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Second stage energy conservation experience with a textile industry
ARTICLE IN PRESS
Energy Policy 33 (2005) 603–609
Second stage energy conservation experience with a textile industry C. Palanichamya,*, N. Sundar Babub a
Department of Electrical and Electronic Engineering, Sultan Saiful Rijal Technical College, Simpang 125, Jalan Muara, Brunei BB 2313, Brunei Darussalam b Drexel University, Philadelphia, PA 19104, USA
Abstract The Indian textile industrial sector is one of the oldest industrial sectors in the country, which is also energy intensive. It is currently undergoing several studies to reduce its energy consumption and hence energy conservation (EC) in this context offers an excellent opportunity. This paper, at the beginning, addresses the experiences of the authors with a textile industry, which has already carried out some fruitful EC measures. Then it highlights the EC potential availability and suggests some practicable environmental friendly EC policies suitable for the Indian context to achieve the estimated potential, and finally it highlights the Government’s role in the EC endeavour. r 2003 Elsevier Ltd. All rights reserved. Keywords: Energy conservation experience; Textile industry; Potential availability; Energy conservation policy suggestion; Government’s role
1. Introduction The Indian textile industrial sector is energy intensive (ADB, 1999; Palanichamy et al., 2001, pp. 340–345) consuming nearly 3.0 million tons of coal, 0.6 million tons of furnace oil, 0.2 million tons of high-speed diesel and 5000 million units of power in the organised sector alone. In view of the liberalisation in India and the necessity to compete with modern textile industries (ADB, 1999; UNIDO, 1992) of countries, such as China, Korea, Japan, etc. in the international market, there is a remarkable need to reduce the production cost. At present prices, even a 1% reduction in energy consumption could mean substantial savings annually. The authors’ experiences are with a privately owned medium size spinning and sewing thread industry in Tamilnadu state, producing 15 tons of yarn and 10 tons of sewing thread/day. The industry considered is a hightension consumer, receiving electricity from the State Electricity Board (SEB) under Tariff I. The permitted Maximum Demand is 3250 kVA, and the Sanctioned Demand is 2600 kVA. The electrical energy consump*Corresponding author. Tel.: +673-2344717; fax: +673-2343207. E-mail addresses: [email protected] (C. Palanichamy), nsb25@ drexel.edu (N. Sundar Babu). 0301-4215/$ - see front matter r 2003 Elsevier Ltd. All rights reserved. doi:10.1016/j.enpol.2003.09.004
tion is 58,250 kWh/day, the steam requirement is 0.6 tons/h, and the furnace oil requirement is 1000 l/ day. The industry has already undergone energy conservation (EC) measures (called the first stage) during the financial year 1998–1999. Some of the earlier measures carried out are: Running parallel cables, Change of motor connections, Power factor improvement, Introducing energy efficient motors, Efficient lighting systems, and Peak shaving. Such measures resulted in a saving of 18.23% on the electricity cost, and an attractive benefit/investment ratio of 61.29% during the first year itself. The successful first stage EC measures encouraged the industry and made them to go for further (called as the second stage) measures as presented in this paper. This paper initially addresses the second stage EC experiences of the authors; later it highlights the EC potential availability and suggests some practicable environmental friendly EC policies suitable to the Indian context, and finally it points out the Government’s role in the EC endeavour.
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2. Second stage EC experience 2.1. Audit outcome The EC team, through second stage energy audit noticed that, the first stage EC involved only measures of conserving electrical energy, which brought down the electrical energy consumption to 47,630 kWh during 1999–2000. As the next stage of EC, the management of the industry is further interested only in conserving electrical energy, and if at all is there any possibility of conserving energy in other forms, the industry wanted to reserve such measures as the third stage of conservation. Since EC has been already carried out, the EC team had a hard time to identify the areas for further electrical EC. However, it identified the following areas for further EC after studying all the loads irrespective of their capacities: * * * * * * *
Computer loads; Building insulation; Introducing natural lighting; Motor belts; Change of spindle tapes; Steam use in place of electrical energy and Renewable energy in place of conventional energy.
2.2. Energy saving from computers loads The EC team felt that there would be a possibility of conserving energy by properly changing the computer usage culture (Chan et al., 1997) and hence the team conducted a survey regarding the number of computers in use, the hours of operation of each computer, and the user’s practice. There were 23 PCs, 4 Laser Printers, and 4 Scanners available for use. Fifty-five persons (both clerical and technical) were found to be capable of using the computers. The users had different practices like switching on all peripherals like printer, scanner, etc.
at the same time they turn their computers on, and seldom shut down the computers when they were away for 30 min or longer, etc. Such activities resulted in higher energy consumption. The EC team carried out the following activities in order to conserve energy: *
*
*
*
*
To change their habit of switching on the computer peripherals equipment as soon as they enter the office every day. To switch on peripherals like a laser printer only when one is ready to print. To switch off computer monitors while they are away. Security guards were instructed to switch off the computer power supply after the working hours and on holidays. Automatic Power Management System (APMS) designed to switch off computers and peripherals after a certain period of inactivity has been introduced.
The benefits of EC by changing the computer usage culture are given in Table 1. 2.3. Conservation through building insulation The industry is around 30 years old. Computers were introduced along with air conditioners without renovating the buildings. It has 27 numbers of 1.5-ton capacity air conditioners. Except 7, remaining 20 were used for the computer rooms environment. The rooms were maintained at an operating temperature of 24 C always irrespective of the changing seasons. The south and west facing walls are having an area of 1688 square feet. The windows are of single glass type and the total area is found to be 700 square feet. The EC team felt that changes in the windows glasses and additional insulation to south and west facing wall areas would result in reduced cooling load of the
Table 1 Energy saving, saving in energy cost, investment, and payback period Measures
Saving in electricity consumption
Net annual saving in electricity cost ($)
Investment ($)
Payback period (months)
kWh/yr
kWh/ton
Computer loads Building insulation Natural lighting Flat belts Sandwich tapes Steam heating: (a) Canteen use (b) Wax melting
19,116 61,600 82,320 76,667 768,000
2.30 7.40 9.89 9.21 92.25
1673 5390 7203 6708 67,200
2875 8450 12,330 4140 51,840
21 19 21 8 10
400,000 16,650
48.05 2.00
18,200 557
1065 750
1 17
Total
1,424,353
171.10
106,931
81,450
ARTICLE IN PRESS C. Palanichamy, N. Sundar Babu / Energy Policy 33 (2005) 603–609
buildings. Since all the windows are of single glass type, the EC team recommended replacing them by double glass—0.5-in space windows. Also for the south and west facing walls, R-13 insulation has been recommended since it has high resistance to heat flow. Automatic door closers were suggested for the doors. All recommendations were carried out with drivable care. Due to the modifications of the window glasses and wall insulations of the general-purpose and the computer rooms, there was sufficient energy saving as shown in Table 1. 2.4. Saving through natural lighting The existing roof-structure of the spinning and sewing floors were made up of asbestos sheets. During recent years transparent lite-roof has become very popular since it provides adequate amount of lighting depending upon the area of usage and in some cases it provides natural heating too. The EC team felt that replacing some of the asbestos sheets by transparent lite sheets would result in more lighting because of its wider angular coverage of sunlight. The EC team made a special design to control natural lighting and heating at all seasons of the year. A single asbestos sheet has been cut into two equal halves. One half is replaced by means of transparent lite sheet and it has been permanently fixed with one of the cut halves of the asbestos. It forms one full-modified sheet, which has half asbestos and half transparent sheets. This sheet provides sufficient amount of natural lighting and heat and however it does not provide any control for the light and heat. In order to achieve such a control, the other cut half of the asbestos sheet has been fixed with the modified sheet with a parallel sliding mechanism. The slide travels over the transparent sheet and it can partly or fully cover the transparent portion of the modified sheet. The travel of the slide is electric motor operated and the motor operation is automatically controlled by means of light and heat sensors provided in the working floor. The microprocessor-controlled sensors can be set to the required amount of light and heat needed. By this way, the natural light and heat can be controlled during the different seasons of the year. It has been recommended to replace one asbestos sheet for every four asbestos sheets in a uniform fashion by the modified sheet with sensor control. The light sensors are set to a lighting level of 250 lux such that there are no safety problems, and also no reduction in productivity. The sensors switch on sufficient artificial lighting when the natural lighting is less than 250 lux. By experimentation, no safety problems and reduction in productivity are noticed due to the warming up of the lamps, which are switched on under insufficient natural lighting conditions. The benefits of EC by natural lighting are given in Table 1.
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2.5. Conservation through flat belts There were many motors in the spinning floors of different kW capacities, exhaust fans, and compressors running with V-belts. The EC team observed that with V-belts, the efficiency for power transmission was found to be low as high frictional engagement exists between the lateral wedge surfaces of the belts and hence higher power consumption for the same amount of work to be done by the load. V-belts contain higher bending cross section and large mass, which cause higher bending loss. Also, as each groove of the pulley contains individual V-belt, the tension between the belt and the pulley distributes unevenly which causes unequal wear on the belt. This leads to vibrations and noisy running and hence reduces power transmission further. The consequences could be bearing damage also (See-Tech, 1999). In order to improve the efficiency of power transmission, to reduce the wear and tear on the belts, and to reduce the damages of the motor bearings, the EC team recommended replacing the V-belts of all the motors with Flat belts. With these Flat belts, the frictional engagement is on the outer pulley diameter only, which can typically save around 5–10% of the transmitted energy. Due to the introduction of Flat belts in place of V-belts, there was sufficient energy saving as shown in Table 1. 2.6. Synthetic sandwich tapes for spinning frames The Coimbatore (India)-based company (Habasit Iakoka Pvt. Ltd. 2000), an Indo-Swiss joint venture company, is the largest manufacturer of synthetic sandwich spindle tapes in the world, enjoying 70% of the global market. The tapes are made of polyamide, cotton yarn and a special synthetic rubber mix. The sandwich tapes have characteristics like stable running, good dimensional stability, no breakage, less weak-twist yarn, no fibre sticking, and soft & flexible tape bodies. Because of the special characteristics, these tapes offer 5–10% energy saving. Recommendations were made to replace the cotton tapes by the Habasit synthetic sandwich spindle tapes for all the 96 ring frames. The benefits of such modification are shown in Table 1. 2.7. Steam heating in place of electrical heating The textile industry runs a Canteen to provide food and drink to staff and workers at subsidised price. Steam vessels were mainly used for the food preparation. Steam was produced by a boiler fitted with a 50 kW heating element. Electrical energy was the input for the boiler and the boiler was found to be working for about 8000 h in a year. The existing boilers are of sufficient capacities to produce additional steam of 120 kg/h. Usage of steam at
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70 kg/h from the main boiler house has been recommended for the cooking purposes. The electrically operated boiler has been dismantled from the service. Such a conservation measure resulted in 100% return on investment with a payback period of 1 month as shown in Table 1. 2.8. Steam for wax melting From the energy audit, the EC team identified that electrical heating was used for the purpose of melting wax. The power rating of the heating element used is 5 kW and the heating element was found to be working for about 10 h/day. The EC team recommended steam heating in place of electrical heating. Additional connection for the supply of steam at 9 kg/h from the main boiler house has been suggested for wax melting. Due to the introduction of steam for wax melting in place of electrical heating, there was sufficient energy saving as shown in Table 1. 2.9. Introducing renewable energy systems In India, among many matured renewable energy technologies, wind energy systems (WES) have experienced significant commercial market development over the past decade (TEDA, 2001), taking advantage of the combination of tax incentives, favourable utility power purchase agreements, and banking the generated power at 2% commission, etc. The EC team recommended the management to invest on WES of 1 MW capacity at Kayathar sites (in Tamilnadu state), which are having a mean wind speed of 8 m/s. Such an option provides clean energy for the industrial need at a cheaper price, room for sale of excess energy to the Government at attractive buyback rates, and banking the generated energy. For the concerned textile industry, the sanctioned power demand is 2600 kVA, and the energy from WES is expected to meet around 15% of the energy demand of the industry. Since energy from WES is not constant, the total energy demand of the industry could be planned such that whatever generation is available from WES should be used and the deficit in energy demand should be derived from the State Electricity Board’s grid. The estimated cost of electricity generation during the first year is found to be $ 0.06/kWh and the cost of generation during the subsequent years will be considerably reduced due to the repayment of the loan. The return on investment will be around 14% per annum. 2.10. Benefits overview Table 1 provides the consolidated benefits of the second stage EC activities except the benefits of the proposed renewable energy system. Due to these EC
measures, a specific electrical energy saving ranging from 2.00 to 92.25 kWh/ton has been achieved. It resulted in a total saving in annual electricity consumption of 1.424353 million kWh, which is found to be 7.87% of the annual electricity consumption. The investment is found to be 0.081450 million dollars and the net annual saving in electricity cost are estimated as 0.106931 million dollars. The average specific electricity consumption/ton of the textile product has been reduced by 171.10 kWh/ton. The payback period of all the measures is less than 2 years, which is a very attractive figure for the investor. In addition to energy saving, an annual reduction of 311.12 tons of carbon, 9.62 tons of SO2 and 3.72 tons of NOx are estimated as environmental benefits. The introduction of WES also offers saving in electricity cost. The net quantity of electricity available per annum is 2.45 million kWh. Usage of electricity from WES results in a saving of $ 67,375 during the first year itself. However, the capital investment for the WES is 0.85 million dollars, which is quite a high value compared to the other EC measures carried out. The payback period for the WES is estimated as 6–7 years. This is a long-term investment, which offers continuous benefits for about 20 years.
3. Practicable EC policies The industrial sector in India continues to be the largest commercial energy consuming sector using up to 52% of the total commercial energy produced in the country. The Indian industries are found to be highly energy-intensive and its energy-GDP ratio is determined to be 50–60% higher than developed nations. In synthetic fibres & textiles, paper, chemicals, foundries, steel, and cement industries, the energy costs account for about 15–20% of the total production costs. However, during recent years, due to the swift expansion of nonenergy-intensive industries and implementation of modern energy efficient technologies and EC measures resulted in reduced commercial energy-intensity compared to previous years. Still there is substantial scope for EC in major industries like textiles, chemicals and paper & pulp, aluminium, and iron & steel industries. It has been estimated that (Nadarajan, 2002) over 5–8% saving is possible simply by better housekeeping and another 8–15% by development of co-generation facilities, introducing renewable energy policies, improved capacity utilisation, and industrial heat & waste management. The industrial EC potential works out to be 14500–15500 MW, which equals around 15% of the total generating capacity of the country. In this section, some practicable policies are suggested to achieve a major portion of the said target with environmental benefits.
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3.1. Tightening co-generation policy One of the potential sources of environmental friendly power generation is industrial co-generation. Co-generation is the combined generation of process heat and electric power by the sequential use of energy from a common fuel source. It is an energy-efficient and environmental friendly technology that utilises the exhaust heat from the steam turbine for process heating. Though the overall installed generating capacity of the Indian Power Sector is 10,4101.7 MW as on 30th April 2002, it experienced a maximum demand shortage of 16.9% during the financial year, April 2001–March 2002 (Central Electricity Authority, 2002). Inadequate financial investments by the central and state electricity sectors and huge amount of transmission power losses are the major barriers for the generation-demand mismatch. By industrial co-generation, there is no financial burden on the Central and State government electricity sectors because the industries opting for cogeneration facilities themselves meet out the financial requirements, and the transmission power losses are substantially reduced because the energy generated is mostly utilised where it is being produced. Though the captive power installed capacities has a significant magnitude of around 20% of the installed generating capacities, the growth of co-generation so far has reached to a maximum of only 5% of the total installed generating capacities. One of the major barriers for the development of industrial co-generation has been the issue of Central–State jurisdiction. In order to heighten industrial co-generation, it is suggested that both Central and State governments should have a common amicable policy on industrial co-generation and also cogeneration should be made as mandatory for industries like sugar, fertiliser, steel, cement, paper, man-made fibre, and chemical/petrochemical industries of contracted demand above 500 kVA. Apart from captive use, energy produced through co-generation shall be permitted for third-party sales. In that case, the policies for wheeling, banking, third party sales, support for evacuation arrangements and assurance for payments are the key areas that need to be strengthened. By making co-generation as mandatory for industries and permitting third-party sale of excess power, brings about 8500– 9000 MW of power that could be further generated. 3.2. Updating renewable energy policy The depletion of the reserves of fossil fuels and the present rate of excessive fossil fuel consumption together with the global warming gave a new thrust and importance to renewable energy sources. India is sanctified with abundant renewable energy in different forms like solar, wind, tidal, etc. Among the renewables, the importance of power generation from wind energy
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was realised during 1985–1990 and today, power generation from wind has emerged as one of the most successful programmes, making a meaningful contribution to bridging the gap between supply and demand for power. The Ministry for Non-Conventional Energy Sources (MNES), the Indian Renewable Energy Development Agency (IREDA) Ltd, and the State Nodal Agencies has been playing a significant role in promoting wind power projects. India has a gross wind power potential of 45,195 MW, and a technical potential of 13,390 MW. As on March 2003, an installed capacity of 1869.5 MW (Ministry of Non-Conventional Energy Sources, 2003) has been established and out of which 1804.7 MW (96.5%) was from private sector investments. In order to further enhance the renewable energy investments, for new high-tension industries to be established, while licensing for grid electricity to use, the government shall insist for at least 10% of the industries’ sanctioned demand from renewable energy sources. If such a policy were introduced, according to the authors’ estimate, by 2005 there would be an additional installed wind farm capacity of 2625 MW apart from the forecasted growth. For existing industries those seeking enhanced sanctioned demand, 25% of the additional demand should be from renewable energy sources. Such 10% and 25% renewable energy demand charges are naturally exempted from payment to the state utilities. 3.3. Setting standards for specific energy conception The Bureau of Indian Standards (BIS) is responsible for setting standards for manufacturing, operational practices and related areas in the country. Apart from standards, BIS has also laid down guidelines for selection of energy efficient equipments, guidelines for system design and proper matching of components, and codes of practice for proper equipment installation and maintenance. But as on today no policy has been laid on specific energy consumption for key products by different industries. For example, for Spinning and Sewing Thread industries, the average specific energy consumption for producing 1 ton of yarn by Indian industries is found to be 2400 kWh. This value is much higher compared to developed countries, and it needs to be reduced. So BIS should able to set a standard for the specific energy consumption for textile industries based on the international standards and the Indian context. On this basis, the specific energy consumption shall be set to 1900 kWh/ton. Likewise for energy-intensive industries like chemicals, paper & pulp, aluminium, and iron & steel industries, etc., BIS should able to set specific energy consumption standards. As a guideline, by 2005, the specific energy consumption per ton of steel for medium and large-sized iron and steel enterprises shall be set to 0.8 ton of standard coal. Coal
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consumption by thermal power stations shall be set to 0.380 kg standard coal/kWh. The energy consumption for non-ferrous metals per ton of product shall be set to 4.5 tons of standard coal, and the energy consumption for large-sized synthetic ammonia shall be set to 37 GJ, etc. Such a new policy not only helps in reducing the production cost of the commodities but also reduces the damages to the environment. To enforce the specific energy consumption standard, the following practice could be adopted in case of electrical energy consumption. Industries consuming more than the set standard would be cautioned to reduce the specific energy consumption within a stipulated time period. If the same situation continues even after cautioning, there would be a penalty on the excess energy consumption charges by the electric utilities. The penalty charges shall be worked out based on the expected environmental damage caused by the excess energy consumption. Likewise for other energy forms, realistic practices could be formulated. If such a policy were practiced, there would be a saving of around 20% in the electrical energy consumption alone. 3.4. Electrical power demand approval policy The policy for sanctioned (or contracted) demand for industries is generally based on the connected load details submitted by the industries. Industries always demand for higher sanctioned demand anticipating the future growth in electrical demand. The policy for approving the sanctioned demand shall be on the basis of the quantity of daily commodity production, the industry working hours per day and the specific energy consumption standard set by BIS. An additional 10% shall be added to that to get the figure for the sanctioned demand. So the industry will be sanctioned to the figure as arrived at and not as it requested. For example, a textile industry seeks 3500 kW of maximum demand. If its daily yarn production is 25 tons and it works on 3 shifts with 8 h per shift, assuming the specific energy consumption standard set by BIS as 1900 kWh/ton of yarn, then the electrical load demand would be 1980 kW (25 1900/24). Adding 10% on the calculated figure, the sanctioned demand would be around 2200 MW though the industry asked for 3500 MW. Such a policy on approving the contracted demand forces the industries either to improve the performance of their machines or change in production processes and or incorporating energy efficient machineries in case of replacements, and also it gives room for financial saving by reduced demand charges. 3.5. Introducing ration for fossil-fuels Power cuts and load shedding by electric utilities are very common in India. Mostly Indian industries make
use of diesel-generator sets for back up power supply. Most of the diesel-generator sets are old and their fuel consumption is found to be very high and they are mostly operating under part load conditions. Hence their efficiency is low and the pollution level is found to be higher. In order to reduce fuel consumption as well as pollution, either new diesel-generators are to be added or the existing ones need to be renovated. For industries failing to do so, a ration on the sale of diesel shall be introduced. The quantity of permissible fuel ration shall be based on the normal efficiency of diesel-generator sets and the expected duration of utility power cuts and load shedding. 3.6. Load management Industries shall be asked to have different shift timings so that the peak load on the utility grid will be reduced, which results in benefits like less burden on the utility generators, reduced transmission losses, improved load factors, etc. Also load levelling within the industries itself helps in energy saving. State utilities could implement these policies and monitor the outcome during the time of monthly energy consumption recording.
4. The role of the governments The State as well as the Central governments shall formulate policies for implementing the suggestions as discussed earlier. Apart from that it can have few additional norms to promote EC in terms of technology and incentives. (i) Purchasing the products for government and public sector needs only from industries successfully adopting EC policies. (ii) Introducing energy efficiency standards for key industrial energy-consuming equipment such as industrial boiler, transformers, air-conditioners, electric motors, fans, pumps, and lighting, etc. (iii) Providing technological basis for replacing industrial commodities with high-energy consumption and implementing energy-saving product certification and energy efficiency identification system. (iv) Readjusting the industrial structure and the product mix, and transforming traditional industries with high and new technologies, and increase the added value of products. (v) Introducing product labels—information like expected lifetime, average energy consumption, operating efficiency, and pollution level shall be specified on product labels. (vi) Interest free loan facilities to procure energy efficient machineries or soft loans.
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(vii) Introducing mandatory renewable energy sources as a part of their sources of energy and providing 100% depreciation on the investment for the first year. (viii) Making industrial energy audit compulsory. (ix) Policy for introducing Time of the Day metering for industrial consumers for better load management. (x) Cash prizes worth of certain percentage on the amount of energy saved charges. (xi) EC awards every year for different types of industries. (xii) Providing tax benefits and tax holidays for industries successfully implementing EC and introducing tax burden for products with higher energy consumption.
5. Conclusions In this paper, the EC experiences of the authors with a textile industry were presented at the beginning. Conservation measures like equipment operational changes, building structural modifications, changes in machinery accessories, steam heating in place of electrical heating were adopted, which resulted in a reduction of 171.10 kWh/ton of the textile product, and an estimated annual reduction of 311.12 tons of carbon, 9.62 tons of SO2 and 3.72 tons of NOx as environmental benefits. Then the EC potential availability has been highlighted. Following that practicable EC policies for the Indian context have been suggested. Finally, the role of the government in terms of formulation of norms, setting up of standards, and promotional EC incentives has been pointed out. References ADB, 1999. Government of India & Netherlands: ADB Energy Efficiency Support Project. http://www.energyefficiency-cii.com/.
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Chan, A., Siu, W., Li, D., Wong, F., 1997. The Role of Computers in Energy Consumption on Campus. A report prepared by the 1996/ 97 ENV421 H course in the Division of the Environment at the University of Toronto. Central Electricity Authority, 2002. Regional Electricity Boards Report of year 2002, Sewa Bhavan, R.K. Puram, New Delhi. Habasit Iakoka Pvt. Ltd, 2000. Power Transmission Belts and Conveyor Belts in India. http://www.habasitiakoka.com/. Ministry of Non-Conventional Energy Sources, 2003. Government of India—Annual Report 2002–03. Nadarajan, C., 2002. Market for Energy Conservation in India’, Magnum Power, India—Report. Palanichamy, C., Nadarajan, C., Naveen, P., Sundar Babu, N., 2001. Budget Constrained Energy Conservation—An Experience with a Textile Industry. IEEE Transactions on Energy Conversion 16 (4) 340–345. See-Tech, 1999. News for Energy Conservation & Industrial Safety— Conserve Our Essential Companion. Energy & Environment, (1) (Internet Edition), India. http://www.letsconserve.com/newsletter. htm. TEDA, 2001. Tamilnadu Energy Development Agency—Policy Note: 2000–2001. http://www.tn.gov.in/policy/tedapol-e.htm. UNIDO, 1992. Handy Manual of Output of a Seminar on Energy Conservation in Textile Industry. Prof. C. Palanichamy was born in Tamilnadu, India. He received the B.E., M.Sc.Engg. and Ph.D. degrees in electrical and electronic engineering in 1976, 1979 and 1991, respectively, from Madurai Kamaraj University, India. Currently, he is with the Ministry of Education, Brunei Darussalam. In 1979, he began his academic career in India, followed by Iraq and Malaysia. His areas of interest include economic operation of power and energy systems, electrical building services and building automation, renewable sources of energy, energy conservation and software development for power system applications. He has authored three books on electrical and electronic engineering. Dr. N. Sundar Babu was born in Tamilnadu, India. He received his B.Sc. degree in 1992 and M.Sc. degree in applied chemistry in 1994, from Madurai Kamaraj University, India and Ph.D. from University of Malaya, Malaysia in 2000. He is currently working as a scientist with Drexel University, Philadelphia, USA after his post-doctoral research. He is an active researcher and has published many research papers in leading national and international journals. Apart from his areas of specialization, he developed keen interest in inter-disciplinary areas like energy storage systems, renewable energy systems, and real-time simulations of engineering tasks.
Energy Policy 33 (2005) 603–609
Second stage energy conservation experience with a textile industry C. Palanichamya,*, N. Sundar Babub a
Department of Electrical and Electronic Engineering, Sultan Saiful Rijal Technical College, Simpang 125, Jalan Muara, Brunei BB 2313, Brunei Darussalam b Drexel University, Philadelphia, PA 19104, USA
Abstract The Indian textile industrial sector is one of the oldest industrial sectors in the country, which is also energy intensive. It is currently undergoing several studies to reduce its energy consumption and hence energy conservation (EC) in this context offers an excellent opportunity. This paper, at the beginning, addresses the experiences of the authors with a textile industry, which has already carried out some fruitful EC measures. Then it highlights the EC potential availability and suggests some practicable environmental friendly EC policies suitable for the Indian context to achieve the estimated potential, and finally it highlights the Government’s role in the EC endeavour. r 2003 Elsevier Ltd. All rights reserved. Keywords: Energy conservation experience; Textile industry; Potential availability; Energy conservation policy suggestion; Government’s role
1. Introduction The Indian textile industrial sector is energy intensive (ADB, 1999; Palanichamy et al., 2001, pp. 340–345) consuming nearly 3.0 million tons of coal, 0.6 million tons of furnace oil, 0.2 million tons of high-speed diesel and 5000 million units of power in the organised sector alone. In view of the liberalisation in India and the necessity to compete with modern textile industries (ADB, 1999; UNIDO, 1992) of countries, such as China, Korea, Japan, etc. in the international market, there is a remarkable need to reduce the production cost. At present prices, even a 1% reduction in energy consumption could mean substantial savings annually. The authors’ experiences are with a privately owned medium size spinning and sewing thread industry in Tamilnadu state, producing 15 tons of yarn and 10 tons of sewing thread/day. The industry considered is a hightension consumer, receiving electricity from the State Electricity Board (SEB) under Tariff I. The permitted Maximum Demand is 3250 kVA, and the Sanctioned Demand is 2600 kVA. The electrical energy consump*Corresponding author. Tel.: +673-2344717; fax: +673-2343207. E-mail addresses: [email protected] (C. Palanichamy), nsb25@ drexel.edu (N. Sundar Babu). 0301-4215/$ - see front matter r 2003 Elsevier Ltd. All rights reserved. doi:10.1016/j.enpol.2003.09.004
tion is 58,250 kWh/day, the steam requirement is 0.6 tons/h, and the furnace oil requirement is 1000 l/ day. The industry has already undergone energy conservation (EC) measures (called the first stage) during the financial year 1998–1999. Some of the earlier measures carried out are: Running parallel cables, Change of motor connections, Power factor improvement, Introducing energy efficient motors, Efficient lighting systems, and Peak shaving. Such measures resulted in a saving of 18.23% on the electricity cost, and an attractive benefit/investment ratio of 61.29% during the first year itself. The successful first stage EC measures encouraged the industry and made them to go for further (called as the second stage) measures as presented in this paper. This paper initially addresses the second stage EC experiences of the authors; later it highlights the EC potential availability and suggests some practicable environmental friendly EC policies suitable to the Indian context, and finally it points out the Government’s role in the EC endeavour.
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2. Second stage EC experience 2.1. Audit outcome The EC team, through second stage energy audit noticed that, the first stage EC involved only measures of conserving electrical energy, which brought down the electrical energy consumption to 47,630 kWh during 1999–2000. As the next stage of EC, the management of the industry is further interested only in conserving electrical energy, and if at all is there any possibility of conserving energy in other forms, the industry wanted to reserve such measures as the third stage of conservation. Since EC has been already carried out, the EC team had a hard time to identify the areas for further electrical EC. However, it identified the following areas for further EC after studying all the loads irrespective of their capacities: * * * * * * *
Computer loads; Building insulation; Introducing natural lighting; Motor belts; Change of spindle tapes; Steam use in place of electrical energy and Renewable energy in place of conventional energy.
2.2. Energy saving from computers loads The EC team felt that there would be a possibility of conserving energy by properly changing the computer usage culture (Chan et al., 1997) and hence the team conducted a survey regarding the number of computers in use, the hours of operation of each computer, and the user’s practice. There were 23 PCs, 4 Laser Printers, and 4 Scanners available for use. Fifty-five persons (both clerical and technical) were found to be capable of using the computers. The users had different practices like switching on all peripherals like printer, scanner, etc.
at the same time they turn their computers on, and seldom shut down the computers when they were away for 30 min or longer, etc. Such activities resulted in higher energy consumption. The EC team carried out the following activities in order to conserve energy: *
*
*
*
*
To change their habit of switching on the computer peripherals equipment as soon as they enter the office every day. To switch on peripherals like a laser printer only when one is ready to print. To switch off computer monitors while they are away. Security guards were instructed to switch off the computer power supply after the working hours and on holidays. Automatic Power Management System (APMS) designed to switch off computers and peripherals after a certain period of inactivity has been introduced.
The benefits of EC by changing the computer usage culture are given in Table 1. 2.3. Conservation through building insulation The industry is around 30 years old. Computers were introduced along with air conditioners without renovating the buildings. It has 27 numbers of 1.5-ton capacity air conditioners. Except 7, remaining 20 were used for the computer rooms environment. The rooms were maintained at an operating temperature of 24 C always irrespective of the changing seasons. The south and west facing walls are having an area of 1688 square feet. The windows are of single glass type and the total area is found to be 700 square feet. The EC team felt that changes in the windows glasses and additional insulation to south and west facing wall areas would result in reduced cooling load of the
Table 1 Energy saving, saving in energy cost, investment, and payback period Measures
Saving in electricity consumption
Net annual saving in electricity cost ($)
Investment ($)
Payback period (months)
kWh/yr
kWh/ton
Computer loads Building insulation Natural lighting Flat belts Sandwich tapes Steam heating: (a) Canteen use (b) Wax melting
19,116 61,600 82,320 76,667 768,000
2.30 7.40 9.89 9.21 92.25
1673 5390 7203 6708 67,200
2875 8450 12,330 4140 51,840
21 19 21 8 10
400,000 16,650
48.05 2.00
18,200 557
1065 750
1 17
Total
1,424,353
171.10
106,931
81,450
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buildings. Since all the windows are of single glass type, the EC team recommended replacing them by double glass—0.5-in space windows. Also for the south and west facing walls, R-13 insulation has been recommended since it has high resistance to heat flow. Automatic door closers were suggested for the doors. All recommendations were carried out with drivable care. Due to the modifications of the window glasses and wall insulations of the general-purpose and the computer rooms, there was sufficient energy saving as shown in Table 1. 2.4. Saving through natural lighting The existing roof-structure of the spinning and sewing floors were made up of asbestos sheets. During recent years transparent lite-roof has become very popular since it provides adequate amount of lighting depending upon the area of usage and in some cases it provides natural heating too. The EC team felt that replacing some of the asbestos sheets by transparent lite sheets would result in more lighting because of its wider angular coverage of sunlight. The EC team made a special design to control natural lighting and heating at all seasons of the year. A single asbestos sheet has been cut into two equal halves. One half is replaced by means of transparent lite sheet and it has been permanently fixed with one of the cut halves of the asbestos. It forms one full-modified sheet, which has half asbestos and half transparent sheets. This sheet provides sufficient amount of natural lighting and heat and however it does not provide any control for the light and heat. In order to achieve such a control, the other cut half of the asbestos sheet has been fixed with the modified sheet with a parallel sliding mechanism. The slide travels over the transparent sheet and it can partly or fully cover the transparent portion of the modified sheet. The travel of the slide is electric motor operated and the motor operation is automatically controlled by means of light and heat sensors provided in the working floor. The microprocessor-controlled sensors can be set to the required amount of light and heat needed. By this way, the natural light and heat can be controlled during the different seasons of the year. It has been recommended to replace one asbestos sheet for every four asbestos sheets in a uniform fashion by the modified sheet with sensor control. The light sensors are set to a lighting level of 250 lux such that there are no safety problems, and also no reduction in productivity. The sensors switch on sufficient artificial lighting when the natural lighting is less than 250 lux. By experimentation, no safety problems and reduction in productivity are noticed due to the warming up of the lamps, which are switched on under insufficient natural lighting conditions. The benefits of EC by natural lighting are given in Table 1.
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2.5. Conservation through flat belts There were many motors in the spinning floors of different kW capacities, exhaust fans, and compressors running with V-belts. The EC team observed that with V-belts, the efficiency for power transmission was found to be low as high frictional engagement exists between the lateral wedge surfaces of the belts and hence higher power consumption for the same amount of work to be done by the load. V-belts contain higher bending cross section and large mass, which cause higher bending loss. Also, as each groove of the pulley contains individual V-belt, the tension between the belt and the pulley distributes unevenly which causes unequal wear on the belt. This leads to vibrations and noisy running and hence reduces power transmission further. The consequences could be bearing damage also (See-Tech, 1999). In order to improve the efficiency of power transmission, to reduce the wear and tear on the belts, and to reduce the damages of the motor bearings, the EC team recommended replacing the V-belts of all the motors with Flat belts. With these Flat belts, the frictional engagement is on the outer pulley diameter only, which can typically save around 5–10% of the transmitted energy. Due to the introduction of Flat belts in place of V-belts, there was sufficient energy saving as shown in Table 1. 2.6. Synthetic sandwich tapes for spinning frames The Coimbatore (India)-based company (Habasit Iakoka Pvt. Ltd. 2000), an Indo-Swiss joint venture company, is the largest manufacturer of synthetic sandwich spindle tapes in the world, enjoying 70% of the global market. The tapes are made of polyamide, cotton yarn and a special synthetic rubber mix. The sandwich tapes have characteristics like stable running, good dimensional stability, no breakage, less weak-twist yarn, no fibre sticking, and soft & flexible tape bodies. Because of the special characteristics, these tapes offer 5–10% energy saving. Recommendations were made to replace the cotton tapes by the Habasit synthetic sandwich spindle tapes for all the 96 ring frames. The benefits of such modification are shown in Table 1. 2.7. Steam heating in place of electrical heating The textile industry runs a Canteen to provide food and drink to staff and workers at subsidised price. Steam vessels were mainly used for the food preparation. Steam was produced by a boiler fitted with a 50 kW heating element. Electrical energy was the input for the boiler and the boiler was found to be working for about 8000 h in a year. The existing boilers are of sufficient capacities to produce additional steam of 120 kg/h. Usage of steam at
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70 kg/h from the main boiler house has been recommended for the cooking purposes. The electrically operated boiler has been dismantled from the service. Such a conservation measure resulted in 100% return on investment with a payback period of 1 month as shown in Table 1. 2.8. Steam for wax melting From the energy audit, the EC team identified that electrical heating was used for the purpose of melting wax. The power rating of the heating element used is 5 kW and the heating element was found to be working for about 10 h/day. The EC team recommended steam heating in place of electrical heating. Additional connection for the supply of steam at 9 kg/h from the main boiler house has been suggested for wax melting. Due to the introduction of steam for wax melting in place of electrical heating, there was sufficient energy saving as shown in Table 1. 2.9. Introducing renewable energy systems In India, among many matured renewable energy technologies, wind energy systems (WES) have experienced significant commercial market development over the past decade (TEDA, 2001), taking advantage of the combination of tax incentives, favourable utility power purchase agreements, and banking the generated power at 2% commission, etc. The EC team recommended the management to invest on WES of 1 MW capacity at Kayathar sites (in Tamilnadu state), which are having a mean wind speed of 8 m/s. Such an option provides clean energy for the industrial need at a cheaper price, room for sale of excess energy to the Government at attractive buyback rates, and banking the generated energy. For the concerned textile industry, the sanctioned power demand is 2600 kVA, and the energy from WES is expected to meet around 15% of the energy demand of the industry. Since energy from WES is not constant, the total energy demand of the industry could be planned such that whatever generation is available from WES should be used and the deficit in energy demand should be derived from the State Electricity Board’s grid. The estimated cost of electricity generation during the first year is found to be $ 0.06/kWh and the cost of generation during the subsequent years will be considerably reduced due to the repayment of the loan. The return on investment will be around 14% per annum. 2.10. Benefits overview Table 1 provides the consolidated benefits of the second stage EC activities except the benefits of the proposed renewable energy system. Due to these EC
measures, a specific electrical energy saving ranging from 2.00 to 92.25 kWh/ton has been achieved. It resulted in a total saving in annual electricity consumption of 1.424353 million kWh, which is found to be 7.87% of the annual electricity consumption. The investment is found to be 0.081450 million dollars and the net annual saving in electricity cost are estimated as 0.106931 million dollars. The average specific electricity consumption/ton of the textile product has been reduced by 171.10 kWh/ton. The payback period of all the measures is less than 2 years, which is a very attractive figure for the investor. In addition to energy saving, an annual reduction of 311.12 tons of carbon, 9.62 tons of SO2 and 3.72 tons of NOx are estimated as environmental benefits. The introduction of WES also offers saving in electricity cost. The net quantity of electricity available per annum is 2.45 million kWh. Usage of electricity from WES results in a saving of $ 67,375 during the first year itself. However, the capital investment for the WES is 0.85 million dollars, which is quite a high value compared to the other EC measures carried out. The payback period for the WES is estimated as 6–7 years. This is a long-term investment, which offers continuous benefits for about 20 years.
3. Practicable EC policies The industrial sector in India continues to be the largest commercial energy consuming sector using up to 52% of the total commercial energy produced in the country. The Indian industries are found to be highly energy-intensive and its energy-GDP ratio is determined to be 50–60% higher than developed nations. In synthetic fibres & textiles, paper, chemicals, foundries, steel, and cement industries, the energy costs account for about 15–20% of the total production costs. However, during recent years, due to the swift expansion of nonenergy-intensive industries and implementation of modern energy efficient technologies and EC measures resulted in reduced commercial energy-intensity compared to previous years. Still there is substantial scope for EC in major industries like textiles, chemicals and paper & pulp, aluminium, and iron & steel industries. It has been estimated that (Nadarajan, 2002) over 5–8% saving is possible simply by better housekeeping and another 8–15% by development of co-generation facilities, introducing renewable energy policies, improved capacity utilisation, and industrial heat & waste management. The industrial EC potential works out to be 14500–15500 MW, which equals around 15% of the total generating capacity of the country. In this section, some practicable policies are suggested to achieve a major portion of the said target with environmental benefits.
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3.1. Tightening co-generation policy One of the potential sources of environmental friendly power generation is industrial co-generation. Co-generation is the combined generation of process heat and electric power by the sequential use of energy from a common fuel source. It is an energy-efficient and environmental friendly technology that utilises the exhaust heat from the steam turbine for process heating. Though the overall installed generating capacity of the Indian Power Sector is 10,4101.7 MW as on 30th April 2002, it experienced a maximum demand shortage of 16.9% during the financial year, April 2001–March 2002 (Central Electricity Authority, 2002). Inadequate financial investments by the central and state electricity sectors and huge amount of transmission power losses are the major barriers for the generation-demand mismatch. By industrial co-generation, there is no financial burden on the Central and State government electricity sectors because the industries opting for cogeneration facilities themselves meet out the financial requirements, and the transmission power losses are substantially reduced because the energy generated is mostly utilised where it is being produced. Though the captive power installed capacities has a significant magnitude of around 20% of the installed generating capacities, the growth of co-generation so far has reached to a maximum of only 5% of the total installed generating capacities. One of the major barriers for the development of industrial co-generation has been the issue of Central–State jurisdiction. In order to heighten industrial co-generation, it is suggested that both Central and State governments should have a common amicable policy on industrial co-generation and also cogeneration should be made as mandatory for industries like sugar, fertiliser, steel, cement, paper, man-made fibre, and chemical/petrochemical industries of contracted demand above 500 kVA. Apart from captive use, energy produced through co-generation shall be permitted for third-party sales. In that case, the policies for wheeling, banking, third party sales, support for evacuation arrangements and assurance for payments are the key areas that need to be strengthened. By making co-generation as mandatory for industries and permitting third-party sale of excess power, brings about 8500– 9000 MW of power that could be further generated. 3.2. Updating renewable energy policy The depletion of the reserves of fossil fuels and the present rate of excessive fossil fuel consumption together with the global warming gave a new thrust and importance to renewable energy sources. India is sanctified with abundant renewable energy in different forms like solar, wind, tidal, etc. Among the renewables, the importance of power generation from wind energy
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was realised during 1985–1990 and today, power generation from wind has emerged as one of the most successful programmes, making a meaningful contribution to bridging the gap between supply and demand for power. The Ministry for Non-Conventional Energy Sources (MNES), the Indian Renewable Energy Development Agency (IREDA) Ltd, and the State Nodal Agencies has been playing a significant role in promoting wind power projects. India has a gross wind power potential of 45,195 MW, and a technical potential of 13,390 MW. As on March 2003, an installed capacity of 1869.5 MW (Ministry of Non-Conventional Energy Sources, 2003) has been established and out of which 1804.7 MW (96.5%) was from private sector investments. In order to further enhance the renewable energy investments, for new high-tension industries to be established, while licensing for grid electricity to use, the government shall insist for at least 10% of the industries’ sanctioned demand from renewable energy sources. If such a policy were introduced, according to the authors’ estimate, by 2005 there would be an additional installed wind farm capacity of 2625 MW apart from the forecasted growth. For existing industries those seeking enhanced sanctioned demand, 25% of the additional demand should be from renewable energy sources. Such 10% and 25% renewable energy demand charges are naturally exempted from payment to the state utilities. 3.3. Setting standards for specific energy conception The Bureau of Indian Standards (BIS) is responsible for setting standards for manufacturing, operational practices and related areas in the country. Apart from standards, BIS has also laid down guidelines for selection of energy efficient equipments, guidelines for system design and proper matching of components, and codes of practice for proper equipment installation and maintenance. But as on today no policy has been laid on specific energy consumption for key products by different industries. For example, for Spinning and Sewing Thread industries, the average specific energy consumption for producing 1 ton of yarn by Indian industries is found to be 2400 kWh. This value is much higher compared to developed countries, and it needs to be reduced. So BIS should able to set a standard for the specific energy consumption for textile industries based on the international standards and the Indian context. On this basis, the specific energy consumption shall be set to 1900 kWh/ton. Likewise for energy-intensive industries like chemicals, paper & pulp, aluminium, and iron & steel industries, etc., BIS should able to set specific energy consumption standards. As a guideline, by 2005, the specific energy consumption per ton of steel for medium and large-sized iron and steel enterprises shall be set to 0.8 ton of standard coal. Coal
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consumption by thermal power stations shall be set to 0.380 kg standard coal/kWh. The energy consumption for non-ferrous metals per ton of product shall be set to 4.5 tons of standard coal, and the energy consumption for large-sized synthetic ammonia shall be set to 37 GJ, etc. Such a new policy not only helps in reducing the production cost of the commodities but also reduces the damages to the environment. To enforce the specific energy consumption standard, the following practice could be adopted in case of electrical energy consumption. Industries consuming more than the set standard would be cautioned to reduce the specific energy consumption within a stipulated time period. If the same situation continues even after cautioning, there would be a penalty on the excess energy consumption charges by the electric utilities. The penalty charges shall be worked out based on the expected environmental damage caused by the excess energy consumption. Likewise for other energy forms, realistic practices could be formulated. If such a policy were practiced, there would be a saving of around 20% in the electrical energy consumption alone. 3.4. Electrical power demand approval policy The policy for sanctioned (or contracted) demand for industries is generally based on the connected load details submitted by the industries. Industries always demand for higher sanctioned demand anticipating the future growth in electrical demand. The policy for approving the sanctioned demand shall be on the basis of the quantity of daily commodity production, the industry working hours per day and the specific energy consumption standard set by BIS. An additional 10% shall be added to that to get the figure for the sanctioned demand. So the industry will be sanctioned to the figure as arrived at and not as it requested. For example, a textile industry seeks 3500 kW of maximum demand. If its daily yarn production is 25 tons and it works on 3 shifts with 8 h per shift, assuming the specific energy consumption standard set by BIS as 1900 kWh/ton of yarn, then the electrical load demand would be 1980 kW (25 1900/24). Adding 10% on the calculated figure, the sanctioned demand would be around 2200 MW though the industry asked for 3500 MW. Such a policy on approving the contracted demand forces the industries either to improve the performance of their machines or change in production processes and or incorporating energy efficient machineries in case of replacements, and also it gives room for financial saving by reduced demand charges. 3.5. Introducing ration for fossil-fuels Power cuts and load shedding by electric utilities are very common in India. Mostly Indian industries make
use of diesel-generator sets for back up power supply. Most of the diesel-generator sets are old and their fuel consumption is found to be very high and they are mostly operating under part load conditions. Hence their efficiency is low and the pollution level is found to be higher. In order to reduce fuel consumption as well as pollution, either new diesel-generators are to be added or the existing ones need to be renovated. For industries failing to do so, a ration on the sale of diesel shall be introduced. The quantity of permissible fuel ration shall be based on the normal efficiency of diesel-generator sets and the expected duration of utility power cuts and load shedding. 3.6. Load management Industries shall be asked to have different shift timings so that the peak load on the utility grid will be reduced, which results in benefits like less burden on the utility generators, reduced transmission losses, improved load factors, etc. Also load levelling within the industries itself helps in energy saving. State utilities could implement these policies and monitor the outcome during the time of monthly energy consumption recording.
4. The role of the governments The State as well as the Central governments shall formulate policies for implementing the suggestions as discussed earlier. Apart from that it can have few additional norms to promote EC in terms of technology and incentives. (i) Purchasing the products for government and public sector needs only from industries successfully adopting EC policies. (ii) Introducing energy efficiency standards for key industrial energy-consuming equipment such as industrial boiler, transformers, air-conditioners, electric motors, fans, pumps, and lighting, etc. (iii) Providing technological basis for replacing industrial commodities with high-energy consumption and implementing energy-saving product certification and energy efficiency identification system. (iv) Readjusting the industrial structure and the product mix, and transforming traditional industries with high and new technologies, and increase the added value of products. (v) Introducing product labels—information like expected lifetime, average energy consumption, operating efficiency, and pollution level shall be specified on product labels. (vi) Interest free loan facilities to procure energy efficient machineries or soft loans.
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(vii) Introducing mandatory renewable energy sources as a part of their sources of energy and providing 100% depreciation on the investment for the first year. (viii) Making industrial energy audit compulsory. (ix) Policy for introducing Time of the Day metering for industrial consumers for better load management. (x) Cash prizes worth of certain percentage on the amount of energy saved charges. (xi) EC awards every year for different types of industries. (xii) Providing tax benefits and tax holidays for industries successfully implementing EC and introducing tax burden for products with higher energy consumption.
5. Conclusions In this paper, the EC experiences of the authors with a textile industry were presented at the beginning. Conservation measures like equipment operational changes, building structural modifications, changes in machinery accessories, steam heating in place of electrical heating were adopted, which resulted in a reduction of 171.10 kWh/ton of the textile product, and an estimated annual reduction of 311.12 tons of carbon, 9.62 tons of SO2 and 3.72 tons of NOx as environmental benefits. Then the EC potential availability has been highlighted. Following that practicable EC policies for the Indian context have been suggested. Finally, the role of the government in terms of formulation of norms, setting up of standards, and promotional EC incentives has been pointed out. References ADB, 1999. Government of India & Netherlands: ADB Energy Efficiency Support Project. http://www.energyefficiency-cii.com/.
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Chan, A., Siu, W., Li, D., Wong, F., 1997. The Role of Computers in Energy Consumption on Campus. A report prepared by the 1996/ 97 ENV421 H course in the Division of the Environment at the University of Toronto. Central Electricity Authority, 2002. Regional Electricity Boards Report of year 2002, Sewa Bhavan, R.K. Puram, New Delhi. Habasit Iakoka Pvt. Ltd, 2000. Power Transmission Belts and Conveyor Belts in India. http://www.habasitiakoka.com/. Ministry of Non-Conventional Energy Sources, 2003. Government of India—Annual Report 2002–03. Nadarajan, C., 2002. Market for Energy Conservation in India’, Magnum Power, India—Report. Palanichamy, C., Nadarajan, C., Naveen, P., Sundar Babu, N., 2001. Budget Constrained Energy Conservation—An Experience with a Textile Industry. IEEE Transactions on Energy Conversion 16 (4) 340–345. See-Tech, 1999. News for Energy Conservation & Industrial Safety— Conserve Our Essential Companion. Energy & Environment, (1) (Internet Edition), India. http://www.letsconserve.com/newsletter. htm. TEDA, 2001. Tamilnadu Energy Development Agency—Policy Note: 2000–2001. http://www.tn.gov.in/policy/tedapol-e.htm. UNIDO, 1992. Handy Manual of Output of a Seminar on Energy Conservation in Textile Industry. Prof. C. Palanichamy was born in Tamilnadu, India. He received the B.E., M.Sc.Engg. and Ph.D. degrees in electrical and electronic engineering in 1976, 1979 and 1991, respectively, from Madurai Kamaraj University, India. Currently, he is with the Ministry of Education, Brunei Darussalam. In 1979, he began his academic career in India, followed by Iraq and Malaysia. His areas of interest include economic operation of power and energy systems, electrical building services and building automation, renewable sources of energy, energy conservation and software development for power system applications. He has authored three books on electrical and electronic engineering. Dr. N. Sundar Babu was born in Tamilnadu, India. He received his B.Sc. degree in 1992 and M.Sc. degree in applied chemistry in 1994, from Madurai Kamaraj University, India and Ph.D. from University of Malaya, Malaysia in 2000. He is currently working as a scientist with Drexel University, Philadelphia, USA after his post-doctoral research. He is an active researcher and has published many research papers in leading national and international journals. Apart from his areas of specialization, he developed keen interest in inter-disciplinary areas like energy storage systems, renewable energy systems, and real-time simulations of engineering tasks.