ENCON Compendium 2024

Best Practices in Energy Efficiency

Table Of Introduction 03

Methodology 04
Contents Overview 05

Best Practices 06

Way Forward 34

Citation: CII-Consultivo ENCON Compendium 2024 - Best Practices in Energy Efficiency

Publication Date: 20 November 2024

Acknowledgement
Our sincere gratitude is extended to the companies that shared their energy efficiency project details for this
compendium. Their efforts in advancing energy efficiency have been highlighted as an example for others to
follow.
By contributing these practices, significant steps have been taken to benefit industries and society as a whole.
The leadership demonstrated by these organizations in this area is deeply appreciated.

Disclaimer
Users of this report shall take their own independent business decisions at their own risk and, in particular, without undue
reliance on this report. Nothing in this report shall constitute professional advice, and no representation or warranty, express
or implied, is made in respect to the completeness or accuracy of the contents of this report.

Confederation of Indian Industry (CII) and Consultivo Business Solutions Pvt. Ltd. (Consultivo) do not accept any liability
whatsoever for any direct or indirect damages resulting from the use of this report or its contents. The views expressed do not
necessarily represent the views or policy of either CII or Consultivo.
Chapter 01 02 03 04

01
Introduction
Energy Efficiency: A Cornerstone of
Sustainability

Energy efficiency has evolved beyond a simple cost-saving measure or

compliance checkbox; it is now a strategic priority for businesses around the
globe.
With the growing focus on Environmental, Social, and Governance (ESG)
considerations, energy efficiency has become integral to corporate sustainability
efforts. By committing to energy conservation and resource optimization,
organizations not only lower their environmental footprint and operational
expenses but also strengthen their brand reputation, increase resilience, and
boost overall business performance.

About This Compendium of Best Practices in Energy Efficiency

The CII-Consultivo ENCON Compendium 2024 reflects the This compilation aims to showcase
expanding commitment of organizations to energy efficiency. the powerful impact of well-planned
energy efficiency programs. By
Featuring a variety of case studies from different industries, it cultivating a culture focused on
highlights how leading companies are embedding energy energy efficiency, organizations can
efficiency within their ESG strategies. By sharing successful lower costs, reduce carbon footprints,
practices and innovative solutions, this compendium seeks to progress toward net-zero goals, and
inspire and equip organizations to enhance their energy contribute meaningfully to
management and climate risk mitigation efforts. sustainable development.

These effective practices have been chosen from a wide

range of energy efficiency initiatives implemented by
organizations across various plants. By sharing these best
practices, we aim to help other organizations excel in their
own energy efficiency journeys.

03 CII-Consultivo ENCON Compendium 2024

Chapter 01 02 03 04

02
Methodology
This compendium presents a curated collection of energy efficiency best
practices drawn from various industries. The methodology behind its
development involved a comprehensive research process focused on
identifying and analyzing impactful energy efficiency initiatives.

Effective practices were gathered from a diverse array of organizations across

multiple sectors and were categorized into two distinct categories
(manufacturing and power sectors) to facilitate understanding and
application.

For each identified practice, the compendium details the specific energy
efficiency challenge addressed, the innovative solution implemented,
supporting visuals, and the corresponding benefits achieved.

By showcasing these real-world examples, this document aims to provide

practical insights and inspiration for organizations looking to enhance their
energy efficiency performance and contribute to a more sustainable future.

Energy Efficiency Excellence is Driven by Commitment, Innovation, and Technology

04 CII-Consultivo ENCON Compendium 2024

Chapter 01 02 03 04

03
Energy Efficiency
Best Practices
Overview

2 27
Total No. of Categories Total No. of Best Practices

Mapping with the SDGs

By integrating innovative solutions, organizations are significantly

enhancing energy efficiency, improving operational performance, and
advancing overall sustainability.

These technological advancements are directly aligned with Sustainable

Development Goals (SDGs), fostering a more efficient, resilient, and
environmentally responsible operation.

05 CII-Consultivo ENCON Compendium 2024

Best Practices Overview

Company Name (Plant Company Name (Plant

Sl. No Best practices Sl. No Best practices
Location) Location)

A. Manufacturing: Construction Equipment Manufacturing: Glass

Hindusthan National Glass &

Tata Hitachi Construction A13 Compressor Energy Reduction Industries Ltd, Rishra, West
Optimization of Compressed Air
A1 Machinery Company Pvt. Bengal
System
Ltd, Kharagpur, West Bengal
Manufacturing: Paper

Manufacturing: Steel Processing Optimizing the operational ITC Limited, Hooghly, West
A14
stages of Pulper Bengal
Enhancing Efficiency of CPL Tata BlueScope Steel Private
A2 Primary Heat Exchanger through Limited, Jamshedpur, Manufacturing: Steel
Design Upgradation Jharkhand
Injection of Mixed Gas (Coke
SAIL, Rourkela Steel Plant,
Energy saving initiatives in JCAPCPL, Jamshedpur, A15 Oven Gas, BF Gas and LD Gas) for
A3 Rourkela, Odisha
utilities Jharkhand Stove Heating

Manufacturing: Refractories Implementation of Dual Fuel Electrosteel Castings

A16 Burner System to Replace LDO Limited, Khardah, West
With Blast Furnace Gas (BFG) Bengal
Reduction in Specific Energy TRL Krosaki Refractories
A4
Consumption of H/A Tunnel Kiln Limited, Belpahar, Odisha Jindal Stainless Limited,
A17 Installation of Floating Solar Plant
Jajpur, Odissa
Manufacturing: Steel Wire
Air Heater Installation in Place of
ESL Steel Limited, Bokaro,
A18 LDO Burner System at BCM Post-
Tata Steel Limited Wires Jharkhand
A5 Reduction of LPG consumption Heating Chamber
Division, Jamshedpur
Utilization of waste high pressure
Manufacturing: Rail Crossing
energy to generate power by JSW BPSL, Sambalpur,
A19
Installation of Back Pressure Odisha
Energy recovery system used for Vossloh Beekay Castings Micro turbine
A6
drying the wet silica sand Limited, Bhilai, Chhattisgarh
Manufacturing: Textile

Manufacturing: Cement Installation of PRS (Pressure

Grasim Industries Ltd.,
A20 Reducing Station) at Fibre Dye
De-bottlenecking of Pyro Rishra, West Bengal
Nu Vista Cement, Risda, House
A7
Processing Chattisgarh
Manufacturing - Cutting Tools
Interconnection of Service Air
UltraTech Cement Unit- Introduction Of Indirect/Direct Ceratizit India Private
Compressor Line for Both TPPs
A8 Maihar Cement Works, A21 Evaporative Cooling Machine Limited, Uluberia, Howrah
for Reduction in Power
Maihar, Madhya Pradesh (IDEC).
Consumption

B. Power
Manufacturing: Aluminium
Optimization Of Boiler Feed
Revamping Turbine Efficiency Crescent Power Limited,
Aditya Aluminium, A Unit of B1 Pump Discharge Header
using Strategic Planning and Asansol, West Bengal
A9 Hindalco Industries Limited, Pressure
Computational Method
Sambalpur, Odisha
Utilization Indian Metals and Ferro
Process Modification using
B2 Alloys Limited, Cuttack,
Alternate Fuel to Save Energy
Revamping of Remelt Furnace Odisha
Hindalco Industries Limited ,
A10 and Implementation of Low
Belur, West Bengal
Firing Mode De NOX combustion system
installation in Boiler, Large Scale Haldia Energy Limited,
B3
Manufacturing: Conveyor Belt Rainwater Harvesting and Green Haldia, West Bengal
Belt Development
Continental (Legal entity -
Conversion of Pumping System Phoenix Conveyor Belt India Santaldih Thermal Power
A11 Zero Liquid Discharge Scheme
to Gravitational Transportation B4 Station under WBPDCL,
Pvt Ltd), Kalyani, West implementation at STPS
Bengal Santaldih, West Bengal

Single Compressor Operation Industrial Energy Limited,

Manufacturing: Fertiliser B5
out of 4 Compressors Kalinganagar, Odisha

Replacement of Existing Transforming Power Efficiency

Condensing Turbine with ITC Limited, Hooghly, West with Uptime AI: Predictive and
A12 B6 Tata Power, Jojobera
Extraction Cum Condensing Bengal Prescriptive Analytics for
Turbine Optimized Operations

06 CII-Consultivo ENCON Compendium 2024

 A1 [Category A: Manufacturing / Construction Equipment / Energy Efficiency Best Practice 1]

Optimization of Compressed Air System

Industry: Manufacturing - Construction Equipment

Tata Hitachi Construction
Machinery Company Pvt. Ltd.
Location: Kharagpur, West Bengal

Tata Hitachi optimized its compressed air system by

reducing supply pressure and incorporating fast-acting
valves, saving 85,700 kWh annually, cutting carbon
emissions by 62,561 kg, and achieving an 11-month ROI.

SDG
Linkage

Problem Statement
Elevated control limits for the compressed air Master Air Controller
system (6.5 bar to 5.5 bar)

Solution/Good Practice
Reason to Select the Problem
Reduced the compressed air supply pressure
Significant energy consumption associated with the to a level closer to the lower limit
compressed air system

Benefits/Outcomes
Innovation
Power Saving
Incorporate fast-acting pressure control valves in 85,700 kWh per annum
conjunction with master air controllers

Carbon emissions reduction

62,561 kg
Technology Application
Reduced the operating range of the air supply system to a KPIs
narrower range of 5.8 bar to 5.5 bar
10% Reduction in Variable cost

2% Reduction in
environmental load

ROI
Within 11 months

07 CII-Consultivo ENCON Compendium 2024

 A2 [Category A: Manufacturing: Steel Processing / Energy Efficiency Best Practice 2]

Enhancing Efficiency of CPL Primary Heat

Exchanger through Design Upgradation

Industry: Manufacturing - Steel Processing

Tata BlueScope Steel
Private Limited
Location: Jamshedpur, Jharkhand

Tata BlueScope Steel upgraded its CPL Heat Exchanger

design, combining conduction and convection to improve
Solution/Good Practice
efficiency, achieving annual savings of INR 99 lakh,
Modification of Design engineering
reducing carbon emissions by 446 tonnes, with a 13-
month ROI.

Benefits/Outcomes
SDG
Annual saving
Linkage
INR 99 Lakh

Carbon emissions reduction

Problem Statement 446 Tons per annum
Traditional Heat Exchanger with lower efficiency

KPIs
Reduction in propane
Reason to Select the Problem consumption by

Organizational demand for Energy Conservation 1 Kg/Ton of production

ROI
Technology Application 13 months

Combination of Conduction and Convection

Fuel Switching / RE Application

No change (Propane being used as fuel)

Change in Heat Exchanger Design

08 CII-Consultivo ENCON Compendium 2024

 A3 [Category A: Manufacturing: Steel Processing / Energy Efficiency Best Practice 3]

Energy Saving Initiatives in Utilities

Jamshedpur Continuous Industry: Manufacturing - Steel Processing

Annealing and Processing
Company Pvt. Ltd. (JCAPCPL) Location: Jamshedpur, Jharkhand

JCAPCPL added energy efficiency by optimizing chiller and

compressor systems, installing EC blowers, VFDs, and a 2.8 Solution/Good Practice
MWp rooftop solar plant. This reduced CO₂ emissions by
5,822 tons annually, with a payback period under 3 years. Chiller Plant Initiatives

Replacement of Over-rated condensate

SDG water pumps & motors with optimum
Linkage capacity energy efficient pumps & motors.
Installation of automatic tube cleaning
system in chillers to prevent fouling and
scale formation.
Problem Statement Installation of energy efficient EC
High energy consumption in Utilities. (Electronically Commutated) Blowers in
AHUs (Air Handling Units) in place of belt
driven centrifugal fans.
Reason to Select the Problem Installation of VFD Chiller for better energy
After Continuous annealing line, Chillers and air efficiency in variable load.
compressors are most energy consuming units and there Installation of VFDs in Chilled water pumps
is a lot of scope for improvement in the energy efficiency of for efficient operation of chilled water
these units. pumps.

Air Compressor Initiative

Innovation
Installation of VFD Compressor to take care
Reduction in COG Consumption by reusing tail gas. of variable load and reduce run time of
fixed speed compressor in unload
Reduction in wear and tear resulting improved
condition to save energy.
equipment life.

Carbon emission reduction: Through

Technology Application energy Saving Projects in Chillers & air
Installation of EC (Electronically Commutated) Blowers in compressor
AHUs (Air Handling Units)
2624 Tons of CO₂
Benefits/Outcomes Rooftop solar:

Reduction in Overall Sp. Energy Consumption (MJ/T) 3198 Tons of CO₂

Reduction in COG consumption
Reduction in power consumption

KPIs
Reduction in power consumption

ROI
New VFD Chiller 2.8MWp rooftop
All project payback period is under 3 years
Solar plant

09 CII-Consultivo ENCON Compendium 2024

 A4 [Category A: Manufacturing: Refractories / Energy Efficiency Best Practice 4]

Reduction in Specific Energy

Consumption of H/A Tunnel Kiln

Industry: Manufacturing - Refractories

TRL Krosaki
Refractories Limited
Location: Belpahar, Odisha

TRL Krosaki Refractories replaced a 60-year-old Tunnel Kiln

with an energy-efficient, dual-fuel model using natural gas, Solution/Good Practice
reducing specific energy consumption and CO₂ emissions
by 1,301 MT, achieving a cleaner environment. A new energy efficient tunnel kiln was installed
to meet the present demand.

SDG Benefits/Outcomes
Linkage
Specific energy consumption of the
kiln was reduced from
1655 to 1386 Kcal/Kg
Problem Statement
Low specific energy consumption.
H/A Tunnel Kiln was a 60-year-old kiln & its energy
Cleaner environment.
efficiency & productivity was low

Carbon emissions reduction by

Reason to Select the Problem 1301MT
Low Energy efficiency & productivity
KPIs
Low specific energy consumption
Innovation
Replaced by new energy efficient kiln. Cleaner fuel ROI
(Natural Gas) was used replacing Furnace Oil & Producer Main benefits are cleaner environment
Gas. and reduction in CO₂ emission.

Technology Application
Use of Natural Gas for high temperature application in
plant.

Fuel Switching / RE Application

New kiln is of dual firing system e.g. N.Gas/Oil

Natural Gas Firing in Fire Bricks Tunnel Kiln

10 CII-Consultivo ENCON Compendium 2024

 A5 [Category A: Manufacturing: Steel Wire / Energy Efficiency Best Practice 5]

Reduction of LPG Consumption

Industry: Manufacturing - Steel Wire

Tata Steel Limited Wires
Division Jamshedpur
Location: Jamshedpur, Jharkhand

Tata Steel Wires Division Jamshedpur reduced LPG

consumption by upgrading to dual-fuel, energy-efficient
furnaces for annealing and zinc baths. This change cut LPG
use by 4.31 kg/MT, reduced CO₂ emissions by 700 MT
annually, and achieved a 3-year ROI.

SDG
Linkage

Top Fired Zinc Bath Furnace with Ceramic

Problem Statement Tank
Excess energy consumption in zinc and lead bath furnace.
Solution/Good Practice
The annealing process transitioned from a lead
Reason to Select the Problem
bath to an open-fired furnace. The zinc melting
Significant opportunity for improvement process shifted from a traditional bath to a
ceramic tank with top-fired burners.

Innovation Benefits/Outcomes
Upgraded the annealing process from lead bath to The open-fired annealing furnaces
open-fired, leveraging direct convection heating of achieved
wires. This optimization led to a 2 kg/MT decrease in 2 kg/MT reduction in energy
fuel/thermal energy expenditure. consumption
Zinc bath furnaces saw a
Replaced MS tank with ceramic tank, enabling
direct burner heating of zinc. This reduced dross 2.3 kg/MT decrease in LPG
consumption
formation by 50% and lowered fuel/thermal energy
consumption by 2.3 kg/MT Total overall reduction around 1.6%
(0.242 tco2/ton to 0.239 tco2/ton).
Reduction in absolute terms in LPG
Technology Application consumption is around 700
Installation of new furnace. tco2/annum

KPIs
Reduction of LPG Consumption from
Fuel Switching / RE Application 35.53 Kg/MT to
The two new furnaces (open-fired annealing and top-fired 31.22 Kg/MT
zinc bath) are built on a dual-fuel technology platform,
enabling a seamless transition from LPG to NG in the ROI
future. 3 Years

11 CII-Consultivo ENCON Compendium 2024

 A6 [Category A: Manufacturing: Rail Crossing / Energy Efficiency Best Practice 6]

Energy Recovery System Used for

Drying the Wet Silica Sand

Industry: Rail crossing manufacturing (Medium scale)

Vossloh Beekay
Castings Limited
Location: Bhilai, Chhattisgarh

Vossloh Beekay Castings implemented an energy recovery

system, using hot water instead of Light Diesel Oil to dry Solution/Good Practice
silica sand, reducing carbon emissions by 134 tons monthly
and saving INR 33 lakhs, with a 2-month ROI. Using Hot water which is coming from
ER to dry silica sand

Fuel Switching / Reapplication- Light

SDG diesel oil to Hot water (carbon
Linkage emission free)

Benefits/Outcomes
Problem Statement
LDO used to dry silica sand in sand plant Carbon emissions reduction
134 ton monthly

Reason to Select the Problem Saving monthly

(by stopping using LDO)
To decrease the carbon emission from using Light
Diesel Oil
Rs. 33 lakhs

KPIs
12 ton
Innovation silica sand required daily

Energy recovery system used for drying the wet silica sand
ROI
2 months
Technology Application
The resultant hot water can be used for the
washrooms also.

Fuel Switching / RE Application

Light diesel oil to Hot water (carbon emission free)

Energy Recovery System

12 CII-Consultivo ENCON Compendium 2024
 A7 [Category A: Manufacturing: Cement / Energy Efficiency Best Practice 7]

De-Bottlenecking of Pyro Processing

Industry: Manufacturing - Cement

Nu Vista Cement
Location: Risda, Chhattisgarh

Nu Vista Cement optimized pyro-processing by upgrading

equipment and using Variable Frequency Drives, enabling
17% coal replacement with alternative fuels, reducing costs
by ₹8 crore in six months, and achieving a 2-year ROI.

SDG
Linkage

Problem Statement
Pyro-processing units can reduce energy consumption Master Air Controller
and utilize Alternative Fuel Resources (AFR).

Solution/Good Practice
Reason to Select the Problem
Upgraded preheater and ESP fans, and added a
Promote community waste management and energy coal Pfister.
conservation

Benefits/Outcomes
Innovation
Significant cost reduction of
Modified Raw VRM fan inlet box to improve airflow
and reduce pressure drop. ₹8 crore
realized in just half a year
Increased cement mill capacity by using a Variable
Frequency Drive (VFD) to adjust ID fan RPM.
KPIs

2% Reduced kiln power

Technology Application
15% increased TSR
PID looping and advance research using CII good practices

ROI
2 Years
Fuel Switching / RE Application
Up to 17% of coal can be replaced with environmentally
friendly Alternative Fuel Resources (AFR).

13 CII-Consultivo ENCON Compendium 2024

 A8 [Category A: Manufacturing: Cement / Energy Efficiency Best Practice 8]

Interconnection of Service Air Compressor Line for

Both TPPs for Reduction in Power Consumption

Industry: Manufacturing - Cement

UltraTech Cement Unit-
Maihar Cement Works
Location: Maihar, Madhya Pradesh

UltraTech Cement reduced auxiliary power consumption

by interconnecting service air compressor lines for both Solution/Good Practice
TPPs, cutting power usage by 1984 kWh/day, lowering
emissions by 382 MT annually, with an ROI of 1.9 months. Interconnected both TPPs' service air lines and
operated both conveying systems from a single
compressor.

SDG
Linkage
Benefits/Outcomes

Carbon emissions reduction:

Problem Statement 382 MT/Year

High auxiliary power consumption due to separate
service air compressors for each TPP's fly ash system. Reduction in power consumption by

1984 Kwh/Day
Reason to Select the Problem
KPIs
Higher power consumption by service air compressor
Reduction in auxiliary power
consumption by
0.91% out of 6.46%
Innovation
Conducted air consumption study and optimized ROI
compressor operation to reduce power and air pressure. 1.9 months

Technology Application
Kaizen

Fuel Switching / RE Application

Up to 17% of coal can be replaced with environmentally
friendly Alternative Fuel Resources (AFR).

14 CII-Consultivo ENCON Compendium 2024

 A9 [Category A: Manufacturing: Aluminium / Energy Efficiency Best Practice 9]

Revamping Turbine Efficiency Using Strategic

Planning and Computational Method Utilization

Aditya Aluminium, A Unit Industry: Manufacturing - Aluminium

of Hindalco Industries
Limited Location: Sambalpur, Odisha

Aditya Aluminium optimized turbine efficiency by auditing

steam flow, analyzing decay patterns, and using predictive Solution/Good Practice
models, achieving a CO₂ reduction of 51,838 tons and
saving INR 16.41 crore (USD 1.95 million) with a 1.9-year ROI. To optimize Turbine Heat Rate despite variable
coal quality, analyzed turbine decay patterns,
audited steam flow, identified key factors,
developed predictive models, and implemented
SDG strategies validated through rigorous testing to
Linkage restore performance.

Benefits/Outcomes
Problem Statement
Finance (report both in Cr INR and Mn
Aditya Aluminium Smelter in Odisha has seen declining USD):
turbine efficiency since commissioning, leading to higher Overall Rupee/Dollar Value Saved: 16.41
coal use, increased power costs, and elevated metal Cr (1.95 Mn USD)-
production costs. #1 – 55 Cr INR (project over 5 years)
#5 – 7.37 Cr INR (project over 5 years)
Reason to Select the Problem Savings in OPEX: 16.41 Cr (1.95 Mn USD)

This project aims to optimize the Turbine Heat Rate (THR) Operational Efficiency:
by implementing strategies to reduce decay rates and Reduction in energy consumption (in
restore the turbine's performance to its original kCal/kWhr)-
commissioning state. THR Saving of 25 kCal/Kwhr in Unit-05
and THR saving of 86 kCal/kWhr in
Innovation Unit-01.

1. Partnering with an external vendor, a Steam Path Audit Reliability:

was conducted to quantify factors contributing to Turbine Reduction in Customer Complaints-
Heat Rate (THR) degradation. Increase in Reliability (Zero Breakdown
2. Advanced data analysis methods were used to classify in overhauled unit)
losses and assess the correlation between operational
variables and THR decay. Carbon emissions reduction:
3. Regression analysis modeled THR degradation trends,
enabling future performance predictions.
in TCO2e - 51838 tCO₂e

KPIs :
Technology Application
Turbine Heat Rate (Kcal/Kwh)
A computational method utilized using software eSTPE Sp Steam Consumption(Kg/Kwh)
Encotech USA to evaluate component wise losses by
various measurements undertaken inside the steam
ROI:
turbine.
Net payback 1.9

15 CII-Consultivo ENCON Compendium 2024

 A10 [Category A: Manufacturing: Aluminium / Energy Efficiency Best Practice 10]

Revamping of Remelt Furnace and

Implementation of Low Firing Mode

Industry: Manufacturing - Aluminium

Hindalco Industries
Limited
Location: Belur, West Bengal

Hindalco Industries revamped its remelt furnace and

implemented a low firing mode using data analytics, Solution/Good Practice
enhancing fuel efficiency and reducing specific fuel
consumption by 3.6 L/T, achieving savings of INR 11.1
By revamping the furnace, the fuel efficiency
million.
was improved.

SDG
Linkage
Benefits/Outcomes
Reduction in specific fuel consumption
Problem Statement 3.6 Lt/T
Revamping of Remelt Furnace and implementation of low
firing mode
KPIs
Fuel Efficiency in terms of Liters/Ton
Reason to Select the Problem
Energy saving can be achieved in terms of annual thermal
ROI
saving. Saving of INR 11.1 million was achieved
through the same process.

Innovation
With the help of data analytics low firing mode was
studied which contributed in the above objective.

Technology Application
Data Analytics

16 CII-Consultivo ENCON Compendium 2024

 A11 [Category A: Manufacturing: Conveyor Belt / Energy Efficiency Best Practice 11]

Conversion of Pumping System to

Gravitational Transportation

Industry: Manufacturing - Rubber, conveyor Belt

Continental (Legal entity - Phoenix
Conveyor Belt India Pvt Ltd)
Location: Kalyani, West Bengal

Continental improved efficiency by converting its cooling

water pumping system to gravitational flow through an
overhead tank, saving 110,880 kWh annually, reducing CO₂
emissions by 23.54 tons, with a six-month ROI.

SDG
Linkage

Problem Statement
The cooling water from the vulcanizing presses, after
cooling the hot plates, is collected in a sump and
pumped to the cooling tower's supply sump.

Solution/Good Practice
Reason to Select the Problem
Reduced electricity consumption and fewer breakdown An overhead tank was installed to divert return
hours due to pump or motor failures. cooling water, which flows by gravity to the
cooling tower's supply sump, eliminating the
need for a pump and motor.

Innovation
Benefits/Outcomes
This innovation by the Fitters of the Manufacturing
Complete elimination of use of
Engineering department applies simple technology to
electricity. Less downtime of the
achieve significant savings in electrical energy and
system.
reduce machine downtime.

Reduction in indirect CO₂ emission

Technology Application 23.54 ton/year

Simple technology by lifting or escalating the height of the KPIs
water Storage to get the benefit of transportation of water Reduction in consumption of
by gravity. Electrical Energy
110,880 Units / year
ROI
Within six months

17 CII-Consultivo ENCON Compendium 2024

 A12 [Category A: Manufacturing: Fertiliser / Energy Efficiency Best Practice 12]

Replacement of Existing Condensing Turbine

with Extraction Cum Condensing Turbine

Indian Farmers Industry: Fertiliser

Fertiliser Cooperative
Limited Location: Paradeep, Odisha

Indian Farmers Fertiliser Cooperative replaced a

condensing turbine with an extraction-cum-condensing Solution/Good Practice
turbine, saving 53 TPH HP steam, reducing CO₂ emissions
by 1.5 lakh MT annually, and achieving ₹67.77 crore in To save energy, the original Turbo
annual savings with a 1.32-year payback. Generator (TG)-2 was replaced with an
extraction-cum-condensing turbine to
eliminate HP steam letdown and
SDG meet MP and LP steam requirements.
Linkage

Benefits/Outcomes
Problem Statement New turbine is capable of 55 MWh
power generation along with 75 MTPH
The original condensing-type turbo generator required
MP steam and 120 MTPH LP steam
45 TPH MP and 120 TPH LP steam, but reducing HP steam
extraction.
through PRDS to meet these needs resulted in energy
losses. This replacement has resulted in
savings of approximately 53 MTPH of
HP steam consumption in the
Reason to Select the Problem complex.

There was lot of energy saving potential by avoiding HP

steam letdown. Carbon emissions reduction

1.5 Lakh MT CO₂

Technology Application
Power Generation (55 MWh) & Steam Generation (75 MTPH KPIs
MP & 120 MTPH LP steam) Specific steam consumption factor
(Steam consumption/ Power
Generation): The heat rate of the old
turbo generator was 2915 kcal/kWh,
while the new extraction turbine has
improved efficiency with a heat rate
of 1190 kcal/kWh.

Turbo Generator-
2: Extraction cum ROI
Condensing Invested about Rs. 90 Cr. & Annual
Turbine monetary savings of Rs. 67.77 Cr with
payback period of 1.32 years.

18 CII-Consultivo ENCON Compendium 2024

 A13 [Category A: Manufacturing: Glass / Energy Efficiency Best Practice 13]

Compressor Energy Reduction

Industry: Manufacturing (Container Glass)

Hindusthan National
Glass & Industries Ltd
Location: Rishra, West Bengal

Hindusthan National Glass reduced compressor energy

consumption by upgrading discharge lines and optimizing Solution/Good Practice
pressure, saving 52 kW/hour, reducing carbon emissions by
18,872 tCO₂e annually, and achieving a 1-year ROI. Brainstorming & analytical approach
was undertaken to solve the problem
which resulted in simultaneous
practical orientation of each & every
SDG team member.
Linkage

Problem Statement Benefits/Outcomes

Compressor energy consumption was high due to disparity
of discharge pipe lines. Overall consumption 74000 Carbon footprint reduced from
kwh/day.
146463 to 127591 tCO₂e
Reason to Select the Problem
Substantial pressure drop at user end leading to Established saving of 52KW/Hr
frequent section jamming and container defects
Less energy generation
and its rejection.
Compressor energy is major contributor of the Lesser container glass defect
total energy consumption (41%).

KPIs
Innovation Energy conservation per 3KWH/MTD
4” discharge line has been replaced by 8” dia
discharge pipe. Authenticated by OEM.

As per OEM 40 PSI air is mandatory for ROI

manufacturing glass bottles. System design has 1 Year
been modified in such a way that bottle can be
manufactured at 35 PSI.

Technology Application
Bernoulli’s theory & Boyles’s law has been applied

Fuel Switching / RE Application

1,34,247 MT CO₂ emission reduction equivalent to 42% of
the plant’s own energy consumption, certified by IIT-
Mumbai.

19 CII-Consultivo ENCON Compendium 2024

 A14 [Category A: Manufacturing: Paper / Energy Efficiency Best Practice 14]

Optimizing the Operational Stages of Pulper

Industry: Paper Manufacturing Unit

ITC Limited
PSPD Unit Tribeni
Location: Hooghly, West Bengal

ITC Limited’s Tribeni unit optimized pulper operation by

installing a VFD for stage-specific speed control, saving Solution/Good Practice
292,000 kWh annually, reducing CO₂ emissions by 658
tonnes, and yielding ₹14.6 lakh in yearly savings. In the paper machine, pulpers are
vital for stock preparation, but
running at full RPM using a DOL
starter led to unnecessary energy
SDG consumption.
Linkage
A VFD was installed to adjust pulper
speed according to different stages,
reducing energy use without
compromising paper quality.
Problem Statement
The optimized speed settings for
In a paper manufacturing unit, pulpers are critical and various stages were determined
energy-intensive, so efficient operation is essential to through trials and are displayed in a
reduce energy consumption. graphical format.

Reason to Select the Problem

Benefits/Outcomes
Decarbonization projects across the organization aim to
reduce CO₂ emissions, with energy consumption
The Improved systems lead to:
reductions in the power plant—where coal burning
generates CO₂ —contributing to this goal. Overall energy savings of

292000 kWH/Year

CO₂ Reduction of

658 Tons/Year

Monetary benefit of
14.6 L/Year

Before After

20 CII-Consultivo ENCON Compendium 2024

 A15 [Category A: Manufacturing: Steel / Energy Efficiency Best Practice 15]

Injection of Mixed Gas (Coke Oven Gas, BF Gas

and LD Gas) for Stove Heating

Industry: Iron & Steel

SAIL, Rourkela
Steel Plant
Rourkela Steel Plant
Location: Rourkela, Odisha

SAIL Rourkela Steel Plant optimized stove heating by

injecting surplus mixed gas into the BF gas line, raising hot Solution/Good Practice
blast temperature, reducing coke rate by 4 kg/THM, and
cutting carbon emissions by 10,335 tons with an ROI of less Surplus Mixed Gas, generated during weekly off
than one month. days, is injected into the BF gas line, increasing
Hot Blast Temperature by ~40°C and reducing
Coke Rate.
SDG
Linkage

Benefits/Outcomes
Carbon emissions reduction:
Problem Statement 10335 Tons
Minimizing loss of by-product gas
Saving of
Reason to Select the Problem 4 Kg/THM of Coke
Lower carbon footprint
KPIs
Increase in HBT
Technology Application
Proven technology used
ROI
Less Than 1 Month
Fuel Switching / RE Application
While Uptime AI is primarily focused on optimizing
operational efficiency and reliability, it indirectly
contributes to Tata Power's renewable energy initiatives.

Injection of Mixed Gas

21 CII-Consultivo ENCON Compendium 2024

 A16 [Category A: Manufacturing: Steel / Energy Efficiency Best Practice 16]

Implementation of Dual Fuel Burner System to

Replace LDO With Blast Furnace Gas (BFG)

Electrosteel Castings Industry: Iron & Steel

Limited, Khardah,
West Bengal Location: Khardah, West Bengal

Electrosteel Castings implemented a dual fuel burner

system, shifting from Light Diesel Oil (LDO) to Blast
Furnace Gas (BFG), reducing LDO usage by 98%, cutting
CO₂ emissions by 382 MT annually, and achieving a 1 year
9-month ROI.

SDG
Linkage

Problem Statement
The reliance on Fuel Oil (LDO) as the primary fuel source,
coupled with the inability to utilize Blast Furnace Gas (BFG),
a process byproduct, resulted in substantial CO₂ emissions.
Modified Dual Fuel Burner

Reason to Select the Problem

Minimize Carbon Footprint: Reduce carbon Solution/Good Practice
emissions; Lower environmental impact; Promote
sustainability Using Dual Fuel Burner for BF gas as primary
Reduce use of Fossil Fuel: Decrease fossil fuel fuel & LDO as secondary fuel (during non-
consumption; Minimize reliance on fossil fuels; availability of BFG) to supplement for
Transition to cleaner energy sources continuous process.
Better use of Blast Furnace Gas resulting in
reducing Flaring to Air: To Optimize Blast Furnace Benefits/Outcomes
Gas utilization; Minimize flaring of excess gas;
Carbon emissions reduction:
Reduce air pollution from gas flaring
382 MT/Year
Innovation LDO consumption / Annum:
Modified Dual Fuel Burner design for lean gas Before: 1,553 KL: After: 30 KL
applications like BFG. BFG usage per day: Before: 2,68,500
NM3; After: 3,69,426 NM3

Technology Application Flare %: Before: 10 - 11; After: 5 - 6.

Nozzle Mixed combustion system of burner
KPIs
5% Flare reduction
Fuel Switching / RE Application
To Blast Furnace Gas (Process By-Product) from LDO ROI
(Fossil Fuel). 1 Yr 9 Months

22 CII-Consultivo ENCON Compendium 2024

 A17 [Category A: Manufacturing: Steel / Energy Efficiency Best Practice 17]

Installation of Floating Solar Plant

Industry: Metal
Jindal Stainless
Limited
Location: Jajpur, Odissa

Jindal Stainless installed a floating solar plant to reduce

reliance on coal, saving 16 acres of land and cutting water
evaporation by 285.8 lakh m³. This initiative will reduce
184,000 TCO₂ over 25 years, with an ROI of 6.41 years.

SDG
Linkage

Problem Statement
The rapid expansion of the stainless steel sector and
the 264 MW coal-fired power plant contribute to Floating Solar Plant
rising carbon emissions.
This project seeks to identify cleaner energy
solutions and emission reduction strategies to Solution/Good Practice
balance industrial growth with environmental
sustainability.
Incorporating renewable energy sources like
solar and wind into our power supply is a viable
Reason to Select the Problem solution to support expanding stainless steel
The challenge is to expand plant capacity and meet capacity while reducing CO₂ emissions.
growing energy demands without relying on coal, in line
with our commitment to sustainability and reducing
carbon emissions. Benefits/Outcomes
Integrating floating solar plants with
Innovation our power supply meets the energy
Floating solar projects optimize land, conserve water, and needs of expanding stainless steel
enhance sustainability. capacity while lowering carbon
emissions and supporting
Technology Application sustainability goals.

Solar cell Technology - Mono crystalline Silicon cells Using existing water bodies for solar
Floaters - HDPE generation saves 16 acres of land and
Anchoring Method - Dynamically Embedded Plate reduces water evaporation by 285.8
Anchors (DEPLA) Lakh m³, improving resource
efficiency and aligning with
KPIs environmental objectives.
KPIs include solar generation, carbon reduction,
and water evaporation rates. Carbon emissions reduction

ROI
184000 TCO₂ / Lifetime
6.41 Years (25 Years)

23 CII-Consultivo ENCON Compendium 2024

 A18 [Category A: Manufacturing: Steel / Energy Efficiency Best Practice 18]

Air Heater Installation in Place of LDO Burner

System at BCM Post-Heating Chamber

Industry: Integrated Steel Plan

ESL Steel
Limited
Location: Bokaro, Jharkhand

ESL Steel replaced LDO burners with electric air heaters in

the BCM-4 post heating chamber, improving energy Solution/Good Practice
efficiency, safety, and temperature control, eliminating
machine stoppages, and achieving a 2-month ROI. Electric heaters convert nearly all
electrical energy into heat with
minimal energy waste, providing
efficient heating.
SDG
Linkage They allow precise temperature
control and can be integrated into
automated systems for optimal
temperature regulation.

Problem Statement
BCM-4 post heating furnace, heating process is through Benefits/Outcomes
LDO burner, there are several disadvantages as mentioned:
Internment stoppages of machines
Internment stoppages of machine as LDO system due to LDO system almost eliminated,
not working properly. Hence productivity increases.

Leakages of oil is a safety concern & wastage.

KPIs:
Carbon emission through fuel burning. Energy Saving, cost saving, improved
safety.
DI pipe bitumen peel off issue was observed due to
improper furnace temperature.

ROI
2 months
Reason to Select the Problem
Energy Consumption and Cost Savings.

Innovation
Minimized wastage of LDO due to leakages eliminated.

Technology Application
Electric air heating technology.
Automated temperature control systems.

Fuel Switching / RE Application:

From Light Diesel Oil (LDO) to electricity.
Master Air Controller

24 CII-Consultivo ENCON Compendium 2024

 A19 [Category A: Manufacturing: Steel / Energy Efficiency Best Practice 19]

Utilization of Waste High Pressure Energy to Generate

Power by Installation of Back Pressure Micro Turbine

Industry: Steel
JSW BPSL Sambalpur
Location: Sambalpur, Odisha

JSW BPSL Sambalpur installed a back pressure micro

turbine to capture energy from steam throttling in the
PRDS, generating an additional 3,225 kWh of power,
reducing CO₂ emissions by 847 tons annually, with an ROI
under six months

SDG
Linkage

Problem Statement
Steam throttling losses in Pressure Reducing and
Desuperheating Station (PRDS)

Reason to Select the Problem

Huge scope in APC reduction Solution/Good Practice
Installation of back pressure micro turbine in
Innovation PRDS

Installing an energy conservation turbine parallel to the

PRDS that can capture high-pressure steam energy loss Benefits/Outcomes
and generate power without affecting process steam
Total extra power generation
requirements.
3225 KWh
Technology Application
Carbon emissions reduction
Turbogenerator serves the same steam function as a
Pressure-Reducing Valve (PRV) it reduces steam pressure 847 TCO₂
but uses the pressure drop to produce highly valued
electricity in addition to the low-pressure steam.

KPIs
Auxiliary power consumption (APC)

ROI
Below 06 months

25 CII-Consultivo ENCON Compendium 2024

 A20 [Category A: Manufacturing: Textile / Energy Efficiency Best Practice 20]

Installation of PRS (Pressure Reducing

Station) at Fibre Dye House

Grasim Industries Ltd. Industry: Textile

(Unit: Jaya Shree
Textiles, Rishra) Location: Rishra, West Bengal

Grasim Industries installed a Pressure Reducing Station

(PRS) at its Fibre Dye House, optimizing steam pressure, Solution/Good Practice
enhancing safety, and reducing carbon emissions by 887.7
tonnes annually, with significant savings in steam and coal, Installing a Pressure Reducing Station
achieving a 371% ROI. (PRS) ensured consistent, regulated
pressure for dyeing machines, reducing
risks from high-pressure steam.
SDG
Linkage
Benefits/Outcomes
Steam Savings
Problem Statement
Specific Steam Consumption
The Fibre Dye House faced inefficiencies and higher costs
Coal Savings
due to excessive steam loss and frequent safety valve
openings from using high-pressure steam (9.3 Kg/cm²) Carbon Emission Reduction
directly from the boiler. Scope-1 Emissions
Enhanced Operational Safety
Reason to Select the Problem Long-Term Cost Stability

Addressing intermittent steam loss was crucial to reduce Improved Asset Longevity
energy costs, improve safety, and lessen environmental Employee Well-Being
impact.
The PRS has led to a direct
reduction of
Innovation 887.7 tons
The PRS system enables real-time pressure regulation, Carbon emissions annually.
ensuring optimal machine operation, improved efficiency,
KPIs
and lower operational costs.
Daily Steam Savings
5.281 tons
Technology Application Specific Steam Consumption:
Decreased to
The PRS employs advanced control mechanisms and
safety features to maintain desired pressure levels, 4.80 Kg Steam/Kg
enhancing the overall steam distribution system’s Products
reliability and efficiency.
Annual Coal Savings
367 tons
Fuel Switching / RE Application: Annual Carbon Emission Reduction
While this project primarily focuses on steam pressure 887.7 tons
regulation, the energy savings may facilitate a future
transition to renewable energy sources, aligning with
ROI
sustainability goals. 371%

26 CII-Consultivo ENCON Compendium 2024

 A21 [Category A: Manufacturing: Cutting Tools / Energy Efficiency Best Practice 21]

Introduction Of Indirect/Direct Evaporative

Cooling Machine (IDEC).

Industry: Manufacturing & Selling of Tungsten Carbide Cutting

Ceratizit India Tools & Inserts
Private Limited
Location: Uluberia, Howrah

Grasim Industries installed a Pressure Reducing Station

(PRS) at its Fibre Dye House, optimizing steam pressure, Solution/Good Practice
enhancing safety, and reducing carbon emissions by 887.7
tonnes annually, with significant savings in steam and coal, Introduction of Indirect/Direct
achieving a 371% ROI. Evaporative Cooling Machine (IDEC)

SDG
Linkage Benefits/Outcomes
Energy conservation by the Indirect /
Direct Evaporative Cooling Machine is
about 1.15 lacks KWh / Year which
Problem Statement involve cost about Rs. 10 lakhs.
OEM requirement for maintaining the CVD-3 machine
shed inside surrounding area temperature between 25 –
30 degrees centigrade. Carbon emissions reduction

105 tons
in the last FY 2023-2024.
Reason to Select the Problem
The objective is to ensure the availability of high-quality
ROI
products at reduced costs through sustainable, eco-
Cost of the installed indirect / direct
friendly, and energy-conserving practices to achieve our
evaporative cooling machine (IDEC)
ultimate goal of net-zero emissions by 2040.
is Rs. 30 lakhs. As the Conserved
energy cost is about Rs. 10 lakhs, then
ROI is just 3.01 years
Fuel Switching / RE Application:
In the FY: 2023-2024 Solar energy generated by our 100
KWp roof top solar power plant is about 81568 Kwh and
simultaneously by the utilization of this generated kwh
the carbon foot-print reduction is about 43 ton.

27 CII-Consultivo ENCON Compendium 2024

 B1 [Category B: Power: Energy Efficiency Best Practice 1]

Optimization Of Boiler Feed Pump Discharge

Header Pressure through VFD

Industry: Power
Crescent Power Limited
Location: Asansol, West Bengal

Crescent Power optimized boiler feed pump efficiency with

VFD and a sliding pressure setpoint, saving 88 kW per hour
(0.73 MU annually) and reducing CO₂ emissions by 153 tons,
achieving a 4.6-year payback.

SDG
Linkage

Problem Statement
Master Air Controller
During the energy audit at CPL, it was found that energy
loss occurred due to throttling of the feed control valve to
achieve the required flow, and this loss could be avoided
by operating the pump at a lower RPM.

Solution/Good Practice
Innovation The installation of VFD can be a suitable
option to avoid this loss of energy.
The BFP discharge pressure setpoint is maintained
as a sliding setpoint, 7 kg/cm2 above the boiler
drum pressure, which can be adjusted based on
operational requirements. Benefits/Outcomes
This DP can be adjusted to meet operational We were able to achieve energy savings
needs. At 42 MW load, feed control valve openings to the tune of 88KW per hour for two
BFPs. This amounts to annual energy
for Boiler-1 and 2 were increased from 45% and 55%
savings of 0.73 MU.
to 74% and 67%, respectively.

Reduction in indirect CO₂ emission

153 ton CO₂e

ROI:
Simple Payback Period is 4.6 Years &
ROI is 21.6%

28 CII-Consultivo ENCON Compendium 2024

 B2 [Category B: Power: Energy Efficiency Best Practice 2]

Process Modification using Alternate

Fuel to Save Energy

Industry: Ferro Alloys with Captive Power Plant

Indian Metals and
Ferro Alloys Limited
Location: Cuttack, Odisha

Indian Metals and Ferro Alloys switched from LDO to LPG,

reducing energy costs, cutting CO₂ emissions by 530,500
Solution/Good Practice
kg annually, and achieving cleaner combustion with less
maintenance, yielding an ROI of less than one year. Fuel change from LDO to LPG ( CNG can be
used if available)

SDG Benefits/Outcomes
Linkage
High Energy Value, Less Kcal used for
same work, Clean fuel.

Clean burning, Give good flame control,

Problem Statement Uniformity in temperature, better heat
transfer.
Process Modification using alternate fuel to save Energy No spillage and wastage of fuel. No soot,
Burner has longer life, less maintenance.

Reason to Select the Problem Environmentally friendly Fuel, Sulphur

free emission. Less CO₂ generation
Kcal Energy reduction, Cost reduction, CO₂ reduction.
Reduction in indirect CO₂ emission

Technology Application 530500 Kg of CO₂ per

Burner and Fuel handling system changed Annum

KPIs
Fuel Switching / RE Application Cost of Fuel
Fuel change from LDO to LPG
ROI
Less than 1 year

LPG Storage Shed Dryer Burner System

29 CII-Consultivo ENCON Compendium 2024

 B3 [Category B: Power: Energy Efficiency Best Practice 3]

De NOX combustion system installation in Boiler,

Large Scale Rainwater Harvesting and
Green Belt Development
Industry: Thermal Power Plant
Haldia Energy
Limited
Location: Haldia, West Bengal

Haldia Energy implemented sustainable practices,

including De-NOx combustion systems, large-scale Solution/Good Practice
rainwater harvesting saving 15% of water and 500 tons of
coal, and planting 1.3 lakh trees, reducing CO₂ emissions De NOx combustion system has been
by 134,247 MT annually. installed in both the boilers in 2023 as
an endeavour for NOx abatement for
sustainability and maintaining
SDG environment clean and sustainable.
Linkage
Large scale rainwater harvesting,
saving almost 15% of annual water
requirement and 500 tons of coal

Problem Statement HEL has planted 1.3 Lakhs living

trees to generate green belt.
Environmental initiatives for sustainability

Benefits/Outcomes
Reason to Select the Problem
To develop sustainable practice under ESG initiatives 42% of the plant’s own energy
consumption saved, certified by IIT-
Mumbai.

Innovation
CO₂ emission reduction /Yearly
The PRS system enables real-time pressure regulation,
ensuring optimal machine operation, improved efficiency, 1, 34,247 MT
and lower operational costs.

Technology Application
Burner and Fuel handling system changed

Fuel Switching / RE Application:

1,34,247 MT CO₂ emission reduction equivalent to 42% of
the plant’s own energy consumption, certified by IIT-
Mumbai.

Various Environmental Initiatives in Plant

Premises

30 CII-Consultivo ENCON Compendium 2024

 B4 [Category B: Power: Energy Efficiency Best Practice 4]

Zero Liquid Discharge Scheme implementation

at STPS

Santaldih Thermal Industry: Coal Based Thermal Power Station

Power Station under
WBPDCL Location: Santaldih, West Bengal

Santaldih Thermal Power Station implemented a Zero

Liquid Discharge (ZLD) system, enabling effluent reuse, Solution/Good Practice
reducing Specific Water Consumption (SWC), saving 2.35
lakh KL annually, and cutting CO₂ emissions by 446 tons, ZLD installation enabled effluent water reuse,
with a 2.49-year ROI. reducing SWC and water costs.

Benefits/Outcomes
SDG
Linkage Zero Liquid Discharge (ZLD) compliance
fulfilled.

Reuse the Effluent and reduce the plant Specific

Problem Statement Water Consumption (SWC) within the
Normative value for
Prior to ZLD installation, the plant discharged
approximately 643 KLD of effluent. To mitigate this and SWC for FY: 2021-22 Annual Water
recover water, a ZLD system was implemented. 3.78 M³/MWh savings

2.35 Lakh KL
SWC for FY: 2022-23

Reason to Select the Problem 3.43 M³/MWh

Net Annual Energy
SWC for FY: 2023-24 Savings
Excessive water consumption led to high Specific Water
Consumption (SWC), often exceeding the 3.5 M³/MWh 2.93 M³/MWh 91.416 MWh
norm. Additionally, water procurement costs escalated.

CO₂ emission reduction/Yearly

Technology Application 446 Tons

Proven technology used
KPIs
Plant DC, APC, SOC & SWC are within
the Normative value.

ROI
2.49 Years

ZLD Installation

31 CII-Consultivo ENCON Compendium 2024

 B5 [Category B: Power: Energy Efficiency Best Practice 5]

Single Compressor Operation

out of 4 Compressors

Industrial Energy Limited Industry: Power

A JV of Tata Power And
Tata Steel Limited Location: Kalinganagar, Odisha

Industrial Energy Limited optimized compressor usage by

implementing single compressor operation, reducing
power consumption from 6,000 kWh to 3,600 kWh per day.
Air leaks were identified with sonic imaging, and auto-start
logic was added, yielding a ₹13.33 lakh cost saving with
zero investment.

SDG
Linkage

Air Leakages Identification Using Sonic

Problem Statement Industrial Imager
1. Two compressors consume 6000 KWH per day, while a
single compressor reduces consumption to 3600 KWH
per day. Solution/Good Practice
2. Reliability concerns and air leakages prevent operating
1. Air leakages identification by Fluke Acoustic
with a single compressor, and the auto start logic for
Industrial Imager
two working and two stand-by compressors is not
2. Monitoring of Compressors Performance by
supportive.
data analysis.
3. Logic of Compressor auto start in single and
Reason to Select the Problem dual mode implemented.
After commissioning the third turbine generator, APC 4. Audible annunciation included with hooter
increased due to partial load operation from blast furnace sound for monitoring compressor
gas shortage, and while energy-saving initiatives were parameters.
implemented, optimizing compressors could not be done
due to reliability concerns.
Benefits/Outcomes
Technology Application 1. Asset saving by stopping low-efficiency
1. Application of new technology. Air leakages compressor.
identification using sonic industrial imager and 2. Cost saving is 13.33 lacs which is passed on
rectification. to the customer (TSK)
2. Auto start logic implementation for single mode, Dual 3. Increase in customer delight
mode compressor operation and header pressure low
operation.
KPIs:
Auxiliary Power Consumption (APC)
Fuel Switching / RE Application
As this is a gas-based power plant and Blast furnace gas ROI
and Coke oven gases are the primary fuel; this is helping in Zero investment through
carbon emission reduction of TSK. collaboration and in-house resources.

32 CII-Consultivo ENCON Compendium 2024

 B6 [Category B: Power: Energy Efficiency Best Practice 6]

Transforming Power Efficiency with Uptime AI:

Predictive and Prescriptive Analytics for
Optimized Operations
Industry: Power Generation - Thermal
Tata Power
Jojobera
Location: Jojobera, Jharkhand

Tata Power Jojobera enhanced power efficiency with

Fuel Switching / RE
Uptime AI, using predictive analytics to monitor power
consumption and heat rate, reducing forced outages from Application
0.96% to 0.05% and realizing notional savings of ₹4 crore.
While Uptime AI is primarily focused on
optimizing operational efficiency and reliability,
it indirectly contributes to Tata Power's
SDG
Linkage renewable energy initiatives.

Problem Statement Solution/Good Practice

Traditional systems for detecting performance issues were
reactive in nature, resulting in delayed responses to potential The implementation of Uptime AI
efficiency losses or equipment failures. This necessitated the enabled the utilization of predictive
development of more effective methods to monitor and analytics models to track auxiliary
optimize auxiliary power consumption and heat rate. power consumption and heat rate in
real-time

Reason to Select the Problem

The objective was to decrease auxiliary power consumption,
Benefits/Outcomes
enhance heat rate, improve plant reliability, and ultimately
Reduced forced outage rates from
reduce operational costs by proactively identifying and
addressing potential issues. 0.96% to 0.05%
Lowering APC by
0.25%
Innovation
Uptime AI's strength lies in its ability to combine machine KPIs
learning with real-time data to identify patterns, predict Forced outage rate reduction from
anomalies, and track equipment performance. Uptime AI 0.96% to 0.06%
correlates multiple data points to provide actionable
insights reducing unplanned downtime, and improving
operational efficiency. ROI
Notional savings exceeding
₹4 crore
were realized due to a
Technology Application
reduction in forced outages
Uptime AI's core technology leverages machine learning and improved efficiency
algorithms to analyze real-time data and predict anomalies.

33 CII-Consultivo ENCON Compendium 2024

Chapter 01 02 03 04

04
Way Forward
The CII-Consultivo ENCON Compendium 2024 offers industries a
practical resource to accelerate their energy efficiency journeys.

By leveraging the 27 best practices showcased across manufacturing

and power sectors, organizations can gain actionable insights to
address their unique energy challenges. Here’s how industries can
make the most of this compendium:

Benchmarking and Gap Analysis Customization and Implementation

Compare your current energy Use the problem statements and solutions
management practices with the detailed outlined in the compendium as a framework
examples in the compendium. to design tailored energy efficiency programs.
Identify gaps and opportunities where Focus on practices that align with your
similar innovations and technologies can organization’s processes, priorities, and
be adapted to your operations. sustainability goals.

Knowledge Sharing and Collaboration Integration into ESG Strategies

Share insights from the compendium Embed these best practices into your ESG
within your teams to foster a culture of strategies to achieve measurable
innovation and energy awareness. improvements in energy performance and
Collaborate with technology providers carbon footprint reduction.
and stakeholders highlighted in the case
studies to explore implementation
opportunities.

Feedback and Continuous Improvement By embracing these practices and fostering

Apply the lessons from the compendium innovation, industries can significantly
and monitor the outcomes. enhance their energy efficiency, reduce costs
Provide feedback on the practices and and emissions, and contribute to a
suggest new ideas or challenges you sustainable future.
encounter. Your inputs will help refine
and expand future editions of the Let this compendium be a catalyst for
compendium. action and collaboration in the energy
transition journey.

34 CII-Consultivo ENCON Compendium 2024

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