A comprehensive study has revealed that industrial boilers across India contribute nearly 7% of the country’s total greenhouse gas emissions, highlighting a critical and under-addressed source of pollution. With more emissions of particulate matter and sulphur dioxide than the entire automobile sector, the report calls for urgent reforms, including a proposed nationwide “Green Boiler Mission.” The findings underline the importance of overhauling aging industrial systems to achieve India’s climate goals, improve air quality, and enhance energy efficiency.
India’s Boilers: A Hidden Climate Challenge
India industrial growth has long depended on the power of boilers, especially in sectors like food processing, textiles, and chemicals. However, a new study released during the National Conclave on Greening Industrial Boilers has exposed the environmental cost of this reliance. Boilers used in Indian factories emit around 182 million tonnes of carbon dioxide annually an amount that forms a staggering 7% of the nation’s total greenhouse gas (GHG) emissions. This figure also represents more than one-quarter of emissions from all industrial sources in the country.
The Pollution Footprint Surpasses the Auto Sector
More alarming is the report’s revelation that emissions from these industrial boilers especially of particulate matter (PM) and sulphur dioxide (SO₂) exceed those generated by the entire automobile sector in India. This high pollution burden is largely attributed to outdated technologies and the absence of stringent emission standards for boilers, allowing them to operate with low efficiency and high pollution output.
Emission Load by Fuel and Region
Of the estimated 45,200 process and co-generation boilers operating in the country, a significant portion still runs on fossil fuels such as coal, gas, and oil. These account for about 40% of the installed boiler capacity and nearly 37% of the total number of boilers. Biomass fuels, including sugarcane waste (bagasse), power nearly half of the steam-generating capacity, but they too contribute substantially to air pollution. Smaller boilers, with a steam generation capacity of up to 2 tonnes per hour, are particularly dependent on coal.
Regionally, the pollution is concentrated in eight key states, with Gujarat, Maharashtra, Tamil Nadu, Andhra Pradesh, and Uttar Pradesh being the top five contributors. These states collectively house two-thirds of India’s total boiler capacity. The report indicates that boilers are responsible for 9% of industrial PM emissions, 8% of SO₂, and a notable 17% of nitrogen oxide (NOx) emissions.
Aging Infrastructure Raises Safety and Efficiency Concerns
Another critical finding of the study is the age profile of India’s boiler fleet. On average, boilers in use are 18 years old, with nearly one-fifth aged 25 years or more. Such aging infrastructure raises multiple concerns not only about pollution but also about operational safety and energy inefficiency. Older boilers typically operate with low thermal efficiency, requiring more fuel to generate the same amount of steam, thereby intensifying emissions and increasing costs.
Proposed Green Boiler Mission for Industrial Transition
To address this urgent environmental and industrial challenge, the study advocates the creation of a nationwide Green Boiler Mission. This initiative would aim to modernize the boiler sector by encouraging the use of cleaner fuels, adopting advanced combustion technologies, and enforcing stricter emission standards. The mission would also promote the use of electric and hybrid steam generators where feasible and incentivize industries to shift toward renewables and high-efficiency systems.
The proposed reforms not only align with India’s net-zero emission targets but also offer significant opportunities for economic growth. The modernization of boiler systems could lead to the development of a green manufacturing ecosystem, generating employment in renewable energy, equipment manufacturing, and maintenance services. Additionally, enhanced boiler efficiency would help industries reduce fuel costs, improve productivity, and minimize their carbon footprint.
Path Forward: Policy and Industry Collaboration
For India to effectively transition its boiler systems, a coordinated approach involving central and state governments, industry stakeholders, and environmental agencies is essential. The report suggests implementing targeted fiscal incentives, policy reforms, and capacity-building programs. It also emphasizes the need for rigorous data collection and monitoring to assess emissions performance and track progress.
Uttar Pradesh, one of the largest contributors to industrial emissions from boilers, is poised to play a key role in implementing these changes. With the right mix of policy support, technology upgrades, and industrial cooperation, the state could become a model for clean industrial practices and sustainable development.
Conclusion
India’s industrial boilers are a major source of emissions and air pollution, yet they remain a relatively overlooked part of the climate conversation. The newly released report offers a clear roadmap to modernize this critical sector, enhance energy efficiency, and reduce pollution. By launching a Green Boiler Mission, India has the opportunity to not only meet its climate commitments but also build a more resilient, competitive, and environmentally sound industrial future.