1st Edition

Energy Efficiency and Conservation in Metal Industries With Selected Cases of Investment Grade Audit

    236 Pages 71 B/W Illustrations
    by CRC Press

    This book provides a deep insight into the energy usage in the energy intensive metal industry and the methodology for efficiency assessment. Various methodologies for energy audits are described, along with concept-level analysis for minimum energy design. Apart from the technical and engineering analysis, the book also describes management aspects such as energy management systems and financial, environmental and social analysis leading to the development of a comprehensive plan for implementation of energy efficiency and conservation in industries. Barriers to investment in energy efficiency and conservation are discussed, based on review of global and Indian case studies.


    • Details fundamental principles driving energy consumption in an industrial set-up backed with illustrative examples
    • Explains various alternative methods for discovery of energy efficiency and conservation projects.
    • Focusses on metal-producing and -processing facilities with an emphasis on environmental quality
    • Supports maximum digitalization of energy audit assessment and report preparation processes
    • Includes global case studies and  tutorials at the end of the corresponding chapters

    This book is useful for researchers, professionals and graduate students in thermodynamics, manufacturing, thermal engineering, energy engineering, energy efficiency and energy processes, especially in the metal industry.

    Chapter 1: Energy Efficiency and conservation  

    1.1 Historical Perspective 
    1.2 Metal Industries: Local and Global Perspectives 
    1.3 Energy Conservation Global Imperatives 
    1.4 Energy Efficiency and Conservation: Future Trends and Scope 
    1.5 Energy Efficiency and Conservation Activities: Metal Industries                                                                     1.6 Conclusion
    Chapter 2: EE&C Policy Considerations 

    2.1 Energy, Environment, Economy and Society
    2.2 EE&C and Sustainable Development 
    2.3 International Agreements and Protocols 
    2.4 National Policy Drivers 
    2.5 EE&C Policy Considerations:Tips on the Top  
    2.6 Concluding Remark on EE&C Policy 

    Chapter 3: Energy Efficiency and Conservation Technologies 

    3.1 Introduction 
    3.2 Thermodynamics & EE 
    3.3 Going beyond Thermodynamic Efficiency 
    3.4 Motor Systems 
    3.5 Electric Furnace Systems
    3.6 Furnace systems 
    3.7 EE&C in (Chemical) Unit Operations 
    3.8 EE&C in WHR, CHP and Other Utilities 
    3.9 Conclusion 

    Chapter 4: Metal manufacturing Processes and Energy Systems

    4.1 Generic Characteristics of Metals and Metal Industries 
    4.2 Ferrous and Non-Ferrous Metallurgy 
    4.3 Energy Systems in Metal Industries
    4.4 Smelting and Refining 
    4.5. Energy and Mass Balance 

    Chapter 5: Energy Audit in Metal Industries

    5.1 Introduction 
    5.2 Energy Audit in Metal Industries 
    5.3 Preliminary Energy Audits 
    5.4 Investment Grade Energy Audit (IGEA) aka Detail Energy Audit 
    5.5 Virtual Energy Audit 
    5.6 Process Synthesis-Minimum Energy Approach 
    5.7 Tools for Energy Audit 
    5.8 Instrumentation 
    5.9 Software Applications 
    5.10 Energy Audits in Ferrous and Non-Ferrous Industries 
    5.11 Performance Achievements and Trade (PAT) Cycle of India Iron and Steel Projections and Achievements until 2030 
    5.12 Energy Saving Potential in Indian Metal  Industries
    5.13 Case Study for Classified Metal Industries 

    Chapter 6: Implementation of Energy Efficiency and Conservation Projects

    6.1 Introduction 
    6.2 Energy Service Companies in Metallurgical Industries 
    6.3 Objective of ESCOs  
    6.4 Progress of the ESCO Industry in India 
    6.5 ESCO Projects in Developed and Developing Countries 
    6.6 Actions of the Industrial Sector to ESCO Business 
    6.7 Risk Analysis
    6.8 Barriers in Implementing ESCO in Promoting Energy Efficiency  
    6.9 Conclusion 

    Chapter 7: Energy Management and Monitoring Systems 

    7.1 Introduction 
    7.2 Objectives of Energy Management and Monitoring Systems 
    7.3 Benchmarking and Energy Performance 
    7.4 Key Elements of Monitoring and Targeting Systems 
    7.5 Energy Analytics with Application of AI and IoT
    7.6 Energy Management Information Systems and ISO 50001 
    7.7 Application of AI in Metal Industries and their Improvement  
    7.8 Conclusion 

    Chapter 8: Sustainability in Metal Industries 

    8.1 Introduction 
    8.2 Regional perspectives Analysis: Comparison to Global and Regional (e.g. ASEAN) Best Practices 
    8.3 Lessons from COVID-19 
    8.4 Economic, Environmental and Social Sustainability 
    8.5 Circular Economy 
    8.6 Extended Producer Responsibility 
    8.7 Development Pathway 
    8.8 Conclusion


    Mr. Swapan Kumar Dutta successfully founded and managed various business ventures in engineering design, manufacturing and consulting in a career spanning more than 30 years. He started his career as a design engineer at International Combustion India. Thereafter, he founded Yantra Shilpa Udyog and Hitech Equipment’s, leading Indian designer, manufacturer and exporters of complex engineering systems used for conveying, bulk materials handling, mineral processing and specialized ceramics. He was also the founder and principal consultant of an energy consulting firm providing advice on energy conservation and energy efficient design.

    Mr. Dutta graduated in (1981) and mastered (1983) In Mechanical Engineering both from Jadavpur University. He completed executive training in Quality Management (IRCA –U.K.), Quality Management (AOTS, Japan), Energy Management & Audit (Jadavpur University) and Advance Environment Management System (EARA – U.K.). He was an internationally accredited energy auditor.

    Mr. Dutta was an Accredited Management Teacher of Management of Public Utility System –AIMA-CMS and a Faculty Member of the Energy Management Department of IISWBM – Kolkata.

    Dr Jitendra Saxena, an engineering professional having vast experience in the field of academic and industry joined The Institution of Engineers (India) on 09 Sep 2016 as Director (Education, Examination and Accreditation). He is having more than 25 years of experience in teaching, technical education, planning and management, project management, and industries. After obtaining AMIE degree from IEI he did his M.Tech in the field of energy management from Devi Ahilya Vishwavidyalaya, Indore. Thereafter, he obtained Doctorate from Maulana Azad National Institute of Technology, Bhopal. He started his modest career from industries and switch over to technical education. Gradually he rose to the level of Director of a technical institution imparting courses of both B.Tech and M.Tech. He also served in Military College of Telecommunication Engineering (MCTE) as visiting Professor. He was associated with various technical and industrial activities of PHD Chamber of Commerce and Confederation of Indian Industry (CII) in various capacities. He was also involved with Energy and Electrical Safety Audit and consultancy in multinational companies and for designated consumers. In result he is a perfect blend of Academic as well as industries. He is Chartered Engineer from The Institution of Engineers (India) and designated Chartered Electrical safety Engineer from Government of Madhya Pradesh (India). He is Fellow member of IEI and IETE and Life member of Solar society of India and Indian Society for Technical Education (ISTE).

    Binoy Krishna Choudhury, a Mechanical Engineering Graduate from Jalpaiguri Government Engineering College, Ph D from the Indian Institute of Technology (IIT) Kharagpur, Fellow of Institution of Engineers (India), Association of Engineers (India) & Indian Water Works Association - is currently Professor in the Energy Management stream of Public Systems Management (PSM) programme. Since his joining IISWBM in 1997, he served as Coordinator of Energy Management for about ten years and served thereafter his tenure as Head of MPSM and MBA-PS at the Indian Institute of Social Welfare and Business Management (IISWBM), Kolkata. He is also Coordinator Professor-in-Charge: Short Term Course (STC) in Energy Management & Audit and Training Seminar & Examination (TSE) of Association of Energy Engineers (AEE) USA Certified Energy Manager (CEM) & Certified Energy Auditor (CEA) International. He has over 26 years of teaching/professional experience which includes more than 23 years in the present Institute. He served as Principal Investigator/Coordinator in more than fifteen renewable energy and energy efficiency projects which covers community development to industrial profitability/sustainability issues. He is honorary Asst. Director International Member Development Asia Sub-continent in Association of Energy Engineers USA; member in Energy & Environment Standing Committee, the Bengal National Chamber of Commerce & Industry aandThe Bengal Chamber; JICA Alumni Association of India; Energy; Low Carbon Energy for Development Network (UK). He is founder editor of Energy Window, on the editorial board of REASON- A Technical Journal and reviewer of ACTA Press, Energy for Sustainable Development, etc.

    He had secured National Scholarship in 1981, graduated in 1988 (JGEC, North Bengal University), Ph D in 1994 (IIT, Kharagpur) and won best research paper award in 1998 (AIMS, New Delhi) and own the Coal India (J G Kumara Mangalam Memorial) Award 2018. He is a Certified Energy Auditor (CEA), Certified Energy Manager (CEM) and Trainer (CEA & CEM) of Association of Energy Engineers (AEE), USA, MNRE Empanelled National Level Evaluator of Solar Thermal Programmes and Accredited Energy Auditor (AEA) of the Government of India. He served United Nations Economic and Social Commission for Asia and the Pacific (ESCAP) as Economic Affairs Officer in the Energy Resources Section and contributed to the regional energy scenario assessment, improvement of energy efficiency and CDM workshop. He has contributed/published, more than 55 in numbers, in books, journals, international and national seminars, workshops, etc. He is the founder secretary of AEE India Chapter and Energy Club and is life member of Solar Energy Society of India, AEE, Indian Society for Technical Education, Ramakrishna Mission Institute of Culture and Fellow of Institution of Engineers (India) and Indian Water-Works Association (IWWA).