Technological Interventions for Industry

Development & Demonstration of new innovative technology for air pollution control & energy efficiency in Brick Industry

Punjab State Council for Science & Technology (PSCST) had demonstrated technology for air pollution control in brick kilns way back in 1997.  This technology has already been replicated in more than 3000 brick kilns in the country. The main strength of PSCST  while transferring the technology in the ground is imparting extensive training to brick kilns owners and their work force on better feeding, firing and operating practices which helps in reduction of black smoke emissions. This technology for brick kilns had been approved by State Pollution Control Boards of Punjab, Uttar Pradesh, Jammu & Kashmir and Haryana. Further, PSCST, has also been involved in conducting studies on behalf of Central Pollution Control Board for evolving the national emission standards for brick kilns wherein a thorough monitoring of 50 brick kilns, representing all the prominent technologies throughout the country was carried out before framing the emission norms.

The Council has now developed and demonstrated a new energy efficient technology for brick kilns low particulate emissions under the project supported by DST, GOI.   


Promotion of Resource Efficient Brick manufacturing units 

PSCST had earlier functioned as Local Resource Centre (LRC) for Northern region under the UNDP-GEF project on “Energy Efficiency Improvement in Indian Brick Industry” during the period October, 2009 to December, 2011. During this period, PSCST team sensitized brick kiln owners, Architects, Builders and other end users to promote Resource Efficient Bricks (REBs)  i.e. Hollow/Perforated Bricks in the region. PSCST facilitated setting up of 4 REBs production units (one each in Dera Bassi, Ludhiana, Hoshiarpur and Tohana- Haryana). 

UNDP has now assigned the task of “Setting up 3 Resource Efficient Brick (REB) Units and preparation of Investment Plans for 25 REB Units” to PSCST. The project aims at reducing energy consumption and thereby GHG emissions by manufacturing and promoting the use of clay fired Resource Efficient Bricks (REBs) including fly-ash based bricks/ blocks, which will have other co-benefits as well, such as soil conservation in the Northern States of Punjab, Haryana, Himachal Pradesh, Jammu & Kashmir, Western U.P. and Rajasthan. 

The assignment was to be executed in two parts. The Task-I involves identification of 25 interested units and preparation of detailed investment plans for REB production units in the Northern States in a time period of 6 months. Whereas, under Task-II, 3 REB manufacturing units were to be set up in the northern states.

To accomplish Task-1, PSCST interacted with 9 machinery manufacturers/vendors active in India for short-listing the technology as per the requirement of interested parties in the region. Further, discussions were held with interested parties for finalizing the technological options with regards to production, scale of technology etc. PSCST also facilitated visits of few interested parties to the existing REB production units across the country for addressing their doubts/queries. Energy & Resource audit of 4 kilns at Patiala, Ludhiana, Amritsar and Qadian were conducted. Detailed Investment Plans for 26 REB production units were prepared for working out cost benefit analysis of the unit by adopting REB manufacturing technology. These plans could be used as ready-made documents for attracting potential investors. The project benefits w.r.t  implementation of REB technology by all the 26 units under Task-1 are as under:

The REB manufacturing units have been set up at 3 locations i.e. Amritsar (Punjab), Sonipat (Haryana) and Nalagarh (HP). 

PSCST has been consistently following up with the State Government construction departments for inclusion of item rates of REBs in various construction activities. For this, meetings were held at the level of Technical Advisor to Chief Minister, Punjab; consultants, architects and senior officers of different departments in order to sensitize them about the production of REBs and their benefits. Punjab Public Works Department (PPWD) has included perforated and hollow bricks as walling material in government schedule of rates for various items. Further, on the demand of officers of government construction departments, an Awareness Works on Use of REBs was organized in collaboration with TERI.  
 
The Terminal Evaluation of Project was conducted by Third Party Consultants (one international and another Indian) appointed by the UNDP. The team visited two REB manufacturing units at Dera Bassi (Punjab) and Sonipat (Haryana) and have appreciated the efforts of PSCST in accomplishing the project. Besides this, PSCST has also taken up the matter with MoEF & CC and Ministry of MSME for getting incentives for such initiatives of adopting energy efficient and pollution reduction technologies under MSME scheme titled “Credit Linked Capital Subsidy Scheme” (CLCSS).

Energy Efficiency in Rolling Sector

United Nations Development Program (UNDP) awarded a project entitled “Up-scaling Energy Efficient Production in Small Scale Steel Industry in India” to us wherein Council was designated as Cluster Level Agency (CLA) to support energy efficient production in small scale steel industry in Mandi Gobindgarh Cluster. 

The project envisaged facilitating the diffusion of energy efficient technologies  (EETs) in the secondary “Steel Rerolling Mill (SRRM)” and Electric Induction Furnace (EIF) sector to bring down end use energy level, improve productivity and cost competitiveness and to reduce associated emission of green house gases (GHG) and related pollutant level. 

 Under the project, PSCST identified 60 re-rolling mills (both ingot and scrap based) with production capacity ranging between 2-15 tonne per hour. PSCST facilitated baseline studies and implementation of 20156 Energy Efficient Technology (EET) packages in 60 re-rolling mills. The EET package included  shell & shell type waste heat recovery system specially designed for pulverized coal fired furnace, Coal pulverizers with improved metallurgy, Proportional Integrated Differential (PID) based furnace temperature control system, Antifriction roller bearing stands with universal spindles and couplings, Insulation, Y-roller/tilting/conveyer tables etc. PSCST as CLA organized 17 interactive meets/cluster level meeting/workshops/vendor meets/capacity building programs besides exposure visits to the model units to sensitize the mill owners and facilitate transfer of technology in the units. These mills invested around 4 crores on the EET packages and the implemented technologies have payback period of less than 6 months. 

Post implementation studies, conducted by an independent agency- appointed by UNDP, revealed that these 60 units achieved 6-24 % reduction in Specific Energy Consumption (SEC). An annual energy saving of 309.32 TJ worth Rs. 20.35 crores is envisaged besides carbon footprint reduction by 35,533 tonnes from Mandi Gobindgarh’s cluster alone. 

PSCST achieved 92% success rate while implementation of technologies and achieving minimum 5% SEC reduction target under the project.

  

 

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