, Small & Medium

Enterprises Development (MSMED) Act, 2006 (www.Laghu-udyog.com; www.

Smallindustryindia.com). However, units graduating out of Medium scale will not

be eligible for assistance.

• Existing units should have satisfactory track record of past performance and

sound financial position.

• Energy saving projects will be screened as per the Energy Saving Equipment

List, which is available on SIDBI or JICA Project website.

• Units should have minimum investment grade rating of SIDBI.

• Sectors such as the arms industry, narcotics industry or any unlawful businesses

are not eligible. Similarly, such projects which may result in larger negative social

and environmental impact are also not eligible under this scheme.

• Equipment/machinery with energy saving potential less than 10% is not eligible.

iv) Application For Loan Assistance

The prospective borrower is required to submit duly filled-in application form along with

the supporting documents as per the prescribed format to the nearest SIDBI branch

office. In addition to the information requested for in the application form, it may be

ensured that the prospective borrower explicitly provides details of the energy saving

potential of the project. This will be an important parameter for deciding the eligibility of

the project financing under the Line of Credit.

v) Disbursement

Disbursement would be carried out after compliance of the terms of sanction.

B) KfW- SIDBI Financing Energy Efficiency Projects in the MSME

Sector

Micro, Small & Medium-Sized Enterprises (MSMEs) can reduce their energy

54

consumption by investing in equipment, technologies or process improvements, which

increase the energy efficiency of their facilities. SIDBI offers financial assistance for

investments in energy efficiency projects to existing MSMEs under a Line of Credit from

KfW Development Bank in framework of the Indo-German Development Cooperation.

i ) Potential Investments

Energy efficiency investments may include:

• Improving insulation off e.g. heat pipe

• Energy efficient lighting

• Installing variable speed drives

• Upgrading or modernizing of industrial boilers

• Heat recovery systems

• Optimization of air pressure systems

• Fuel switching (e.g. from electricity to Liquefied Petroleum Gas (LPG)

• Replacing existing equipment / machinery with efficient equipment /

machinery

ii) Financial Parameters

Parameter Norms

Minimum Assistance Generally not less than Rs. 10 lakh

Minimum Promoter’s

Contribution

25% of project cost

Overall Debt / Equity Ratio 2:1

Interest Rate 1% below Normal Lending Rate

Asset Coverage 1.3 for manufacturing unit and 1.75 for services sector

unit

Repayment Period Need based – normally not more than 7 years

(Source:http://www.sidbi.com/?q=financing-schemes-sustainable-development-

including-energy-efficiency-and-cleaner-production-msmes )

i i i) Eligibil ity Criteria

In order to qualify for a loan an enterprise should:

55

• Be an existing MSME unit (as per the definition of the MSMED Act 2006)

• Have a satisfactory track record of past performance and sound financial

position; and

• Score above the minimum investment grade as per SIDBI’s extant Loan Policy.

iv) Additional Criteria

Proposed investments for the Energy Efficiency Financing Scheme:

• Will result in significant energy savings and reductions of greenhouse gas

emissions

• Will upgrade existing installations and not purely aim at expansion of production

capacities

• May include purchase of machinery and equipment, process modifications and

related civil construction (civil construction <25% of total project cost); and

• Taxes, import duties and other public charges shall be borne by the enterprise.

v) Further Information

Eligible MSMEs may apply for an Energy Efficiency Loan by contacting a local SIDBI

Branch. Contact details of branch network are available at SIDBI’s website

(www.sidbi.in). Further information on SIDBI’s Energy Efficiency Financing Scheme, the

loan application form and the list of required supporting documents can be downloaded

from SIDBI’s website. MSME unit owner and technology-specific advice on how to

reduce company’s energy consumption can be obtained from a SIDBI-appointed

consultant. Contact [email protected] for assistance.

C) KfW- SIDBI Financing Cleaner Production Measures in the

MSME Sector and Cluster

Cleaner production measures are a way to improve business sustainability, save costs

and participate in long-term sustainable growth. SIDBI offers financial assistance to

Micro, Small and Medium-Sized Enterprises (MSMEs) and clusters to invest in cleaner

production and emission reduction measures, waste management and Common Effluent

Treatment Plant (CETP) facilities. These loans are being financed under a Line of Credit

from KfW Development Bank in the framework of the Indo-German Development

Cooperation.

i) Benefits

Benefits of cleaner production (CP) measures include:

56

• Increased efficiency.

• Increased resource productivity.

• Recovery of valuable by products.

• Lower energy consumption.

• Compliance with national standards and regulations.

• Access to new markets, supply chains and financing.

i i ) Financial Parameters

Parameter Norms

Minimum Assistance Generally not less than Rs. 10 lakh

Minimum Promoter’s

Contribution

25% of project cost

Debt / Equity Ratio 2:1

Interest Rate 1% below Normal Lending Rate

Asset Coverage 1.3 for manufacturing unit and 1.75 for services sector

unit

Repayment Period Need based – normally not more than 7 years

i i i ) Eligibil ity Criteria

In order to qualify for a loan an enterprise should:

• Be an existing MSME unit (as per the definition of the MSMED Act 2006)

• Have a satisfactory track record of past performance and sound financial

position; and

• Score above the minimum investment grade as per SIDBI’s extant Loan Policy.

iv) Additional Criteria

Proposed investments for the Energy Efficiency Financing Scheme:

• Will result in significant energy savings and reductions of greenhouse gas

emissions

• Will upgrade existing installations and not purely aim at expansion of production

capacities

• May include purchase of machinery and equipment, process modifications and

related civil construction (civil construction <25% of total project cost); and

57

• Taxes, import duties and other public charges shall be borne by the enterprise

v) Examples of Cleaner Production Measures

Some examples which could be covered under this credit line are:

Furnace fuel switching (e.g. oil to natural gas),

• Sand mixing unit with reclamation plant,

• CNC turning machines, and

• Taxi fuel switching to Compressed Natural Gas (CNG).

Investments in CETPS and waste recycling facilities are also eligible and will be

especially considered for investment financing.

vi) Further Information

Eligible MSMEs may apply for a Cleaner Production Loan by contacting a local SIDBI

Branch. Contact details of SIDBI branch network are available at SIDBI’s website

(www.sidbi.in).

Further information on SIDBI’s Cleaner Production Financing Scheme, the loan

application form and the list of required supporting documents can be downloaded from

SIDBI’s website.

Company and technology-specific advice on how to reduce your company’s

environmental footprint can be obtained from a SIDBI-appointed consultant. Contact

[email protected] for assistance.

D) Credit Guarantee Scheme for Micro and Small Enterprises

(CGMSE)

There are an estimated 26 million micro and small enterprises (MSEs) in the country

providing employment to an estimated 60 million persons. The MSME sector contributes

about 45% of the manufacturing sector output and 40% of the nation's exports. Of all the

problems faced by the MSMEs, non-availability of timely and adequate loan at

reasonable interest rate is one of the most important problems. Major causes for low

availability of bank finance to this sector are the high risk perception of the banks in

lending to MSEs and consequent insistence on collaterals which are not easily available

with these enterprises. The problem is more serious for micro enterprises and the first

generation entrepreneurs requiring small loans.

The Credit Guarantee Fund Scheme for Micro and Small Enterprises (CGMSE) was

launched by the Government of India to make available collateral-free credit to the micro

58

and small enterprise sector. Both the existing and the new enterprises are eligible to be

covered under the scheme. The Ministry of Micro, Small and Medium Enterprises and

Small Industries Development Bank of India (SIDBI), established a Trust named Credit

Guarantee Fund Trust for Micro and Small Enterprises (CGTMSE) to implement the

Credit Guarantee Fund Scheme for Micro and Small Enterprises. The scheme was

formally launched on August 30, 2000 and is operational with effect from 1st January

2001. The corpus of CGTMSE is being contributed by the Government and SIDBI in the

ratio of 4:1 respectively and has contributed Rs.1906.55 crore to the corpus of the Trust

up to March 31, 2010. As announced in the Package for MSEs, the corpus is to be

raised to Rs.2500 crore by the end of 11th Plan.

i ) Eligible Lending Institutions

The institutions, which are eligible under the scheme, are scheduled commercial banks

(Public Sector Banks/ Private Sector Banks/ Foreign Banks) and select Regional Rural

Banks (which have been classified under 'Sustainable Viable' category by NABARD).

National Small Industries Corporation Ltd. (NSIC), North Eastern Development Finance

Corporation Ltd. (NEDFi) and SIDBI have also been made eligible institutions. As on

March 31, 2010, there were 112 eligible Lending Institutions registered as (MLIs) of the

Trust, comprising of 27 Public Sector Banks, 16 Private Sector Banks, 61 Regional Rural

Banks, 2 Foreign Banks and 6 other Institutions viz., NSIC, NEDFI, SIDBI and

Tamilnadu Industrial Investment Corporation(TIIC).

i i ) Eligible Credit Faci lity

The credit facilities which are eligible to be covered under the scheme are both term

loans and working capital facility up to Rs.100 lakh per borrowing unit, extended without

any collateral security or third party guarantee, to a new or existing micro and small

enterprise. For those units covered under the guarantee scheme, which may become

sick owing to factors beyond the control of management, rehabilitation assistance

extended by the lender could also be covered under the guarantee scheme. It is

noteworthy that if the credit facility exceeds Rs.50 lakh, it may still be covered under the

scheme but the guarantee cover will be extended for credit assistance of Rs.50 lakh

only. Another important requirement under the scheme is that the credit facility should be

availed by the borrowing unit from a single lending institution. However, the unit already

assisted by the State Level Institution/ NSIC/ NEDFi can be covered under the scheme

for the credit facility availed from member bank, subject to fulfillment of other eligibility

criteria. Any credit facility in respect of which risks are additionally covered under a

scheme, operated by Government or other agencies, will not be eligible for coverage

under the scheme.

59

i i i ) Guarantee Cover

The guarantee cover available under the scheme is to the extent of 75 per cent of the

sanctioned amount of the credit facility. The extent of guarantee cover is 80 per cent for

(i) micro enterprises for loans up to Rs.5 lakh; (ii) MSEs operated and/or owned by

women; and (iii) all loans in the North-East Region. In case of default, Trust settles the

claim up to 75% (or 80% wherever applicable) of the amount in default of the credit

facility extended by the lending institution. For this purpose the amount in default is

reckoned as the principal amount outstanding in the account of the borrower, in respect

of term loan, and amount of outstanding working capital facilities, including interest, as

on the date of the account turning Non-Performing Asset (NPA).

iv) Tenure of Guarantee

The Guarantee cover under the scheme is for the agreed tenure of the term loan/

composite credit. In case of working capital, the guarantee cover is of 5 years or block of

5 years.

v) Fee for Guarantee

The fee payable to the Trust under the scheme is one-time guarantee fee of 1.5% and

annual service fee of 0.75% on the credit facilities sanctioned. For loans up to Rs.5 lakh,

the one-time guarantee fee and annual service fee is 1% and 0.5% respectively. Further,

for loans in the North-East Region, the one-time guarantee fee is only 0.75%.

vi) Website

Operations of CGTMSE are conducted through Internet. The website of CGTMSE has

been hosted at www.cgtsi.org.in.

On the basis of the guidelines issued by CGTMSE, bank offers collateral free loans up to

Rs. 1 crore and enable MSEs realize their dreams. The scheme details are summarized

in the table below:

Field Content

Eligible

Segments

• Should be a Micro/ Small Enterprise (manufacturing/ services) as

defined under MSMED Act and by RBI.

• Should not appear in the defaulters list of RBI, ECGC, CIBIL etc.

Purpose /

Facility

• Fund Based: Working Capital & Term Finance for capex/ takeover

of existing loans.

• Non-Fund based limit viz., Bank Guarantee (BG) and Letter of

60

Credit (LC).

Loan Amount • Minimum: No minimum amount

• Maximum: Rs. 1 crore.

Tenor • Cash Credit: 12 months.

• Term Loan: Max 5 years.

• Bill Discounting: Max 90 days for inland; Max 180 days for foreign

bills.

• Letter of Credit: Max 90 days for inland; Max 180 days for foreign

LCs.

• Bank Guarantee: Not to exceed 12 months.

Pricing • Interest Rate linked to Base Rate.

Security • Primary: Exclusive charge on current and fixed assets.

(Primarysecurity is the asset created out of the credit facility

extended to the borrower and / or which are directly associated

with the business / project of the borrower for which the credit

facility has been extended)

• No Collateral / Third party guarantee

(Source: http://www.cgtsi.org.in/schemes.aspx)

E) TIFAC-SIDBI Revolving Fund for Technology Innovation

Need for developing national capabilities to innovate and create business opportunities

in emerging technological areas has been acutely felt as there continues to be a dearth

of early stage funding for commercialization of innovations by MSMEs due to higher

risks of investment in un-proven technologies. Thus, major proportion of the available

early stage funding gets invested in relatively low risk opportunities based on proven

technologies, thereby limiting innovations to reach the market.

TIFAC created a Revolving Fund of Rs. 30.00 crores for Technology Innovation and

placed it with SIDBI to provide assistance to MSMEs for development, up-scaling,

demonstration and commercialization of innovative technology based projects.

MSMEs seeking financial assistance from the Fund for technology innovation projects

may send detailed project proposal either to TIFAC or SIDBI. The technical evaluation of

61

the project proposals shall be carried out by TIFAC and financial appraisal shall be done

by SIDBI. The proposals recommended both technically & financially shall be considered

for sanction towards implementation by a Project Approval Committee (PAC) consisting

of SIDBI and TIFAC officials. SIDBI will manage the Fund on behalf of TIFAC. The

detailed format for submission of proposals can be downloaded from www.tifac.org.in or

www.sidbi.in.

i ) Objective

The collaborative programme of TIFAC & SIDBI launched on November 01, 2010, aims

at facilitating development, demonstration and commercialization of technology

innovation projects pertaining to new product or process development to encourage and

promote development of capabilities in MSMEs to innovate and to bring high-risk

innovations to the market for opening up opportunities for business linked with

innovations.

i i ) Financial Parameters

Eligibility New / existing Indian MSME units.

Quantum of

assistance

Assistance upto 80% of the total project cost, which would

normally be not more than Rs. 100.00 lakh. Higher assistance

could be considered selectively based on innovation content in

the projects.

Project Cost

• Capital expenditure e.g. factory shed for the project, plants

&machinery, utilities, testing & quality control equipment etc.

• Intangibles e.g. patents/ copy rights / R&D / technology

transfer fee /licensing / Marketing / brand building expenses

• Working capital margin

• Pre-operative expenses

•Upfront Fee Not more than 0.5% of the sanctioned amount + service tax as

applicable for the sanctioned projects only.

Instruments of

Finance Secured Term Loan

Rate of Interest Not more than 5% p.a.

Repayment Period Loan repayment period including moratorium should generally be

not more than 6 years from the date of completion of the project.

62

Security

• First charge on assets (both moveable / immoveable) created

/ to be created under the project

• First / pari passu / second charge on other assets of the unit

depending upon prior charge created/ to be created

• Personal guarantees of promoters Promoter's

Contribution Minimum 20% of the total project cost

( Source: http://www.sidbi.com/?q=tifac-sidbi-revolving-fund-technology-

innovation-srijan-scheme )

i i i) Contact for further details:

1) P.R. Basak

In-Charge

TIFAC-SIDBI Technology Innovation Programme Technology Information,

Forecasting & Assessment Council (TIFAC)

'A' Wing, Vishwakarma Bhavan

Shaheed Jeet Singh Marg, New Delhi - 110 016

Tel: +91-11-26526926, 42525759

Fax: +91-11-2696 1158, 26863866

E-mail : [email protected]

Website : www.tifac.org.in

2) Mr. Rajiv Kumar, Deputy General Manager

ENERGY EFFICIENCY CENTRE

Small Industries Development Bank of India (SIDBI)

Ground Floor, Block-"E",

NSIC Complex , Okhla Indl.Area, Phase-III

New Delhi-110020.

Phone Nos: 011-26382034 (extn. 24), 011-26382063

Fax : 011-26382062 / 26382298

7.4 Other Banks/ Financial Institutions

63

F) Scheme for Financing Energy Efficiency Projects, Bank of

Baroda

The scheme is for financing SMEs for acquisition of equipments, services and adopting

measures for enhancement of energy efficiency/conservation of energy.

i ) Eligibil ity

SME units financed by bank as also other units desirous of shifting their account to Bank

of Baroda

i i ) Limit

Upto 75% of the total project cost, subject to maximum of Rs.1 crore. (Minimum amount

of loan Rs.5 lakh)

i i i ) Project cost may include the following

• Cost of acquisition/modification/renovation of equipment/software

• Cost of alterations to existing machinery

• Cost of structural / layout changes

• Cost of energy audit/consultancy

• Preparation of Detailed Project Report (DPR)

iv) Rate of Interest

Base rate plus 4.00% per annum

v) Repayment

Maximum 5 years, including moratorium, if any

vi) Security

• For Sole Banking Accounts:

Extension of first charge on all fixed assets.

• For Consortium/Multiple Banking Accounts:

First charge on equipments acquired out of loan and collateral, if any, with the

total security coverage being not less than 1.25

More information about this can be obtained at

http://www.bankofbaroda.cpm/bbs/financeenergy.asp

7.5 Central Government Schemes

64

G) Technology and Quality Up-Gradation (TEQUP) support to Micro, Small and Medium Enterprises

The present scheme is one of the ten components of the National Manufacturing

Competitiveness Programme (NMCP). While the other nine components of NMCP and

other Government schemes address other aspects of competitiveness of MSMEs, the

present scheme focuses the two important aspects, namely, enhancing competitiveness

of the MSME sector through Energy Efficiency and Product Quality Certification. The

present scheme will also deal with the issue relating to reduction in emission of Green

House Gas (GHG) by the MSME sector, through energy efficiency. The first objective of

the present Scheme is to sensitize the manufacturing MSME sector in India to the use of

energy efficient technologies and manufacturing processes so as to reduce cost of

production and the emissions of GHGs.

The scheme also focuses on additional spin-offs for the MSME sector through Clean

Development Mechanism (CDM). While the large manufacturers/users of energy in India

are deriving additional income through CDM by trading with the buyers from developed

economies, the MSME sector is not able to do so in the absence of suitable mechanism

for aggregation. An innovative concept of cluster-based carbon credit aggregation

centres (CCAs) has been planned under the scheme to initiate MSMEs to avail CDM

benefits.

The second objective will be to improve the product quality of MSMEs and to encourage

them towards becoming globally competitive. In spite of their diverse manufacturing

capability and low manufacturing costs, the products of the Indian MSMEs could not

move up the value chain in the global market basically due to the concerns about their

quality. Certification of products to national and international standards is an important

tool to enhance the product value of Indian MSMEs. Moreover, in many international

markets, consumer products cannot be sold without compulsory certification, namely,

CE marking. In India also, certain products like bottled drinking water, electrical

appliances, etc., cannot be marketed without Indian Standard Certifications. In the area

of energy efficiency, the energy star ratings initiated by BEE are not compulsory but will

surely motivate consumer preference.

i ) Major Activities under the Scheme

The above objectives of the Scheme will be achieved through the following major

activities:

• Capacity Building of MSME Clusters for Energy Efficiency/ Clean Development

Interventions and other technologies mandated as per the global standards.

• Implementation of Energy Efficient Technologies (EET) in MSME units.

65

• Setting up of Carbon Credit Aggregation Centres (CCA) for introducing and

popularizing Clean Development Mechanism (CDM) in MSME clusters.

• Encouraging MSMEs to acquire product certification/ licenses from National/

International bodies and adopt other technologies mandated as per the global

standards.

• Study of Impact of the scheme, administrative and other miscellaneous items.

i i ) Scheme: Implementation of Energy Eff icient Technologies and

other Technologies mandated as per the Global Standards in MSMEs

� Objective

The basic objective of this Activity is to encourage MSMEs in adopting energy efficient

technologies. For this purpose, bankable DPRs for the implementation of energy

efficient technologies will be invited from the MSMEs. To facilitate the initiative, MSMEs

in the identified clusters will be supported in preparation of bankable DPRs under the

major activity. It is expected that the initiatives under the major activity will provide a

shelf of bankable DPRs for financing by SIDBI/other financial institutions. DPRs on

energy efficiency projects developed under the SME support schemes of BEE, PCRA or

other expert agencies will also be eligible for support. Individual MSMEs may also

submit their DPRs (prepared by competent agency) to the banks and financial

institutions. Under the present activity, MSMEs will be assisted in implementation of the

projects through loans from SIDBI/ banks/financial institutions for which subsidy upto

25% of the cost of the project will be provided.

� Implementation

This Activity will be implemented through SIDBI who will function as the Implementing

Agency. After finalization of the DPR, the concerned MSME units can approach SIDBI

directly or through their Bankers for seeking loan/ subsidy for implementation of the

Projects. Both technical and bank ability appraisal by SIDBI/ Bank will be taken into

consideration prior to the sanction of the assistance in the form of grants. The sanction

of financial assistance under the Scheme will be accorded by the Steering Committee.

The decision would be conveyed to SIDBI and the respective sponsoring Bank under

intimation to the applicant within 10 days of the decision of the Steering Committee.

SIDBI would release proportionate amount of assistance to the beneficiary units. The

total GOI assistance released will not exceed the amount eligible as per the scheme.

The funds will be released to SIDBI after receiving the claims on periodic basis for the

cases sanctioned by the SIDBI. The Steering Committee would periodically review the

requirement of assistance as well as release of funds to SIDBI. A Memorandum of

Understanding (MoU) between SIDBI and office of DC (MSME) will be signed for this

66

purpose, which will also stipulate time frame for each sub activity under this component

of the scheme.

� Components of Grant

The Government of India will provide financial support to the extent of 25% of the project

cost for implementation of Energy Efficient Technologies (EET), as per the approved

DPR. The maximum amount of GOI assistance from the scheme will be Rs.10 lakhs

(Average subsidy for one EET project is estimated to be Rs. 5.0 lakh). The project cost

may include cost of machines, sales and excise tax, transportation and transit insurance

cost, import related duty etc. (which will be limited to the maximum cost of machine at

F.O.R factory of the beneficiary).

While 25% of the project cost will be provided as subsidy by the Government of India,

the balance amount is to be funded through loan from SIDBI/ banks/ financial

institutions. The minimum contribution as required by the funding agency will have to be

made by the MSME unit.

� Implementation Schedule and Funding Pattern

The Bank/ SIDBI will get an agreement executed on behalf of Government of India with

the MSME unit prior to disbursement of financial assistance. The GOI financial

assistance under the scheme will be released by the concerned banks/SIDBI after the

installation of new machinery and equipment at site and after execution of the

agreement on behalf of the Government of India. SIDBI shall furnish Utilization

Certificate to the Office of the Development Commissioner (MSME) for the amount

disbursed (under the Scheme) against individual projects. While submitting the

Utilization Certificate to DC (MSME) office, SIDBI will also enclose a certificate from

competent agency/ Energy Auditor certifying that the new machinery and equipment

installed are capable of giving 15% energy savings.

� Eligibil ity

Any MSME unit who has filed an Entrepreneurial Memorandum with the appropriate

authority or who has erstwhile DIC registration will be eligible for support under the

Scheme. The general eligibility conditions are:

• The MSME should have been audited for energy consumption and have

developed a Detail Project Report on EETs.

• The DPR should be prepared by a qualified Energy Manager/ Auditor.

• Enterprises in the clusters intervened under the Activity 1 or identified by PCRA/

BEE or any other expert agency will be given preference for support under this

67

Activity.

• The project should primarily focus on energy efficiency for the applicant MSME

units and must lead to at least 15% reduction in the energy consumption by the

enterprise. For this purpose the baseline and the projected energy consumption

reflected in the approved DPR will be taken into consideration

• Investments in new plant, machinery and equipments focused towards

enhancing energy efficiency shall only be eligible for subsidy under the scheme.

• The Government financial assistance cannot be utilized for purposes other than

for which it has been sanctioned. The amount released by the Government will

not be utilized towards adjustment of default in repayment of principal and

payment of interest by the borrower.

• After completion of the EET project, the industrial unit will be required to submit

a completion certificate to SIDBI in the prescribed format (to be approved by the

Steering Committee).

• From the date of completion, up to two years, the industrial unit availing the

Government financial assistance will be required to submit operational and

performance details to SIDBI who would apprise the Steering Committee of the

same.

• In case the industrial unit becomes non-operational within two years of the

receipt of Government financial assistance, it will be liable to refund the

financial assistance availed, along with the interest to be charged from the date

of closure till the date of refund at the prime lending rate of SIDBI (as the case

may be). In case of non-compliance, the Bank concerned will take necessary

legal action.

• At any time if it is found that financial assistance from Government has been

availed on the basis of any false information, the industrial unit shall be liable to

refund the amount of Government financial assistance, along with interest to be

charged from the date of disbursal to date of refund. The rate of interest shall be

the prime lending rate of the Bank concerned at the time of invoking this penal

clause.

H) Credit l inked capital Subsidy scheme (CLCSS)

Credit Linked Capital Subsidy Scheme (CLCSS) was launched by the Ministry of Micro,

Small and Medium Enterprises [MSME], (then known as Ministry of Small Scale

Industries [SSI], Government of India) in October 2000 with the objective of facilitating

technology upgradation in the specified products / sub-sectors approved under the

scheme by providing upfront capital subsidy to SSI units, including tiny, khadi, village

68

and coir industrial units on institutional finance (credit) availed of by them for

modernization of their production equipment (plant and machinery) and techniques.

Consequent upon enactment of Micro Small and Medium Enterprises Development

[MSMED] Act, 2006, the scheme has now been extended to MSME sector with effect

from October 2, 2006. Presently, 48 products/ sub sectors are eligible for subsidy.

� Nodal Agencies

Following Financial Institutions, Public Sector Banks, and Government Agencies are

acting as nodal agencies for implementation and release of subsidy.

1. Small Industries Development Bank of India, (SIDBI)

2. National Bank for Agriculture and Rural Development (NABARD)

3. State Bank of India

4. Canara Bank

5. Bank of Baroda

6. Punjab National Bank

7. Bank of India

8. Andhra Bank

9. State Bank of Bikaner and Jaipur

10. Tamil Nadu Industrial Investment Corporation Ltd.

11. National Small Industries Corporation Ltd

The above nodal agencies consider proposals only in respect of credit approves by their

respective branches. For other Primary Lending Institutions, SIDBI and NABARD are the

nodal agencies for release of subsidy under the scheme.

� Eligible Primary Lending Institutions

All Scheduled Commercial Banks, Scheduled Cooperative Banks (including the urban

cooperative banks co-opted by SIDBI under the Technological Upgradation Fund

Scheme (TUFS) of the Ministry of Textiles, Government of India), Regional Rural Banks,

State Financial Corporations and North Eastern Development Financial Institution are

eligible, Primary lending Institutions under the scheme after they execute a General

Agreement either with SIDBI or NABARD.

� Eligible beneficiaries

69

New as well as existing units set up as Sole Proprietorship, Partnership, Co-operative

Societies, Private and Public Limited Companies in MSME sector are eligible for

subsidy. Priority is given to women entrepreneurs.

� Quantum of subsidy

The Scheme originally provided for 12% capital subsidy to SSI units, including tiny units,

on institutional finance availed of by them not exceeding Rs. 40 lakh. Rate of subsidy

has been enhanced from 12% to 15% with effect from September 29, 2005. The

maximum limit of eligible loan is Rs. 100 lakh. Accordingly, the ceiling on subsidy would

be Rs.15 lakh or 15% of the investment in eligible plant & machinery, whichever is lower.

For more details, visit:

www.smallindustryindia.com

www.laghu-udyog.com

( I) Prime Minister's Employment Generation Programme (PMEGP)

Prime Minister's Employment Generation Programme (PMEGP) has been announced on

15th August, 2008 and launched in place of REGP Scheme. Prime Minister’s

Employment Generation Programme (PMEGP) is a credit linked subsidy programme of

Government of India. It has been introduced by merging the two schemes, namely,

Prime Minister’s Rojgar Yojana (PMRY) and Rural Employment Generation Programme

(REGP). The scheme was launched on 15th August, 2008.

i ) Objectives

Providing new avenues of employment for rural unemployed people in the countryside

has all along been the prime concern of the Government of India. Keeping in mind the

expectations of various sections of rural area, the Ministry of Autonomous Research

Institution (ARI), Govt. of India launched REGP through KVIC in a big way.

The broad objectives that the KVIC has set before it are to:

� Generate employment in rural area.

� Develop entrepreneurial skill among the rural unemployed youth.

� Facilitate participation of financial institutions for higher credit flow to rural industries.

70

� Achieve the goal of rural industrialization.

i i ) REGP (Rural Employment Generation Programme) Scheme

The Institutions/ Co-operative Societies /Trusts specifically registered as all SC/ST/OBC/

Women/PH/Ex-Servicemen and Minority Institutions with necessary provision in the bye-

laws to that effect alone are eligible for Margin Money @ 30% of the project cost up to

Rs.10.00 lakh and @ 10% on the remaining project cost up to Rs.25.00 lakh. A certified

copy of the bye-laws is required to be appended to the Margin Money Claim.

Project cost will include Capital Expenditure and one cycle of Working Capital. Projects

without Capital Expenditure are not eligible for financing under the Scheme. Projects of

more than Rs.5.00 lakhs, which do not require working capital, need clearance from the

Regional Office or Controller of the Bank’s Branch and claims are required to be

submitted with such certified copy of approval from Regional Office or Controller, as the

case may be. Cost of the land should not be included in the Project. Cost of the ready

built as well as long lease or rental Work-shed/Workshop can be included in the project.

Gramodyog Rojgar Yojana is applicable for all viable new Village Industries projects

except activities indicated in the negative list of Village Industries. Existing/old units are

not eligible. Only one person from one family is eligible for obtaining finance under the

Gramodyog Rojgar Yojana.

� Beneficiaries

• Individuals (Rural artisans/Entrepreneurs)

• Self Help Groups

• Institutions registered under Societies Registration Act, 1860

• Cooperative Societies

• Trusts and Public Limited Companies owned by State/ Central Government

(Partnership firms/ Private Limited Companies/ Joint Borrowers/ Co- Borrowers/ Co-

obligators/ Joint Ventures/ HUF do not come under the ambit of Gramodyog Rojgar

Yojana)

For further details, please check the link:

http://kvic-regppmegp.in/regpschemes.html

To view the PMEGP website visit:

71

www.pmegp.in.

72

Annexure 1

Tirunelveli Lime Manufacturers’ Welfare Association Members List

S.No. Name of the Company Address

1 Sri Lakshmi Lime Industries Quarry Road, Sankarnagar, Tirunelveli Cell no: 9360119209

2 Uthaya clays & minerals

242 Madhava Kurichi Road Rastha, Tirunelveli Cell No: 9443156458 0462-2920505

3 Metro Coat Rajapalauam Pvt Ltd.

1699/ 3, Madurai road, Gankai Konan village, Sankarnagar,Tirunelveli Cell no: 9360119209

4 Bharathi Chemicals Bharthi Chemicals, 351/A, Madhava Kurinchi Road, Tirunelveli

5 BGS Chemicals

184/2,Saankaran Koil Raod, Sethurayan pudur. Cell:9443403282 9486066666 04622531474

6 Uthra Enterprises 334, Sankarankovil road, Rastha, Manur post - 627201 Cell no: 9443130697

7 Sri Raja Ganapathi Lime Products

229/2A,2B,Sankarankovil Road, Nariyoothu, Madava Kurinchi, Rasta CELL:9443870207

8 Saranva Chemicals 2/339-A, ,Sankarankovil Road, Madava Kurinchi, Rasta Cell:9443473510

9 Jayalakshmi Industries S.N. 4C Madavakuruchi Rastha, Tirunelveli Cell no: 9842104836

10 Siva Agency

Therkkumalai Colony, Therikalam, Sankarnagat post Cell no: 9443450457

11 Sri Bhuvaneswari 315, Sankarankovil Road, Madava Kurinchi, Rasta Cell no: 9486272850

73

12 JRV Eneterprises

190, Sankarankovil Road, Madhavakurichi (PO) Rastha Cell no: 9443337490, 9487718090

13 M/s Anand Chemicals 3/ 60 A, Ghidambara nagar, Sankarnagar (PO) Ph: 2300348

14 L K C Enterprises

S.NO.165,Sankarankovil Street, Sethurayanpudur Tachanallur(P.O.), Cell no: 9443365495

15 Sri Ram Chemicals

337, Sankarankovil Road, Rasta Madavakurchi Post Tirunelveli Distt Cell no:9942662929

16 M/s Hari Lime Industries 306/1, Nariyuthu rastha Tirunelveli Cell no: 9994881888

17 Sri Dhanalakshmi Eneterprises 9/ 183 D Tenkalam Road Thalayuthu, Tirunelveli Cell no: 9443330637

18 United Chemicals

II/ 361-Sankarankovil Road, Rastha, Madavakurchi (PO) Tirunelveli Cell no: 9443972154

19 Ram Balaji Industries

397/2, Sankarankovil road, Madavakurchi village, Tirunelveli Cell no: 9843324499

20 ARCHEAN GRANITES

3/106 D Sankarankovil Road, Sethurayarpudur. Tirunelveli Cell no: 9443363077

21 Bathiya Enterprises 444/2A1 Madavakurchi Rasta, Tirunelveli Cell no: 9952795859

22 Natarajan Lime Industries

kangaikondan Village, opp: Abcoy Garden Sankarnagar Post -627357 Cell no: 9443190653

23 JPR Industries

1699/1 Opp: Abcoy garden Madurai road Sankarnagar (PO) Tirunelveli-627357 Cell no: 9842126699 Ph: 0462 - 2302067

74

24 Sri Sivasakthi Chemicals

346/1 Mangammal salai Madavakurchi, Rastha Manu Block, Nellai Distt Cell no: 9442021617

25 Sanah Chemicals

5/582/1, Thalaiyuthm Sankarnagar Post Tirunelveli - 627357 Cell no: 8903172111

27 M/s Mineral Industries Madavakurichi Rastha (keer Parai), Tirunelveli Cell no: 9843559659

28 M/s New Star Chemicals 336. A. Madavakurachi (PO) Rastha, Tirunelveli Cell no: 9843180151

29 Universal Colours 435 Sethurayarpudur. Tirunelveli Cell no: 9443363077

30 Cretacous Lime Industries 3/106D/1 Sethurayanpudu Tirunelveli Cell no: 9443353057

31 Arasan Chemicals 9/183 k Thenkalam Road Thalayuthu Cell no: 9965530488

32 Faizal Eneterprises 8/77 Middle Street, Thalayuthu, Tirunelveli Cell no: 9965530488

33 JRV Limes 190/1, Sankarankovil Rastha, Tirunelveli Cell no: 9442570090

34 Sri Ramakrishna Industries

181/A, Sankarankovil Road, Rasta,Madava Kurinchi Tirunelveli-627201 Cell : 9443367578

35 Bhathiya Enterprises 251/1, Rasta,Madava Kurinchi, Tirunelveli Cell: 9952795849

36 Mani Enterprises

334/1 SANKARANKIL ROAD, RASTHA,MANUR POST, TIRUNELVELI-627201 CELL : 9443130697

37 Lakshmi Minerals 235 Madurai Road, Gangaikondan, Paruthikulam. Cell:9443130575

38 R J Chemicals

102/2 Madhavakurichi Rastha Cell: 9443130870

75

39 Anand Chemicals

246/2, Sankarankovil Road, Madhavakurichi (PO) Rastha, Tirunelveli Cell:9842988566

40 S S Industrial Corporation 3/160A Chithapara Nagar, Sankarnagar, Tirunelveli Cell: 9842988566

41 Innovation India rubber and Chemical Private Limited

Thenkalam, Tirunelveli Cell:9842872377

42 Pradtheep Kumar Enterprises

354 Sankarankovil Road, Madhavakurichi (PO) Rastha Tirunelvali. Cell:9443156458

76

Annexure 2

Rajasthan Lime Manufacturers Association

S.No. Name & Address Key Persons Mobile No.

1 Aditya Chemicasl B-163, Near Circuit House, Jodhpur

Sh. Sudhir Moondra 94144-44222

2 Amar Chemicals Industries 58, Subhash Colony, Bhagat Ki Kothi, New Pali Road, Jodhpur

Sh. Daya Ram Choudhary 94141-95669

3 Ankur Mienrals (P) Ltd. E-54, Kunti Tower, 1st Floor, Kalpatru Shopping Centre, Shastri Nagar, Jodhpur

Sh. M. K. Pitti 98290-27207

4 Aziz Lime & Plaster Industries Gotan Road, Gotan

Mr. Mohd. Ali 94141-19159

5 Banzara Lime Products Panna Niwas, Ghantaghar, Jodhpur

Sh. Laxmi Narayan Banzara

92141-31000

6 Barunda Minerals (P) Ltd. 52/53, Shastri Nagar, Jodhpur

Sh. M. K. Kesri 94141-32405

7 Bera Chemical & Minerals 95-96, Rajiv Nagar, Sector 'A', Mahamandir, Jodhpur

Sh. Narayan Ram Bera 94141-29907

8 Golden Cement Pvt. Ltd. 12/33, Chopasni Housing Board, Jodhpur

Sh. Manchand Choudhary 94141-35024

9 Gotan Lime Stone Co. Jodhpur Tower (First Floor) Paota, Jodhpur

Sh. Ram Chandra Chauhan 94141-35822

10 Gotan Limes (P) Ltd. 77, Laxmi Nagar, Paota 'C' Road, Jodhpur

Sh. Ram Niwas Chauhan 99280-22511

11 Hari Chemicals Jodhpur Bilara Road, V & P Kaparda, Distt. Jodhpur

Sh. Ramu Ram Bishnoi 94141-26713

12 Jai Balaji Chemicals Pipar City, Jodhpur

Sh. Ram Vilas Chandak 94141-26725

13 Jangid Lime Industries Gotan, Distt. Jodhpur

Sh. Ramdeen Jangid 94141-18901

77

14 Jodhpur Lime Company New Power House Road, Industrial Area, Jodhpur

Sh. Bhanwar Lal Sh. Rajesh

93523-21865

15 Jyoti Chemicals C/O Laxmi Nath Mandir Pipar City, Jodhpur

Sh. Om Ji Sharma 94135-08719

16 Kartik Alkalies And Chemicals A-Ii, Riico Housing Colony, Beawar

Sh. Inder Singh Rathore

17 Lohia Mine-Chem Rakhi House, Jodhpur

Sh. O. P. Lohiya 94141-28615

18 Luxmi Chemicals Industries Near Mudit Mansion, Pal Link Road, Jodhpur Factory: Gotan, Borunda, Jodhpur

Sh. Brij Gopal Pitti 94141-45763

19 Mahadev Lime Products Pipar City Jodhpur

Sh. Ghanshyam Tiwari 94141-26371

20 Mahesh Chemicals Industries Pipar City - 342 601 Jodhpur

Sh. Shyam Sunder Mundra 94141-17932 94144-17932

21 Mahesh Lime Industries 15-C, Paota Road, First Polo, Jodhpur

Sh. Gopal Bang 93143-41978

22 Mahesh Lime (P) Ltd. Pipar City Jodhpur

Sh. Gokul Ram Choudhary 94149-88434

23 Malborough Polychem (P) Ltd. D-7, Shastri Nagar, Jodhpur

Sh. Ram Gopal Ji 94141-22532 9536601 (O)

24 Mantri Chemicals P. Ltd. Baghtawar Mal Ji Ka Bagh, Jodhpur

Sh. C. S. Mantri 94141-29917

25 Mayur Industries Residency Road, Jodhpur

Sh. Anil Daga 98290-21547

26 Mayur Inorganics Limited Residency Road, Jodhpur

Sh. Bhagwan Ji Daga 94141-26852

27 Mishra Lime (P) Ltd. H.No. 11/565, Chopasni Housing Board, Jodhpur

Sh. Nitin Mishra 93147-14354

28 Niki Chemical Industries F-414, M.I.A., Phase-Ii, Basni, Jodhpur- 342 005

Sh. Megh Raj Lohiya 98290-21825

29 Orient Chemicals Village: Jawasia Pipar City, Jodhpur

Sh. Vinod Ji Jain Sh. Jitu Sa Choudhary

94141-96421

78

30 Quality Chemicals E-99, M.I.A., Phase-Ii, Basni, Jodhpur-342 005

Sh. Surendra Gupta 93147-12111

31 Quality Chemicals & Allied Products Gotan

Mr. Allanoor Sunee 94133-69375

32 Raghav Lime Industries F-389 (D-1), M.I.A, Phase-Ii, Basni, Jodhpur

Sh. Suresh Joshi 94144-99152

33 Raj Chemicals & Minerals Plot No. 2, Jalam Vilas Scheme, Paota B Road, Jodhpur

Sh. Narpat Singh Rajpurohit

98290-26449 94140-77411

34 Ram Shyam Chemicals Anand, 32-A, Opp. K. N. College, Jodhpur

Sh. Ghanshyam Soni 98298-20620

35 Ransi Minerals (P) Ltd. Bhagtawar Mal Ji Ka Bagh, Chopasni Road, Jodhpur

Sh. C. S. Mantri 94141-29917

36 Shivam Chemicals 37-A/1, Ajit Colony, Jodhpur

Sh. N. K. Mundra 94141-31953

37 Shree Bajrang Lime Products Sh. Sanjay Agarwal 98290-20740

38 Shree Chemicals & Minerals V & P Jawasia Pipar City, Distt. Jodhpur

Sh. Gordhan Choudhary 94144-62732

39 Shree Ram Industries V & P Jawasia Pipar City, Distt. Jodhpur

Sh. Subhash Chand Soni 94141-95179

40 Shree Ram Lime Products (P) Ltd. 39/A, Dharam Narayan Ji Ka Hattha, Paota, Jodhpur

Sh. Om Prakash Lakhotia 98290-26421

41 Siddhant Chemical Pvt. Ltd. 49 & 50, Ashapurna Nagar, Near Delhi Pulic School, Jodhpur

Sh. Anil Agarwal 94141-34134

42 Sigma Mienrals Limited 4, Heavy Industrial Area, Jodhpur

Sh. S. N. Bhargava Sh. O. P. Phophaliya Sh. T. D. Boob

93147-09331

43 Srikant Minerals Pvt. Ltd. 302, Marudhar Kesri Apartment, Mohanpura, Jodhpur

Sh. Venu Joshi Sh. Kamal Mehta

98290-21913 98290-21224

44 Suraj Lime Industries Girdhar Bhawan, First B Road, Sardarpura, Jodhpur

Sh. Manohar Lal Tak 94141-32554

45 Tara Minerals & Chemicals 751, Umed Hospital Road, Near Geeta Bhawan, Jodhpur

Sh. Rakesh Boob 94141-32823

79

46 White 'N' White Minerals (P) Ltd. Jodhpur Tower, Paota, Jodhpur

Sh. Hari Prasad Agarwal 94141-26851

47 Clasic Hydra Chem 58, Kamla Nehru Nagar, Chopasni Road, Jodhpur

Sh. Ramesh Bang 98281-40848

48 Shree Lime Industries Sh. Harish Choudhary 94141-06999

49 Deepika Minerals & Chemicals Behind Mahalaxmi Sweet Home, Kamla Nehru Nagar, Jodhpur

Sh. Rinku Sehgal 94144-77818

50 Dhanlaxmi Industries Pipar City, Jodhpur

Sh. Dilkhush Choudhary 94141-45521

51 Special Lime Stone (P) Ltd. J-190, M.I.A., Phase-Ii, Jodhpur

Sh. Vishnu Jajoo 94141-28386

52 Kushal Chemicals (P) Ltd. Choudhary Sadan, Mandi Ka Bass, Pipar City, Jodhpur

Sh. Pukhsa Choudhary Sh. Rakesh Chodhary

94141-27665 94141-33849

53 Latiyal Lime Chem Jodhpur

Sh. Sharma Ji 94141-36663

54 Mahadev Mineral Pipar City Jodhpur

Sh. Mahesh Tank 94141-26536

55 Puja Minerals (P) Ltd. Jodhpur Tower, Paota, Jodhpur

Sh. Moti Lal Chouhan 94141-28406

56 Rama Enterprises Opp. Raj Hans Industries Extn. 7th, Nph Road, Jodhpur

Sh. Ram Narayan Khadav Sh. Amit Ji Sh. Atul Ji

94141-26867 94141-79456

57 Ravi Minerals Ransi Gaon, Jodhpur

Sh. Sunil Soni 94141-00743

58 Regal Chemicals Pipar City Jodhpur

Sh. Ajit Singh 98290-26326

59 Ridhi Sidhi Limes (P) Ltd. 21-A, Paota C Road, Jodhpur

Sh. Manish Gehlot Sh. Sanjay Surana

94141-26662

60 Shree Kishan Rani Gaon

Sh. Dharindhar Dadhich 94141-28767

61 Shree Ram Udyog Pipar City Jodhpur

Sh. Purshottam Ojha 94141-94872

62 Santosh Chemicals Jodhpur Tower, Paota, Jodhpur

Sh. Badri Chouhan 94141-30469

63 Rathore Lime Udyog, Borunda

Sh. Prem Singh Rathore 94144-40757

80

64 Pankaj Lime Products, Borunda

Sh. Hanuman Singh 94146-02664

65 Rishab Industries Pipar City

Sh. Prasan Raj Choudhary

66 Silver Line Minerals & Chemicals Jodhpur

Sh. Ram Swaroop Fadak 94141-28851

67 Marwar Chemicals & Allied Products Kamla Nehru Nagar, Jodhpur

Sh. C. P. Mishra 99283-83800 98290-25380

68 Khoja Lime Udyog Sh. Umed Ji Khoja 94141-32261

69 Kanhaiya Lal Gotan

Sh. Kanhaiya Lal 94141-34326

70 Sarvotam Chemicals Gotan

Sh. Deen Dayal Agarwal 94141-96164 230428 (O)

71 Bansal Lime Industries Merta City

Sh. Lal Chand Agarwal 94141-19045

72 Star Chemicals & Allied Products Gotan

Sh. D. R. Agarwal 94130-36714

73 S. R. Chemicals Khejarla

Sh. Padam Ji Banzara Sh. Bachhuji

94141-26599 94140-70446

74 Hari Om Enterprises Ransi Gaon

Sh. Kishan Ji 94141-23430 94602-15494

75 Shyam Lime Products Ransi Gaon

Sh. Radhey Shyam Sh. Mukesh Sh. Gopi Nath

98240-92822 99833-58338 98293-35205

76 Rajshree Chemicals Ransi Gaon

Sh. Chand Singh 94140-72686

77 Amrit Lime Ransigaon

Sh. Arjun Singh 98298-93174

78 Mansukhi Chemicals Ransigaon

Sh. Gopal Ji 98280-44620

79 Saraswati Hydrated Lime Sh. Mohan Singh Gwola 94141-24652

80 Devshree Lime Products Sh. Kamal Ji Dadhich 94141-76415

81 Hind Limes Jaitaran

Sh. Mohan Paliwal 02939-230240 (O)

82 Purnima Lime Industries Sh. Mahendra Ji 94140-71301

83 Balaji Lime Chemicals

Sh. Babu Ram Ji Sh. Hazari Ram Ji

94600-52689

84 Sh. Dharma Ram Tank 94141-44681

85 J. P. Lime Sh. Chothu Ji Dadhich 94141-35630

86 Sh. Mahendra Singh 94147-03997

87 Choudhary Lime Corporation Sh. Umed Raj Ji 94141-32738

88 J. B. Lime Merta Lime

Sh. Rusttam Bhai 94146-11082

89 Prince White Lime Sh. Rusttam Bhai 94139-26486

90 Suraj Mienrals (China Clay)

Sh. Suraj Ji Sh. Krishan Ram

94133-29541 94145-29925

81

Choudhary

91 Vishwakarma Udyog (China Clay)

Sh. Mohanlal Ji 94131-32090

92 Ganpati Lime Sh. Banty Ji 94146-02655

93 Mansukhi Lime

Sh. Srigopal Sharma Sh. Manji Datta

94613-52399 94141-01222

94 Hudda Lime 90018-67237

95 Megha Lime & Chemicals Sh. Mahendra Sanklecha 90290-24912

96 P. R. Chemical (P) Ltd. Sh. Ramratan Ji 94141-96841

97 Ishwar Chemicals Sh. Purohit Ji

94137-66351 94625-68551

98 Virendra Chemicals Ransigaon

Sh. Virendra Ji Bagra Sh. Om Prakash Ji

94141-07479 94141-07517 02930-202787 (F)

99 Goyal Chemicals Sojat

94141-23817

100 Bohra Chemicals Sojat

98290-23008

101 Dehradoon Calcium Minerals P. Ltd. Sh. Babu Lal Ji

94141-96839 2540550 (O)

102 Durga Lime Industries F-32, Riico Industrial Area, Mondoni, Jodhpur

Sh. R. S. Chouhan

98290-25811 0291-2577081 (O) 0291-2577079 (O) 0291-2577083

82

Annexure 3

Details of Local service providers & vendors for EE technologies at


S.No. Name of the company with contact person

details Address Contact No and Email

List of technology /services provided

1 Fluid Aire Technologies

Mr. Sampath Srinivasan

No. 1478, Golden Industries Area

Sriperumbudur

Chennai- 602101

Mobile: 09444068256, 09444140698

Energy Efficient Blowers

2 Air Tech Engineering

Mr. Narasimhan

15, 15-B, 6th West Street Nehru Nagar

Civil Aerodrome Coimbatore- 641014

Phone: 0422 – 2910825

Mobile: 09843052877

[email protected]

Energy Efficient Blowers

3 Sri Jagadish Products

Mr. Rajendran

No. 275/A, Sankaran Koil Road, Rajapalayam

Pin- 626117

Mobile: 09443132628 Pulverizer

4 Sri Ram Machinery Works

Mr. Venkatesh

146/G/2, Andalpuram, Chattrapatti Road, Rajapalayam

Pin- 626108

Mobile: 09843020937 Pulverizer

5 Manikantan Engineering Works

Mr. Pacchaiappan

Ombalur Main Road, Perumalmalai Adivaaram, Narasolpatti, Salem

Mobile: 09842744553

Crushers

6

GMAC Associates

40 & 41 Duraisamy Naidu lay-Out

Peelamedu, Coimbatore-641 004

Tamil Nadu

Telefax : +91 422 2567244

Mobile : +91 97906 41881,

+91 95009 41881

[email protected] [email protected]

Energy Efficient Motors& its Starters

7

Texmo Engineers

P.O. Box: 5303 Mettupalayam Road, Coimbatore - 641 029, Tamil Nadu, India

Phone : +91- 422 - 661 0300, 264 2620 Email:

[email protected]


8

Stark Industries

7-G, Kalapatti Road,

Coimbatore – 641035

Phone:+91-422-4033800, 4274661, 4274662, 6582490,2627909, 2628809

Fax:+91-422-4274661,4274662

[email protected]


9 Suguna Motors & 7-G, Kalapatti Road, Phone : +91 422 2223512 Energy

83

Pumps (Archana Industries)

Coimbatore – 641035

Mobile: +91 99444 79003

Fax : +91 422 2222097

E-mail:[email protected]

[email protected]

Efficient Motors& its Starters

10

Priya Electricals No. 220 Thiruvalluvar DGL, Madurai, 624001

Phone: 0452 – 2421480


11

Kutti & Kashi 103 Armenian St Chn -1

Tirunelveli - 627001

Phone: 0462-25341344


12 Sri Sankar Electricals & Motors

131 S N High Road, Tirunelveli - 627001

Phone: 0462 -2323026


13 Manikantan Engineering Works

Mr. Pacchaiappan

Ombalur Main Road, Perumalai Adivaram, Narasolpatti, Salem

Mobile: 09842744553

Conveyors

14 Nuberg Engineering Ltd.

Mr. Diganta Sahu

Nuberg House A - 38 H, Sector - 64 NOIDA - 201 301 (Uttar Pradesh)

Phone: 91 - 120 – 2403101/ 2403102 / 2403103

Mobile: 09310685846

Fax : 91-120-2403104

[email protected], [email protected]

Vertical Shaft Kiln with Biomass Gasifier Technology Supplier

15 Ujjawal Biotechnologies

Mr. Vikas Verma (Director) Dr. Alok Agarwal (Director)

7th km Stone, Janshat Road, Muzaffarnagar –251002

Uttar Pradesh, India

Mobile: 91-9760078652

Mobile: 91-9760011796


16 Chanderpur Works Pvt. Ltd.

Mr. S K Loomba

Jorian, Yamunanagr - 135 001 Haryana, India

Phone: 91-1732-203460 / 203461 / 203462

Mobile: 91-9891118533

Fax: 91-1732-203463


17 A. B. Engitech

Mr. B. K. Karnani

Director

Shri Kunj, A 16, Shastri Nagar, Jodhpur, Rajasthan - 342 003 (India)

Telephone:

+(91)-(291)-2612153

+(91)-9414131153

[email protected]


84

Annexure 4

Details of Local service providers & vendors for EE technologies at


Equipment suppliers/ Technology providers

Source of Product

Details of Local Vendor / Service Provider

Supplier of Energy Efficient pumps

Raj Pumps Pvt. Ltd.

Address: 9, Heavy Industrial Area, Jodhpur, Rajathan 342003 Telephone: 91-291 2740937 Fax: 91-291-2740905

Energy Efficient Motors Kirloskar Brothers Ltd and Vijay Agencies

Everest Traders & Engineers Private Limited,(Supplier of Energy Efficient motors) Bhandari Buildings, First A Road, Sardarpura Jodhpur 342003 Tel: +91 291 2434410, 2614461 Fax: +91 291 2438610 Mr. Jagdish Agarwal Opp Shiv Mandir, Jodhpur, Tel 07462-220678

Energy Efficient Motors, Automatic Power Factor Controllers, energy efficient lightings

Havells Mr. Sunil Kumar

Translucent Sheet

B.S. Fibres

Mr. Mahesh Khandelwal Plot No.G-890, Badharna Road No.14 VKI Area Jaipur, .09413837371

Improve plant power factor through APFC panel

ABB

Mr. Neeraj Verma Power Product SCO-13-14-15 Sector- 34A Chandigarh Phone: 0172-4321845 Telefax: 0172-2601618 Mobile: 09878613484 email: [email protected]

Energy Efficient Motors Bharat Bijlee Ltd

Mr. Rakesh Verma Sr. Manager – Marketing [email protected] 09871861872

Auto Power factor Controller

Neptune Mr. Manoj 09351328666

Epcos Mr. Jayant

Cont. No. 09829065472

Energy Efficient Kiln/Kiln Insulation

Arihant Refractories & Minerals

New Power House Road, IndustrialArea, Jodhpur - 342003 Tel: +91 291 2649281,2654580 Fax: +91 291 2649281 Contact Person: Mr. V S Porwal

Supplier of Energy Management,Energy

Madhav Enterprises

Q-5, Near Than Chand Mehta Building, Gole Building Road, Jalori

85

conservation, Industrial Process Control Automation

Gate Jodhpur Rajasthan -342001 Contact Person: Mr. Hari Singh Bhandari

Supplier of Energy Efficient motors

Everest Traders & Engineers

Bhandari Buildings, First A Road Sardarpura Jodhpur Rajasthan - 342003 Tel: +91 291 2434410, 2614461 Fax: +91 291 2438610

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Annexure 5

List of Energy Managers & Energy Auditors in Tirunelveli District

Regn No Name Fathers Name

Address for Communication Address1 Address2 Address3 City

Postal code E-mail

EM-0099

Ramasubramanian V

Velayutharaja M S 643, Thiruvananthapuram Street

Rajapalayam Virudhunagar Dist626117 Ramasubramaniam@ parry.murugappa.com

EM-0127

Santaji Nilkanth Jadhav

Nilkanth Govinda Jadhav

Hindustan Construction Co. Ltd.

KKNPP P.O.KudankulamTal. Radhapuram

Tirunelveli 627106 [email protected]

EM-0359

N Pandiyarajan A Nagamuthu Executive - Engg. Madura Coats Ltd. Centenary Mill Madurai 625009 [email protected]

EM-0505

A. Venkatesa Perumal

P. Arunagiri S/o P Arunagiri 25/795 C, 30th Street Shanthinagar Palayamkottai Tirunelveli 627002 [email protected]

EM-0559

P Poovalingam P Palani Manager (Production)

India Cements Ltd. Sankar Nagar Tirunelveli 627357 [email protected]

EM-0597

S Avudaiappan S Subramanian Plot No. 26 S.T.R. Nagar K.T.C. Nagar (Via)

Magaraja Nagar Post


EM-0338

K. Ayyalusamy A. Kasirajan 3/53, T. Karisalkulam

Alangulam Cements Post

Rajapalayam Via.

Dist. Virudhunagar

626127 [email protected]

EA-3506Ramkumar S. Sankaran

Sankaran S R 28, Ponmani Colony Maharaja Nagar Tirunelveli 627011 ram143752yahoo.com

EA-5949Murali R Rajaram V Block No. EF-4 Vajra Aprtments 202, Byepass Road

Madurai 625010 [email protected]

EA-3185C. Sathya Murthi Chelladurai P No.15 Bharathiyar 4th Streert

S.S.Colony Madurai 625010 [email protected]

EA-1626V R Muthukumar T Veerappan C/o S Lakshmanan No.2/504 Kurinji Street Thendral Nagar Gomathipuram Madurai 625020 [email protected]

EA-3480Singh Nimrana. S.P.

Yagya Narain Singh

O/o The Suptd. Engineer (E)

81, East Main Street Anna Nagar Madurai 625020 [email protected]

EA-2515Ram Krishnan R Raghavan T K V C-19 Madras Cements Colony

Ramasamy Raja Nagar

Virudhu Nagar Dist

626204 [email protected]

EA-2835Jawahar S Sudalaiandi C H-10, HIG Quarters Pothigai Nagar Perumalpuram PO


EA-1484Ramkumar S Sundaram K R 162A, New Colony Tuticorin 628003 [email protected]

EA-2150R Sowndararajan T Ramasubramaniam

Executive Engineer / Elec.

No.2/1, Type IV Quarters

Camp II Tuticorin 628004 [email protected]

2

EA-1915M Lakshmanan V Muthiah C-28, SPIC Nagar Muthiyapuram Tuticorin 628005 [email protected]

EA-0801Nallamuthu S. Sakkan Nair A-49 SPIC Nagar Tuticorin 628005 [email protected]

EA-2797Meiyappan N Nachiyappan M B-10, SPIC Nagar Muthiahpuram Tuticorin 628005 [email protected]

EA-3053Ukkirapandian .K Karuppana Thevar S

Joint Manager (Elect.)

M/s. TAC Ltd., Harbour Construction Road

Tuticorin 628005 [email protected]

EA-2109M Geevarghese T Mathen 22 D/2, Kongunagar Ramanathapuram Coimbatore 641045 [email protected]

EA-9243S.Kalidasan Sakkiah 296,3rd MIDDLE STREET

THIYAGARAJANAGAR TIRUNELVELI 627011 [email protected]

EA-9409R.Bharathidasan V.Ramasamy M1/31, SECTOR -4TNHB COLONY RAILAR NAGAR MADURAI 625018 [email protected]

EA-10113

R.Ramesh Babu T.K.Ranganathan C/O-Muthu Nagaraj M.S.K Bhavanam,3/2750-9,Thiruvallur Nagar

10th St,First cross,

Patinamkathan,Ramanathapuram623536 [email protected]

EA-10170

Ragupathi Balu TVS SRICHAKRA LIMITED

PERMALPATTI ROAD VELLARIPATTI MADURAI 625122 [email protected]

EA-11203

Sebestin Rajendran

Thangavel 24, R.C.STREET MUKKUDAL TIRUNELVELI 627601 [email protected]

EM-3165

Kannan Lakshmanan 2A- JAI NAGAR 3RD STREET

PONMENI BYE PASS ROAD

MADURAI 625010 [email protected]

EM-3279

A Selvakumar Alagarsamy K P.S.M Stores 95 Main Road Eruvadi Tirunelveli 627103 [email protected]

EA-10121

M.Malaiarasan M.Mariappan No: 80,KUMARAR STREET

TUTICORIN-2 TUTICORIN DISTRICT

TUTICORIN 628002 [email protected]

3

Annexure 6

List of Energy Managers & Energy Auditors in Jodhpur District

S No

Name Address Registration

No Contact No

1 Abhay Singhal 978, Umaid Hospital Road, Jodhpur-342003 R4//268, STPS Colony, PO:Suratgarh

EA-6450 9414502206/0291-2430946

2 Ajay Kumar Singh T-167 A, Railway D.S. Colony Jodhpur

EA-5681 9414918682 0291-2644781

3 Ajay Kumar Vijay 4-E-2, Talwandi Kota-Rajasthan EA-4574 9414227394

4 Alok Mathur "Alok Villa" , 17, Sector "A" Shastri Nagar Jodhpur Rajasthan

EA-1473 0291-2433207

5 Anil Singhal B-13, Anand Vihar, Sri Ganaga Nagar.

EA-3354 9413359742

6 Anoop K. Somani 10-I-36, Tilak Nagar, Bhilwara-311001

EA-3275 9414114420/01482-234094

7 Ashish Mathur 7/179, M.P. Nagar Bikaner -334001

EA-2666 0511-2253323 9214417402

8 Ashok K. Mathur "Badri Villas" A-239, Shastri Nagar, Jodhpur-342003

EA-1007 9413359033

9 Er. Kamal Kant Vyas C-174, Kamla Nehru Nagar, Jodhpur

EA-2968 9413661695/9413359121

10 Jitendra Jain Sh. Paras Chand Jian, 5/205 Roop Niketan Out side Agra, Ajmer (Rajasthan)-305001

EA-0009 0290-264314 02920-264448

4

11 Jitendra Jain 5/205, Roop Niketan, Outside Area Gate, Ajmer (Raj.) 305001

EA-0009 9829733383/0145-2428244

12 Kamal Kant Vyas C-174, Kamal Nehru Nagar Sector -1 Jodhpur-342009

EA-2968 0291-751442/9414915503

13 Lalit Soni 16, Karamchari Colony 8th Residency Road Jodhpur

EA-7600 9413359286 9414260996

14 Manish Sharma 32, Sardar Club Scheme Jodhpur-342011

EA5673 0291-2644670 9413359796

15 Naveen K. Bharara 17/399, Chopasani Housing Board, Jodhpur

EA-7099 9413359311/0291-2713548

16 Pankaj Pachoree Lane No. 7, Ashok Vihar Colony, Behind Nari Shala, Ajmer-305001

EA-0141 9414322640

17 Pradeep Arya 95, Central School Scheme Air Force Area Jodhpur-342011

EA-0347 0291-2611011 9414628506

18 Rajeev Sharma B-10, White Cement Works, Colony No. 1, PO: Gotan, Nagaur, (Raj.) - 342902

EA-5285 9414603151/01591-230213/01591-230929

19 Rajesh Goyal 171, Panchwati Colony B/H , Adarsh Nagar Railway Station Ajmer-305008

EA-4953

20 Ram Kishor Sani A-91, Ranjeet Nagar Alwar EA-3299 0144-2370025

21 Ram Niwas Bishnoi 2/955, Kudi-Bhagatasani Housing Board Basni Ph-1, Jodhpur-342005

EA-0582

22 S. Vikash Ranjan C-36, J.K. White Cement Works Colony No. 1, PO: Gotan, Distt, Nagaur, Rajasthan 342902

EA-5283 9414484995

5

23 Sunil Bohra 035, Brahm Bag, Nr. ACES Chemicals, Jalori gate, Jodhpur , Rajasthan

EA-9604 9413359291/0291-2617210

24 Sunil Choudhary 288, Laxmi Nagar PAOTA, B' Road Jodhpur

EA-7488 9413359292 9414133114

25 Tarun Singh Naruka 3/38, Saket Nagar Beawar. Distt. Ajmer

EA-1647 93526-41300 9413392941

26 Umendra Singh Chouhan 10, Man Mahal, Sher Vilash Air Force Road Jodhpur-342001

EA-3210 9829283440 0291-2512201

27 Veena Pareek Vyas Harnath Ram Kishan Out side of Sojati Gate Jodhpur Rajasthan

EA-3100 9414498937 0291-264997

6

Annexure 7

List of units Where Preliminary Energy Audit conducted in Limekiln Sector


S.No. Name of the Company Address Owner of the

Industry

1 Sri Lakshmi Lime Industries Quarry Road, Sankarnagar, Tirunelveli Cell no: 9360119209 S. Siva Kumar

3 Metro Coat Rajapalauam Pvt Ltd.

1699/ 3, Madurai road, Gankai Konan village, Sankarnagar,Tirunelveli, Cell no: 9360119209 S. Siva Kumar

4 Bharathi Chemicals Bharthi Chemicals, 351/A, Madhava Kurinchi Road, Tirunelveli I. Raj

5 BGS Chemicals 184/2,Saankaran Koil Raod, Sethurayan pudur. Cell:9443403282, 9486066666

B. Gowriah G.B. Subash

6 Uthra Enterprises 334, Sankarankovil road,Rastha, Manur post – 627201, Cell no: 9443130697 T. Vanaselvi

7 Saranva Chemicals 2/339-A, ,Sankarankovil Road, Madava Kurinchi, Rasta, Cell:9443473510

K. Gomathi Nayagam

8 L K C Enterprises

S.NO.165,Sankarankovil Street, Sethurayanpudur Tachanallur(P.O.), Cell no: 9443365495

P.Seenthamarai Kannan

9 Archean Granites 3/106 D Sankarankovil Road, Sethurayarpudur. Tirunelveli, Cell no: 9443363077 T. Mathimaaran

10 JPR Industries

1699/1 Opp: Abcoy garden, Madurai road, Sankarnagar (PO) Tirunelveli-627357 Cell no: 9842126699,Ph: 0462 - 2302067 N. Ravinthiran

11 M/s Mineral Industries Madavakurichi Rastha (keer Parai), Tirunelveli Cell no: 9843559659 A. Kasi Babu

7


S No Company Production Capacity

1 Ankur Minerals Private Limited 100 TPD

2 Rajasthan Lime Company 40 TPD

3 Bansal Enterprises 90 TPD

4 RK Lime Products 106 TPD

5 Choudary Lime Corporation 30 TPD

6 Choudary Lime Chemicals 32 TPD

7 Jetli Minerals 68 TPD

8 Ganesh Lime 90 TPD

9 Shriram Lime Products Pvt Ltd 91 TPD

10 Jai Balaji Minerals Pvt Ltd 84 TPD

8

Annexure 8

Comparison of various technologies in Jodhpur limekiln cluster

S.No Technology Name Size of the kiln Source of Energy

Required Peat Coke Consumption

Specific Energy Consumption (SEC)

1 Vertical Shaft Kiln, Non- mechanized material handling

Lime production capacity of 10 tons/day and 15 tons/day

Pet coke 170-180 kg of pet coke / tonne of quick lime 1200 kCal/Kg of quick lime

2 Vertical shaft kiln along with hydration unit, Non- mechanized material handling

1. Lime prouction capacity of 10 tons/day and 15 tons/day. 2 Hydration Capacity 6 tons/hr - 8 tons/hr

Pet coke and electricity

170-180 kg of pet coke / tonne of quick lime

1200 kCal/Kg of quick lime 13-14 kWh/ton of hydration

3 Vertical shaft kiln along with hydration unit, semi mechanised material handling

1.Lime prouction capacity of 10 tons/day,15 tons/day and 20 tons/day. 2. Hydration Capacity 6 tons/hr - 8 tons/hr

Pet Coke and electricity

170-180 kg of pet coke / tonne of quick lime

1200 kCal/Kg of quick lime 17-18 kWh/ton of hydration

4 Producer Gas based Vertical Shaft Kiln

Lime prouction capacity of 20 tons/day,30 tons/day and 50 tons/day. Coal/biomass,

electricity 190-195 kg of coal/ tonne of quick lime 950 kCal/kg of quick lime

Note:

Calorific Value of pet coke - 7000 kCal/kg Calorific Value of Coal - 5500 kCal/Kg

Manual for Training Energy Professionals in Limekiln Sector

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