KMB-IIT-MAD-03.04.23-03
The subject plant is located in district of and falls under NIC Category-13121. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2023.
General Info
Principal Product
Textile
Plant Area (Sq.ft)
10,000
No. of Employees
150
Production Hours
8,400
Annual Production
2,70,00,000
Annual Sales
₹1,62,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹22,54,67,014
Total Recommended Investment(one time)
₹15,35,000
Total Recommended Savings(per year)
₹1,20,63,369
Energy Costs Calculation
Electricity
Annual Usage
1,05,01,412
Unit
kWh
Unit Cost
₹9.22
Annual Cost
₹9,68,23,019
Coal
Annual Usage
1,22,51,809
Unit
kg
Unit Cost
₹10.5
Annual Cost
₹12,86,43,995
Total Energy Costs(per year)
₹22,54,67,014
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ineffective Combustion | Optimize the Air-Fuel Ratio | 33,585 | ₹3,52,643 | ₹2,00,000 | 6.8 | |
| Ineffective Combustion | Optimize the Air-Fuel Ratio | 18503 | ₹1,94,282 | ₹50000 | 3.1 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Current & Voltage Harmonics | Install Harmonic Filters | 12000 | ₹1,10,640 | ₹0 | 0.0 | |
| High Voltage Harmonics | Install Harmonic Filters | 18000 | ₹1,65,960 | ₹0 | 0.0 | |
| Absence of On load Tap Changer | Install/Repair On load Tap changer | 54,810 | ₹ | ₹0 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Arrest all identified air leak points and regularly check for air leaks | 483840 | ₹44,61,005 | ₹300000 | 0.8 | |
| High Cut-off Pressure Setting | Reduce air compressor discharge pressure to the lowest acceptable setting.((Reduction of 1 kglcm2 air pressure (8 kg/cm2 to 7 kg/cm2 ) would result in 9% input power savings. | 216160 | ₹ | ₹0 | ||
| No Dryer | Install adequate dryers on air lines to eliminate blowdown | ₹ | ₹ |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Bypass flow | Balance the system to minimize flows and reduce pump power requirements. | 92400 | ₹8,51,928 | ₹200000 | 2.8 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Power Consumption | Use energy-efficient motors for continuous or near-continuous operation. | 12600 | ₹1,16,172 | ₹15000 | 1.5 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 2,52,000 | ₹23,23,440 | ₹1,50,000 | 0.8 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Water TDS | Test and Treat Boiler Water on a Continuing Basis | 288000 | ₹26,55,360 | ₹ | 0.0 |
CHR - Chiller
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Performance | Replace old chillers or compressors with new higher-efficiency models. | 25000 | ₹2,30,500 | ₹350000 | 18.2 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| No dedicated Ducts | Install Dedicated Duct | 23750 | ₹2,18,975 | ₹100000 | 5.5 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Unnecessary ducts are open | Close Unnecessary Ducts | 26250 | ₹2,42,025 | ₹0 | 0.0 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Old Type Fans | Use BLDC fan with same velocity | 15,232 | ₹1,40,439 | ₹170000 | 14.5 |