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Cluster Profile Report Tirunelveli Lime Kiln Cluster

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Cluster Profile Report Tirunelveli Lime Kiln Cluster Cluster Profile Report Tirunelveli Lime Kiln Cluster Prepared for: Small Industries Development Bank of India (SIDBI) 819, 8th Floor, Antriksh Bhawan, 22 Kasturba Gandhi Marg, New Delhi -110001 Page | 1 Tel 91 11 4079 1100 Fax +91 11 4079 1101 Email: [email protected] Oct-12 Disclaimer This document is an output of an exercise undertaken by DESL through a project funded by the Small Industries Development Bank of India (SIDBI) for the benefit of MSME units. While every effort has been made to avoid any mistakes or omissions, SIDBI would not be in any way liable to any person by reason of any mistake/omission in the publication. Suggested form of Citation DESL-2012 Cluster Profile Report – Tirunelveli Lime Kiln Cluster Published By DESL Development Environergy Services Ltd Formerly, Dalkia Energy Services Ltd. For More Information DESL 819, Antriksh Bhavan 22 Kasturba Gandhi Marg New Delhi 110 001, India Tel. +91 11 4079 1100 Fax. +91 11 40791101 Email [email protected] www.deslenergy.com Printed in India at New Delhi Conservation Redefined Page | 2 CONTENTS ABBREVIATIONS .................................................................................................................................................... 4 LIST OF TABLES ...................................................................................................................................................... 5 LIST OF FIGURES ..................................................................................................................................................... 5 LIST OF ANNEXES ................................................................................................................................................... 5 ACKNOWLEDGEMENTS .......................................................................................................................................... 6 CERTIFICATE OF ORIGINALITY ................................................................................................................................ 7 EXECUTIVE SUMMARY ........................................................................................................................................... 8 1. ABOUT THE PROJECT .................................................................................................................................... 11 2. METHODOLOGY ........................................................................................................................................... 12 3. CLUSTER SCENARIO ...................................................................................................................................... 15 4. MAJOR CLUSTER ACTORS ............................................................................................................................. 22 5. TECHNOLOGY USED AND PRODUCTION PROCESS IN CLUSTER ..................................................................... 24 6. ESTIMATED ENERGY CONSUMPTION PATTERN IN CLUSTER AND SAVING POTENTIAL ................................. 27 7. MAJOR CHALLENGES AND SUGGESTIONS FOR IMPROVEMENT IN THE CLUSTER .......................................... 30 8. SWOT ANALYSIS ........................................................................................................................................... 31 9. CONCLUSION ................................................................................................................................................ 32 10. ANNEXES .................................................................................................................................................. 33 Page | 3 ABBREVIATIONS BEE Bureau of Energy Efficiency CBRI Central Building Research Institute CII Confederation of Indian Industry CO 2 Carbon-di-Oxide DESL Development Enviro Energy Services Ltd DIC District Industries Commission EE Energy Efficiency GEF Global Environment Facility MSME Micro Small and Medium Enterprises NLMA Tirunelveli (Nellai) Lime Manufacturers welfare Association SIDBI Small Industries Development Bank of India SME Small & Medium Enterprises SSI Small Scale Industry TANGEDCO Tamil Nadu Generation and Distribution Corporation Ltd TNPCB Tamil Nadu Pollution Control Board TPD Tons per day VSK Vertical Shaft Kiln WB World Bank WTA Walk Through Audit ZESPL Zenith Energy Services P Ltd. Page | 4 LIST OF TABLES TABLE 1: SWOT ANALYSIS ................................................................................................................................................ 9 TABLE 2 : MAIN SOURCES OF DATA (PARTIAL LIST ) ................................................................................................................. 13 2 TABLE 3 : DETAILS OF LIME BASED INDUSTRIES IN TIRUNELVELI ................................................................................................ 16 TABLE 4 : DESL SURVEY OF INDUSTRIES ................................................................................................................................ 16 TABLE 5 : DISAGGREGATION BY CAPACITY AND KILN SIZE .......................................................................................................... 17 TABLE 6 : DETAILS OF TECHNOLOGY UPGRADES IN THE RECENT PAST .......................................................................................... 19 TABLE 7 : LEAD BANK DETAILS IN TAMIL NADU ...................................................................................................................... 23 TABLE 8 : DETAILS OF OTHER BANKS IN TIRUNELVELI ............................................................................................................... 23 TABLE 9 : CHARACTERISTICS OF CHARCOAL – SAMPLE TESTED FROM LOCAL KILN BY DESL .............................................................. 27 TABLE 10 : CHARCOAL CONSUMPTION IN UNITS SURVEYED ...................................................................................................... 27 TABLE 11: TARIFF STRUCTURE ............................................................................................................................................ 28 TABLE 12 : ELECTRICITY CONSUMPTION IN UNITS SURVEYED .................................................................................................... 28 LIST OF FIGURES FIGURE 1 : METHODOLOGY FOR CLUSTER PROFILING : TIRUNELVELI ............................................................................................ 12 FIGURE 2 : LOCATION OF THE CLUSTER ................................................................................................................................. 15 FIGURE 3 : CAPACITY OF UNITS SURVEYED ............................................................................................................................. 17 FIGURE 4 : KILN CAPACITY AND SIZE DISTRIBUTION ................................................................................................................. 18 FIGURE 5 : AGE PROFILE OF 20 UNITS SURVEYED .................................................................................................................... 18 FIGURE 6 :M EDIUM SIZED PLANTS ENGAGED IN LIME MANUFACTURING .................................................................................... 20 FIGURE 7 : LIME KILNS IN TIRUNELVELI ................................................................................................................................. 24 FIGURE 8 : PROCESS FLOW DIAGRAM .................................................................................................................................. 24 FIGURE 9 :J AW CRUSHER ................................................................................................................................................... 25 FIGURE 10 : BLOWER ........................................................................................................................................................ 26 FIGURE 11 : PULVERIZER .................................................................................................................................................... 26 FIGURE 12: FUEL CONSUMPTION BY UNITS SURVEYED ............................................................................................................ 28 FIGURE 13 : TYPICAL HEAT LOSSES IN A COUNTRY KILN (S OURCE : CBRI) .................................................................................... 29 LIST OF ANNEXES ANNEX 1 LIST OF UNITS IN THE CLUSTER SURVEYED ................................................................................................................ 33 ANNEX 2 LIST OF DIC REGISTERED UNITS .............................................................................................................................. 35 ANNEX 3 LIST OF UNITS HAVING CLEARANCE FROM TNPCB (A S ON 31.07.12) .......................................................................... 36 ANNEX 4 LAB ANALYSIS OF LOCAL LIME STONE GRADES ........................................................................................................... 39 Page | 5 ACKNOWLEDGEMENTS DESL places on record its sincere thanks to the World Bank for its role in guiding and steering this prestigious assignment for “providing project development support for enhancement of energy efficiency” at Tirunelveli lime kiln cluster. DESL is grateful to the Small Industries Development Bank of India (SIDBI) for its progressive management and also for vesting its confidence in DESL to carry out this prominent assignment
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