KMB-IIT-MAD-23.02.22-03
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 and processing of textiles
Plant Area (Sq.ft)
30,000
No. of Employees
50
Production Hours
7,200
Annual Production
50,00,000
Annual Sales
₹15,07,00,000
Assessment Summary
Total Energy Costs(per year)
₹8,26,31,125
Total Recommended Investment(one time)
₹20,50,000
Total Recommended Savings(per year)
₹63,37,910
Energy Costs Calculation
Electricity
Annual Usage
24,11,776
Unit
kWh
Unit Cost
₹7.6
Annual Cost
₹1,89,68,625
Indonesian Coal
Annual Usage
57,87,500
Unit
kgs
Unit Cost
₹11
Annual Cost
₹6,36,62,500
Total Energy Costs(per year)
₹8,26,31,125
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Good Combustion | Nil | ₹ | ₹ | |||
| Fuel Weighing System Not Available | Install Fuel Weighing System | ₹ | ₹2,50,000 | |||
| Steam Flow Meter Not Available | Install Steam Flow Measuring Device/Meters to quantify steam generation & usage | ₹ | ₹4,00,000 | |||
| Poor Thermal Insulation | Locate and Repair Defective Insulation on All Heating Plant Equipment and Piping | 1,50,012 | ₹16,50,132 | ₹325000 | 2.4 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Fair Combustion | Optimize the Air-Fuel Ratio | 2,55,000 | ₹28,05,000 | ₹1,75,000 | 0.7 | |
| Poor Thermal Insulation | Locate and Repair Defective Insulation on All Heating Plant Equipment and Piping | 58,750 | ₹6,46,250 | ₹1,50,000 | 2.8 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Current Harmonics | Install Harmonic Filters | 5,460 | ₹41,496 | ₹1,50,000 | 43.4 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Power Factor | Replace the de-rated capacitors with new capacitors | 25,335 | ₹1,92,546 | ₹50,000 | 3.1 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 40,560 | ₹3,08,256 | ₹1,00,000 | 3.9 | |
| Capacity Underutilization | The compressor should be effectively operated in a manner that it should have minimum number of unloading cycles | 40,622 | ₹3,08,727 | ₹1,00,000 | 3.9 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess Power Consumption | Use energy-efficient motors | 14,976 | ₹1,13,818 | ₹1,00,000 | 10.5 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Pump 1 - VFD Self Consumption is High | Use appropriate VFD that consumes less power | 19,070 | ₹1,44,932 | ₹1,25,000 | 10.3 | |
| Pump 2 - VFD Self Consumption is High | Use appropriate VFD that consumes less power | 16,678 | ₹1,26,753 | ₹1,25,000 | 11.8 |