KMB-IIT-MAD-21.04.22-02
The subject plant is located in Tiruppur district of Tamil Nadu and falls under NIC Category-13131. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2022.
General Info
Principal Product
Dyeing
Plant Area (Sq.ft)
30,000
No. of Employees
100
Production Hours
7,200
Annual Production
50,00,000
Annual Sales
₹2,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,69,77,097
Total Recommended Investment(one time)
₹3,94,000
Total Recommended Savings(per year)
₹7,17,400
Energy Costs Calculation
Electricity
Annual Usage
21,48,884
Unit
kWh
Unit Cost
₹6.3
Annual Cost
₹1,35,37,969
Biomass
Annual Usage
6,14,130
Unit
kgs
Unit Cost
₹5.6
Annual Cost
₹34,39,128
Total Energy Costs(per year)
₹1,69,77,097
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Good Combustion | Optimize the Air-Fuel Ratio | 11,082 | ₹62,059 | ₹1,25,000 | 24.2 | |
| Poor Thermal Insulation | Locate and Repair Defective Insulation on All Heating Plant Equipment and Piping | 16,000 | ₹89,600 | ₹1,00,000 | 13.4 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Good Power Factor | Replace the de-rated capacitors with new capacitors | 500 | ₹3,150 | ₹1,000 | 3.8 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 32,400 | ₹2,04,120 | ₹1,00,000 | 5.9 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Motor 4 - Poor Ventilation | Provide proper ventilation(Motor life will be halved for every 10°C rise) | 14,400 | ₹90,720 | ₹5,000 | 0.7 | |
| Motor 3 - Poor Ventilation | Provide proper ventilation(Motor life will be halved for every 10°C rise) | 7,200 | ₹45,360 | ₹5,000 | 1.3 | |
| Motor 2 - Poor Ventilation | Provide proper ventilation(Motor life will be halved for every 10°C rise) | 14,400 | ₹90,720 | ₹5,000 | 0.7 | |
| Motor 1 - Poor Ventilation | Provide proper ventilation(Motor life will be halved for every 10°C rise) | 14,400 | ₹90,720 | ₹5,000 | 0.7 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Pump 1- Rewinded Motor | Replace rewound motors with energy efficient motors | 3,900 | ₹24,570 | ₹15,000 | 7.3 | |
| Pump 2- Rewinded Motor | Replace rewound motors with energy efficient motors | 1,365 | ₹8,600 | ₹15,000 | 20.9 | |
| Manual Throttling of Valves | Modify pumping to minimize throttling. | 485 | ₹3,056 | ₹9,000 | 35.3 | |
| Manual Throttling of Valves | Modify pumping to minimize throttling. | 750 | ₹4,725 | ₹9,000 | 22.9 |