Industrial Sectors

Perform, Achieve and Trade (PAT)The Perform Achieve and Trade (PAT) Scheme is one of the initiatives under the National Mission for Enhanced Energy Efficiency (NMEEE), which was notified on 30th March 2012. PAT scheme is a market-based compliance mechanism to accelerate implementation of cost-effective improvements in energy efficiency in large energy-intensive industries, through certification of energy savings that could be traded. The genesis of the PAT mechanism flows out of the provision of the Energy Conservation Act, 2001 (Amended in 2010).The key goal of the PAT scheme is to mandate specific energy efficiency improvements for the most energy intensive industries. The scheme builds on the large variation in energy intensities of different units in almost each notified sector, ranging from amongst the best in the world to some of the most inefficient units. The scheme envisages improvements in the energy intensity of each unit covered under it. The energy intensity reduction target mandated for each unit is dependent on its current efficiency with reduction target being lower for the more efficient units and higher for the less efficient units.BEE has rolled out seven PAT cycles covering 13 sectors (Aluminium,Cement,Chlor-Alkali, Commercial Buildings (Hotels), DISCOM, Fertilizers, Iron and Steel, Petrochemicals,Petroleum Refinery, Pulp & Paper, Railways, Textile and Thermal Power Plant). PAT Cycle wise number of sectors, number of Designated Consumers (DCs), their energy consumption (Million TOE), energy savings target (Million TOE), target achieved (Million TOE) and CO2 reduction (Million Tonne of CO2) are presented below:PAT CycleNo. of SectorsNo. of DCsAnnual Consumption (MTOE)Target (MTOE)Achieved (MTOE)CO2 Reduction (Million Tonnes)I8478165.226.6838.6731II11621227.0013.6314.0868.43III611635.191.0631.5945.59IV810918.600.701--V811015.240.513--VI613523.301.277--VII9707248.208.485--The realized impact of PAT Cycle I is given below:Source: BEEThe realized impact of PAT Cycle II is given below:Source: BEE

Brief Overview of Sugar SectorIndia ranks as the world's second-largest producer of sugar, with key states like Maharashtra, Gujarat, Bihar, Andhra Pradesh, Haryana, Karnataka, Punjab, Uttar Pradesh, and Tamil Nadu leading the production. This sector significantly impacts the lives of around 50 million sugarcane farmers and nearly 500,000 mill workers, generating employment across various associated sectors such as transportation, trade, machinery, and agricultural inputs. The annual output value of India's sugar industry stands at ₹80,000 crores.As of 2021, India has installed756 sugar factories, equipped with enough crushing capacity to yield approximately 350 lakh MT of sugar. This capacity is almost evenly split between privately-owned units and cooperative sector units. Most sugar mills typically have a crushing capacity ranging from 2500 TCD (Tons of Cane per Day) to 5000 TCD, but there's a growing trend of expansion, with some even surpassing 10000 TCD. Among the 756 installed sugar mills, 522 were operational during the 2021-22 sugar season.Ethanol, primarily derived from molasses, a by-product of the sugar industry, plays a crucial role, particularly during years of surplus sugarcane production. It aids the industry in managing timely payments to farmers. The Ethanol Blending Programme (EBP) aims to blend ethanol with motor fuel to reduce pollution, conserve foreign currency, and support the industry in settling payments to farmers. Manufacturing Process and Energy ConsumptionThe typical sugar production process includes these steps:Juice extraction: The juice extraction facility comprises cane handling, cane preparation, and milling segments. The extraction of juice from the prepared sugarcane involves two distinct methods. Around 95 to 97% of sugar factories utilize the milling process, while the diffusion process is employed by around 3 to 5% of these factories.Cane Handling: The arrival of cane at the mill involves a mechanical unloading process using a grab-type attachment. Occasionally, a truck tippler is installed to aid in unloading the cane, simplifying the transfer of sugar cane onto the cane carrier.Cane Preparation: The sugarcane undergoes levelling in the leveller prior to entering the cutter. This machine shreds the cane into smaller pieces, preparing it for the fibrizer, where the cane is transformed into a pulp-like substance.Milling: The processed sugarcane undergoes milling through a tandem of four to six three-roller mills. High-pressure squeezing in these rollers extracts the juice from the cane. To maximize extraction, the disintegrated cane is thoroughly washed with weak juice and makeup water in a counter-current system. The resulting fibrous residue, known as bagasse, left after milling, serves as fuel for steam generation.Diffusion: The diffusion process involves a methodical washing of cane or bagasse through a continuous counter-current system using imbibition water. Water is introduced at the conveyor's discharge end, filtering through the bed of bagasse and the perforated slats of the conveyor. This water facilitates the dissolution of sugar within the bagasse, resulting in a thin juice collected in a hopper. Through pumping, this juice progresses through stages until it reaches peak concentration at the diffuser's input end. The diffuser can be configured for either a single-flow or parallel-flows circulation of juice.Juice Clarification: The process of juice purification includes several steps: (a) heating the juice, (b) applying sulphitation, (c) clarification, and (d) filtration. Initially, the mixed juice from the mills undergoes heating in raw juice heaters. Chemical treatment follows, causing the precipitation of various dissolved impurities in the heated juice. These precipitates are then separated to achieve clear and pristine juice in clarifiers. Subsequently, the clear juice undergoes another round of heating to reach a temperature of approximately 105°C.Evaporation: The juice undergoes concentration from 15 Brix to ~ 60 Brix using a multiple-effect evaporator. Vapours extracted from these evaporators are utilized for heating the juice in different heat exchangers and for boiling the massecuite (a blend of molten liquid and crystals) in vacuum pans. This process stands as the primary steam-consuming segment within the facility.Crystallisation: Crystallisation, referred to as Pan boiling within the sugar industry, stands as a vital unit operation. Most sugar mills conduct a significant portion of the crystallisation process using batch-type vacuum pans. Following this stage, the massecuite is moved to crystallisers, where the process concludes through the cooling of the mass under stirred conditions.Centrifuging: The massecuite derived from the vacuum pans undergoes separation of sugar crystals from molasses within the centrifuges. These centrifugal devices can be categorized as batch or continuous types and are specifically designed for different massecuite types—'A', 'B', and 'C'. The extracted molasses from this process serves as a valuable by-product, widely regarded as an excellent raw material for distilleries.Drying, Grading and Packing: The moist crystals acquired from centrifugal machines typically hold around 15-20% surface moisture. These crystals undergo drying in conventional dryers, are sorted based on their sizes, and are subsequently packaged into bags.Sugar production in India had been cyclic in nature. Every 2-3 years of high sugar production were followed by low sugar production. However, from the sugar season 2017-18 and onwards, the country has produced surplus sugar than the domestic requirement of about 250-265 Lakh Metric Tonnes. The season-wise production of sugar from 2011-12 and onwards is as belowSugar Season (October – September)Production of Sugar (Qty. in lakh tonne)2011-122632012-132522013-142452014-152842015-162512016-172022017-183222018-193322019-202742020-213102021-223592022-23 (As on 21.03.2023)288 Fig: Sugar Manufacturing Process (Source)Sugar mills, recognized as energy-intensive sectors as per the ‘Energy Conservation Act, 2001’, necessitate substantial energy inputs. The energy usage within these mills is shaped by several factors including capacity, steam generation parameters, equipment age, and the specific machinery employed.Typically, electricity consumption per tonne of sugar produced ranges from 200 to 500 kWh depending on the production year. The average energy consumption in an Indian sugar mill stands at ~ 26 to 40 kWh per tonne of cane (Source: TERI Energy Audit Reports). For a standard sugar mill with a crushing capacity of 3400 TCD, the total power requirement is around 4.0 MW. Steam consumption varies between 30% and 50% per tonne of cane based on factors like capacity, evaporator vapor bleeding arrangement, and equipment age. PAT Scheme for Sugar SectorAs per notification from Ministry of Power dated 6th June 2023, Units of sugar plants or establishment those are under production of sugar and its variants such as white sugar, brown sugar, and liquid sugar, having energy consumption of 10,000 metric tonne of oil equivalent per year or above will qualify as a Designated Consumer in Sugar Sector. This sector is yet to be covered in the PAT scheme. Best Practices Adopted by Sugar SectorSugar industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures: Use of high yielding varietiesDrip IrrigationSoil health improvement Details of Line MinistriesMinistry of Consumer Affairs, Food & Public Distribution Details of Specialised Organization / Research Institute  Indian Institute of Sugarcane Research National Sugar Institute Sugarcane Breeding Institute Details of Industrial AssociationsIndian Sugar Mills Association (ISMA)  List of Key Technologies  Soil Moisture Indicator Sugarcane Sett treatment device Information and Communication Technology in Sugarcane Agriculture  Irrigation Management to Enhance Water Availability Bio-intensive Nutrient Management 

REFINERY SECTOR IN INDIAThe oil and gas sector is among the eight core industries in India, thus holding an influential position in the decision-making processes at the top government level that affect all other important sectors of the Indian economy. With a massive capacity 247.571 MMTPA, the Indian Refinery sector is next only to the US and China in global volumes. Within the country, the sector is the second-largest energy consumer. Of the total refining capacity, more than half comes from public sector refineries. India’s economic growth and demand for energy are strongly interlinked, and hence the forecast for growth in the refinery sector remains positive for several years in the future. PAT SCHEME FOR THE REFINERY SECTOR There are around 23 Petroleum refineries plants in India. Out of this PAT has covered 20 plants. However, these plants are the large plants which has the maximum energy consumption and has the maximum share in India’s total production. It is evident that the large producers which are also the large energy consumers in the sector has been covered under PAT as 87% of the plants the PAT scheme produces more than 94% of the total production in country.PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Refinery Sector are presented below:CyclesNo. of DCsTotal Energy Consumption (Million TOE)Energy Saving Targets (Million TOE)PAT Cycle I---PAT Cycle II1818.501.098PAT Cycle III---PAT Cycle IV---PAT Cycle V---PAT Cycle VI2021.3041.169PAT Cycle VII--- BEST PRACTICES ADOPTED BY THE REFINERY SECTOR Commissioning of heat integrated, energy efficient crude distillation unit (CDU).Implementation of Advance process control (APC) in CCR.Replacement of third stage ejector system by Liquid ring vacuum pump (LRVP) in vacuum distillation unit (VDU).Furnace efficiency improvement of CDU heater.Process parameters and APC optimization.“IndeDiesel Technology” - DHDT Hydrotreatment for Euro-IV & V diesel (S < 50 & 10 ppm, CN > 51).“IndeHex Technology”- Food Grade Hexane Hydrotreatment of hexane for benzene removal (< 100 ppm).“IndJet Technology” - ATF Hydrotreating - Selective Removal of Mercaptan Sulfur in ATF / desulphurisation of kerosene.NDMAX Technologies- A novel technology to produce high yield of light olefins / LPG and high octane gasoline from various petroleum fractions.Innovative methodology for prediction of Refining Characteristics of Oil (BPMARRK).IndSelectG Technology- Selective desulphurization of full range FCC & other cracked gasoline streams to meet BS-VI S spec with minimum loss of RON (~3 units).One Divided wall column in place of 2 columns in FCC Naphtha splitter.LP steam superheating with MP steam in shell and tube exchanger in place of direct mixing.Energy real time optimizer (ERTO software).Substituting N2 blanketing in place Fuel gas in Naphtha splitter receiver. 

Brief Overview of Textile Sector;Indian textile and apparel industry contributes ~2% to the national GDP and 7% of industry output in value terms. India accounts for ~4% of the global trade in textiles and apparel. In 2020-21, textiles, apparel & handicrafts together accounted for ~11.5% of India’s total exports. The domestic textiles & apparel industry stood at GBP 130 bn in 2021. Indian textiles and apparel industry employs 45 million people directly and 100 million people in allied industries, making it the 2nd largest industry by manpower. The textile industry in India includes a wide range of segments – from traditional handloom & handicrafts to cotton, wool & silk, and the ‘organized textile industry’. The organized textile industry is marked by its use of capital-intensive technology for mass production and includes apparel manufacturing, spinning, weaving, processing, etc.Cotton production in India is projected to reach 7.2 million tonnes (~43 million bales of 170 kg each) by 2030 driven by increasing demand from consumers. Thehandicraft exports from India too are expected to rise YoY due to increased participation from industry players to boost handicraft products in the global market. Manufacturing Process & Energy ConsumptionThere are broadly three manufacturing processes, spinning, weaving and processing. A particular unit can be either composite covering all the three processes or a unit just covering one process such as spinning.Spinning Process: In the spinning process, raw cotton is converted into yarns in several steps which includes blow room, carding, drawing, rowing, spinning, sizing and weaving, desizing, scouring, bleaching, calendaring, dyeing and printing. Weaving Process: Weaving is the process of making fabric or cloth using the yarns. In it, two distinct sets of yarns called the warp and the filling or weft are interlaced with each other to form a fabric. Yarn is a long continuous length of interlocked fibres. The lengthwise yarns which run from the back to the front of the loom are called the warp. The crosswise yarns are the filling or weft. A loom is a device for holding the warp threads in place while the filling threads are woven through them. The sub-processes which are usually involved in weaving include warping, sizing, reeding, weft prim winding, weaving, shearing, folding, and packing. Processing: It covers all processes in a textile unit that involve some form of wet or chemical treatment. The wet processing process can be divided into three phases: preparation, coloration, and finishing. It uses different types of technologies depending on the type of yarn or fabric that are dyed. Jigger, winch padding, mangle and jet-dyeing are some of the important dyeing machines. Similarly, there are different types of printing: direct printing, warp printing, discharge printing, resist printing, jet printing, Rotary printing etc.Energy use in a textile mill depends upon the deployed process. For spinning and weaving mills, electricity is the main source of energy whereas for process houses, both electrical and thermal energy are needed, thermal constituting the major source. In an integrated mill, almost 80% of the total energy need is thermal. Typical break up of electricity and thermal energy consumption for an integrated mill is shown in below table: Electricity ConsumptionThermal ConsumptionAreas%Areas%Spinning Preparatory13Boiler Loss25Ring frame28Steam Distribution Loss10Weaving18Bleaching & Finishing35Humidification19Dying and Printing15Processing10Humidification & Sizing15Others12  Energy consumption in a spinning mill is primarily electricity used in the production machineries and auxiliaries. In weaving process, energy is used for operating machines, air conditioning and illuminating the area where fabrics are manufactured. In addition to these, compressors, which provide compressed air to the weaving line, use energy. Electricity is used for machines, air conditioning, illumination and compressors, while thermal energy is consumed by processes such as sizing and sometimes by air conditioning.  PAT Scheme for Textile Sector The Textile sector is one of the designated sectors covered under the BEE’s Perform, Achieve and Trade scheme. The Textile industry in India can be classified into organized and decentralized/ rural sectors. The organized sector comprises mills which include both spinning mills and composite mills. The decentralized power-loom/ hosiery and knitting sector form the textile industry's largest section.In the Indian textile sector, a unit with an annual consumption of over 3,000 tonnes of oil equivalent (TOE) is notified as a designated consumer (DC) under the Energy Conservation Act, 2001. PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Textile Sector are presented below:CyclesNo. of DCsTotal Energy Consumption (Million TOE)Energy Saving Targets (Million TOE)PAT Cycle I901.20.13PAT Cycle II991.480.088PAT Cycle III340.6680.04PAT Cycle IV70.3420.0204PAT Cycle V160.22670.0135PAT Cycle VI70.1120.007PAT Cycle VII1201.920.099PAT Cycle VIII380.56180.0334Energy Savings Achievement in the Textile Sector under PAT Cycle I and PAT Cycle II are 0.13 Million TOE and 0.136 Million TOE respectively. Best Practices Adopted by Textile SectorTextile industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures:Waste heat recovery from PV motex stenter.Installation of a Low-pressure Air compressor with a Heat Recovery unit.Installation of Flash jet recovery system.Installation of VFD in Weaving chiller Cooling tower Fan.High-pressure mist spray system at AWT.Use of Removable reusable insulation.Pulser dyeing technique. Microbial fuel cells technology to generate electricity from textile wastewater treatment. Energy recovery from H-plant exhaust air by providing a special turbine which generates electricity to be used for lighting purpose.   Details of Line Ministries Ministry of Textiles  Details of Specialised Organization / Research Institute Ahmedabad Textile Industry’s Research Association (ATIRA), Gujarat Bombay Textile Research Association (BTRA), MumbaiSouth India Textile Research Association (SITRA), CoimbatoreMan-made Textile Research Association (MANTRA), GujaratNorthern India Textile Research Association (NITRA), GhaziabadIndian Jute Industries Research Association (IJIRA), KolkataWool Research Association, Thane Details of Industrial Associations Textile Association of IndiaConfederation of Indian Textile Industry List of Key Technologies Various Dyeing processes such as Pulser Dyeing Technique, Airflow Dyeing Technology, Digital Dyeing, and Supercritical CO2 Dyeing Technique.Technological processes such as Ultrasonic Assisted Wet Processing, and Closed condensate recovery pump.Wind recovery turbine from humidification exhaust Microbial fuel cells technology to generate electricity from Textile wastewater treatment.Energy Recovery from H-Plant exhaust air by providing a special turbine which generates grid-connected electricity to be used for lighting purposes.Clean-tech digital textile manufacturing solutions.Ultrasonic Assisted Wet ProcessingSupercritical CO2 Dyeing Technique

Brief Overview of Chlor-Alkali SectorThe Chlor-Alkali industry in India produces about 69% of the basic chemicals in India, making it an important sector in manufacturing. Caustic soda, Chlorine, Hydrogen and Hydrochloric Acid are the main components of the Chlor-Alkali industry. These chemicals find their applications in a number of industries such as textiles, chemicals paper, PVC, water treatment, alumina, soaps & detergents, glass, chlorinated paraffin wax, among others. There are 32 plants in the country, with 56% of capacity in Western India alone. India constituted to 4% of global Chlor-Alkali capacity with installed capacity and production of 4.38 million TPA and 4.54 million TPA respectively.Alkali chemicals production rose by 4.32% in FY 2017-18, with growth being steady over the years.With a capacity of 2 million tonnes, Gujarat is the largest State for the manufacturing of Caustic Soda. Gujarat also accounts for about half of India’s annual Caustic Soda production, pegged at 35.39 Lakh MT for 2018-19.Among the 32 plants of the Chlor-Alkali industry in the country, most are merchant units, with an average plant size of about 150 tonnes per day (TPD). Manufacturing Process & Energy ConsumptionThe Chlor-alkali process is so called due to simultaneous production of caustic soda and chlorine. The production process involves electrolysis of brine followed by other processes as shown in the following picture. Electrolytic cell is the core of the process. Three cell technologies; Mercury, Diaphragm and Membrane are used for the electrolysis. Now Membrane technology is widely used in the Chlor-Alkali Plants. Energy consumption is highest in the mercury cell process but it does not require steam for concentration of caustic soda. Membrane cell is most energy efficient but requires some steam for evaporation to concentrate the liquor of about 32-33% concentration to about 50%, the standard market product. Apart from higher level of energy consumption, mercury cells are also polluting and as such have been almost totally phased out in India.Electricity is the primary source of energy for the Chlor-alkali manufacturing process; though some small amount of thermal energy is needed for increasing the concentration of cell liquor produced in diaphragm and membrane cells. The electrolysis energy need in the membrane cell process is close to 90% of the total energy, balance 10% being almost equally shared by auxiliary and thermal energy consumption. In the overall context, typical distribution of energy usage in different sub-processes is shown below:Sub- Processes% of Total Energy Consumption (Equivalent to AC kWh/T CL2)Electrolysis89Auxiliary5Thermal6Further, most of the plants have their coal based captive power plants meeting practically the entire power demand of the manufacturing process. Typical fuel mix of Chlor-Alkali manufacturing process is presented below: Types of Fuels%Coal75Oil2Gas13Grid Electricity10 PAT Scheme for Chlor- Alkali SectorThe Chlor-Alkali Sector is a designated sector covered under the Bureau of Energy Efficiency’s flagship Perform, Achieve and Trade (PAT) scheme for large energy-intensive industrial sectors. PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Chlor-Alkali Sector are presented below:CyclesNo. of DCsTotal Energy Consumption (Million TOE)Energy Saving Targets (Million TOE)PAT Cycle I220.890.09PAT Cycle II241.770.102PAT Cycle III---PAT Cycle IV20.050.003PAT Cycle V20.02820.0017PAT Cycle VI---PAT Cycle VII242.480.097PAT Cycle VIII10.1350.00810Energy Savings Achievement in the Chlor-AlkaliSector under PAT Cycle I and PAT Cycle II are 0.09 Million TOE and 0.136 Million TOE. Best Practices Adopted by Chlor-Alkali SectorChlor-Alkali industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures:Technology upgradation to Zero-gap technology.Installation of micro-turbine.Feeding of 48% hot Caustic Soda Lye direct to flaker plant.Changeover of fuel from Furnace Oil (FO) to Hydrogen in process heating/steam requirement.Utilizing Hydrogen in Captive Power Plant.PEM Fuel Cell Technology using Hydrogen.Hydrogen Compressed Natural Gas (HCNG) (Hydrogen blending with CNG). Details of Line MinistriesDepartment of Chemicals and Petrochemicals (https://chemicals.gov.in/) Details of Specialised Organization / Research InstituteIndian Institute of Chemical Technology, HyderabadNational Chemical LaboratoryIndian Institute of Chemical Engineers Details of Industrial Associations Alkali Manufacturers Association of India (AMAI) List of Key TechnologiesZero Gap ElectrolyserOxygen-Depolarised Cathodes (ODCs)Hydrogen Fuel Cell for Electrolysis in Caustic Soda Production 

Brief Overview of Tyre SectorThe tyre industry is pivotal in the automotive sector, driven by OEM and replacement segments. Current OEM demand aligns with new automobile production trends, while the replacement segment is linked to usage patterns. Presently, the replacement sector holds a significant market share, with a notable 133% surge in radial tyre adoption for passenger cars from April to August 2021. In contrast, only 60% of truck and bus tyres and 40% of LCV tyres have transitioned to radials.In the fiscal year 2019, the Indian tyre industry exceeded £7.41 billion, involving over 40 manufacturers in 60 production facilities. Employing over 2 million people directly and supporting over 1 million jobs indirectly, the industry is substantial.The top 10 players collectively dominate 90-95% of the market share, with the leading few in each segment controlling 70-80%. Major players like MRF, Apollo Tyres, and JK Tyres collectively capture around 60%. Despite intense segment-level competition, no single manufacturer holds dominant market share or significant pricing power, resulting in a moderately competitive industry overall (Source: Present Scenario of Tyre Industry in India, The Role and Relevance in Indian Economy). Manufacturing Process and Energy ConsumptionManufacturing tyres involves the conversion of raw materials into final products utilised in diverse vehicles. The tyre industry, characterised by specialisation, relies on advanced technology and machinery to produce resilient and top-quality tyres. Key raw materials in tyre manufacturing encompass natural and synthetic rubber, carbon black, and various chemicals. These materials undergo meticulous blending and processing to form distinct tyre components, such as treads, sidewalls, and inner liners. The tyre production process encompasses crucial stages like mixing and extrusion, calendaring, building, curing, and inspection and testing, all subject to rigorous quality control to ensure adherence to specifications and performance standards.In the initial step of mixing and extrusion, raw materials are blended in a sizable mixer and then heated and extruded through a machine, forming tyre components like treads, sidewalls, and inner liners. Following this, calendaring involves passing the extruded rubber through rollers to achieve uniform thickness and shape, with the rubber subsequently cut and marked as needed. The subsequent building stage involves the assembly of tyre components into a cohesive unit, including placing the inner liner, adding the tread and sidewall, and moulding the tyre into its final shape.Fig: Tyre Manufacturing Process (Source: Presentation of JK Tyre, Chennai)The total energy consumption at manufacturing sites showed a notable increase of 11% from 2009 to 2010. Following this, it remained relatively steady until 2018. In 2019, the overall energy consumption remained constant when compared to 2018 levels. However, in 2020, amid the COVID-19 pandemic, there was a significant decline in total energy consumption by ~12%, aligning with the production levels. During the period from 2019 to 2020, there was a 5% increase in energy intensity. This heightened intensity can be attributed to a comparatively smaller decrease in energy consumption compared to the reduction in production. Some production lines continued operations despite reduced activity, and certain machinery, such as heating equipment, remained in continuous operation (Source: Environmental Key Performance Indicators for Tire Manufacturing 2009-2020, Tire Industry Project 2021, World Business Council for Sustainable Development). PAT Scheme for Tyre SectorAs per notification from Ministry of Power dated 6th June 2023, Units of tyre manufacturer plants or establishments those are under manufacturing of tyres, having energy consumption of 7,000 metric tonne of oil equivalent per year and above will qualify as a Designated Consumer in Tyre Manufacturing Sector. This sector is yet to be covered in the PAT scheme. Best Practices Adopted by Tyre SectorTyre industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measures:Recycling and Waste Management.Installation of (Variable Frequency Drive) VFDs.Use of energy though Renewable Resources.Replacing air blower fans to energy efficient fans.Use of energy efficient (IE-3) motor in place of conventional motor. Details of Line MinistriesMinistry of Commerce and Industry Details of Specialised Organization / Research InstituteIndian Tyre Technical Advisory Committee (ITTAC) Details of Industrial AssociationsAutomotive Tyre Manufacturers' Association (ATMA) List of Key TechnologiesUse of Eco tyres (made up of compounds of different types of rubber and other materials that work together to decrease friction with the road to increase fuel efficiency).Thermal Energy Management System (TEMS) technology. This can help to improve the efficiency of rubber manufacturing processes by reducing the amount of energy needed to heat and cool the process. This can lead to significant savings on energy costs.Energy efficiency solutions and equipment upgrades.Use of Carbon Nanotubes (CNT) in Tyres.

Brief Overview of Iron & Steel SectorIndia is currently the world’s second-largest steel producer, and second-largest steel consumer (WSA, 2020a). As with any industrializing economy, the steel sector is of vital importance to India, contributing around 2% to the country’s GDP and employing around 2.5 million people in the steel and related sectors (MoS, 2020a). The Indian Iron and Steel segment offers a product mix that includes hot rolled parallel flange beams, columns rails, plates, coils, wire rods, and continuously cast products such as billets, blooms, beams, blanks, rounds, slabs, metallic, and ferroalloys. In FY 2018, India’s crude steel production crossed 100 MT for the first time, reaching 106.5 MT and registering a 4.5% year-on-year growth rate, and becoming the 2nd largest producer of steel in the world after China. India was also the largest producer of Sponge Iron (Direct Reduce Iron or DRI) in the world in 2020.In 2017, the Ministry of Steel (MoS) launched the National Steel Policy (NSP), which laid down the broad roadmap for encouraging long term growth for the Indian Steel Industry, both on demand and supply sides, by 2030-31 including to increase India’s teel making capacity to 300 Mt by 2030. This policy also encompasses targets to reduce energy consumption per tonne of steel, through adopting the latest energy efficiency measures.India is also among the largest iron ore producers in the world, ranking 4th globally. Iron ore is a key input product for manufacturing steel and primary iron. More than 85% of the iron ore reserves in the country are of medium or high-grade and are directly used in blast furnace and Direct Reduced Iron (DRI) plants, in the form of sized lumps, sinters, or pellets. Manufacturing Process & Energy ConsumptionThe basic process of manufacturing of iron & steel is carried out in two stages, sponge and pir iron through the reduction followed by production of crude steel. Secondary process involves production of merchant products from the crude steel. The steel industry in India is relatively heterogeneous compared to other countries, with a wide range of different sized facilities in the primary and secondary steelmaking sectors. There are also several different technologies currently being used, including the Blast Furnace – Basic Oxygen Furnace (BF-BOF), coal-based Direct Reduction (DR), gas-based DR, Electric Induction Furnace (EIF) and Electric Arc Furnace (EAF). BOF technology dominates a growing share of steel production (45%), being the preferred technology for most new capacity, with EAF (28%) and EIF (27%) taking an almost equal share of the remainder of the market.BF-BOF process is primarily used by integrated steel plants. After the BF-BOF process, molten steel is controlled to a target composition and temperature and is then cast by continuous casting machine to produce slabs and billets. These castings are rolled to the required dimensions by the rolling mill to produce the steel products. Sponge iron is produced by DRI process. Originally, natural gas based reformation technology used to be used in the DRI process. However, technology for using coal has since been developed and most of the Indian sponge iron units use coal both as fuel and reducing agent. Direct reduced iron along with steel scrap is then melted in an electric arc furnace (EAF) to produce molten steel and subsequent products.Fig: Process diagram of a typical Integrated Steel Plant(Source)The energy used in steel making is classified under primary and secondary sources. Energy purchased from outside such as coal, coke, electricity, gas etc. is classified as primary resource whereas recovered energy such as blast furnace and coke oven gas, waste heat from furnaces is classified as secondary resources. From the energy conservation perspective, major emphasis has always been increased use of secondary resources, such as recent spur in investment in WHR based power plants in large number of sponge iron making plants. Iron making by far the most energy intensive process accounting for close to 60 to 70% of total energy consumption. Typical fuel mix involves a) Coal (83.5%) b) Oil (2%) c) Gas (1.5%) d) Grid Electricity (13%). (Source) PAT Scheme for Iron & Steel SectorThe Iron & Steel sector is one of the designated sectors covered under the BEE’s PAT scheme. The modified threshold limit for the Iron & Steel Sector is 20,000 metric tonnes of oil equivalent of energy consumption per annum.PAT Cycles wise number of DCs, their total energy consumption (Million TOE) and energy savings targets (Million TOE) of the Iron and Steel Sector are presented belowCyclesNo. of DCsTotal Energy Consumption (Million TOE)Energy Saving Targets (Million TOE)PAT Cycle I6725.322.1PAT Cycle II7140.442.283PAT Cycle III297.6480.457PAT Cycle IV353.3340.1934PAT Cycle V232.82550.1687PAT Cycle VI50.5150.031PAT Cycle VII13460.062.729PAT Cycle VIII663.710.2438Energy Savings Achievement in the Iron & Steel Sector under PAT Cycle I and PAT Cycle II are 2.1Million TOE and 2.921 Million TOE respectively Best Practices Adopted by Iron & Steel SectorIron & Steel industries have adopted the following key operational best practices and technologies as part of their Industrial Energy Efficiency and Decarbonisation (IEED) measuresInstallation of Top Recovery Turbine and Pulverized Coal Injection in Blast Furnace.Commissioning of LD Gas Recovery Plant in Steel melting shop.Use of Hydrogen in steel making reheating furnaces.Use of Plastics to replace PCI in Blast Furnaces.Direct rolling in mini steel plants.Hot charging of DRI in EAF. Details of Line MinistriesMinistry of Steel Details of Specialised Organization / Research InstituteResearch & Development Centre for Iron & Steel (RDCIS) SAIL, RanchiSteel Research & Technology Mission of India (SRTMI), New DelhiCentre of Excellence in Steel Technology (COEST), IIT MumbaiNational Institute of Secondary Steel Technology (NISST), Punjab Details of Industrial AssociationsIndian Steel Association List of Key Technologies100% electrolytic hydrogen based DRI.Waste Heat Recovery in Sinter Plat/ DRI.Hydrogen enrichment.Hisarna with 80-90% capture CCS.Increasing share of production from the secondary sector through scrap recycling.Installation of Top Recovery Turbine.Pulverized Coal Injection in Blast Furnace.Coke Dry QuenchingRegenerative/recuperative burner for reheating furnace