KMB-IIT-MAD-25.05.22-05
The subject plant is located in Erode 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
Fabric processing
Plant Area (Sq.ft)
20,000
No. of Employees
100
Production Hours
7,200
Annual Production
4,00,00,000
Annual Sales
₹20,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹9,60,02,104
Total Recommended Investment(one time)
₹34,50,000
Total Recommended Savings(per year)
₹1,50,89,353
Energy Costs Calculation
Electricity
Annual Usage
54,89,168
Unit
kWh
Unit Cost
₹5.5
Annual Cost
₹3,01,90,424
Biomass
Annual Usage
1,49,57,200
Unit
kgs
Unit Cost
₹4.4
Annual Cost
₹6,58,11,680
Total Energy Costs(per year)
₹9,60,02,104
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ineffective Combustion | Optimize the Air-Fuel Ratio | 324576 | ₹1428134 | ₹175000 | 1.5 | |
| Fair Combustion | Optimize the Air-Fuel Ratio | 50350 | ₹221540 | ₹50000 | 2.7 | |
| Ineffective Combustion | Optimize the Air-Fuel Ratio | 527472 | ₹2320877 | ₹175000 | 0.9 | |
| Absence of Air Pre Heater | Install a Heat Recovery Air Preheater | 37922 | ₹166857 | ₹100000 | 7.2 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ineffective Combustion | Optimize the Air-Fuel Ratio | 630824 | ₹27,75,626 | ₹175000 | 0.8 | |
| Chocking of Air Pre Heater | Clean Fireside Tubes & Heat Exchangers at Appropriate Intervals | 22000 | ₹96800 | ₹25000 | 3.1 | |
| Ineffective Combustion | Optimize the Air-Fuel Ratio | 301760 | ₹1327744 | ₹175000 | 1.6 | |
| Chocking of Air Pre Heater | Clean Fireside Tubes & Heat Exchangers at Appropriate Intervals | 19850 | ₹87340 | ₹25000 | 3.4 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Thermal Insulation | Locate and Repair Defective Insulation on All Heating Plant Equipment and Piping | 691380 | ₹3042072 | ₹600000 | 2.4 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Current Harmonics | Install Harmonic Filters | 16419 | ₹90305 | ₹500000 | 66.4 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Low Power Factor | Replace the de-rated capacitors with new capacitors | 25,000 | ₹1,37,500 | ₹1,50,000 | 13.1 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 156000 | ₹858000 | ₹100000 | 1.4 | |
| Capacity Underutilization | The compressor should be effectively operated in a manner that it should have minimum number of unloading cycles | 48000 | ₹264000 | ₹100000 | 4.5 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Operated at Full Load | Install Soft Starter cum Energy saver for fully loaded motors | 15232 | ₹83,776 | ₹50,000 | 7.2 | |
| Operated at Full Load | Install Soft Starter cum Energy saver for fully loaded motors | 15,552 | ₹85,536 | ₹50,000 | 7.0 | |
| Operated at Full Load | Install Soft Starter cum Energy saver for fully loaded motors | 19,660 | ₹1,08,130 | ₹50,000 | 5.5 | |
| Operated at Full Load | Install Soft Starter cum Energy saver for fully loaded motors | 19,660 | ₹1,08,130 | ₹50,000 | 5.5 | |
| Operated at Full Load | Install Soft Starter cum Energy saver for fully loaded motors | 20,859 | ₹1,14,725 | ₹50,000 | 5.2 | |
| Operated at Full Load | Install Soft Starter cum Energy saver for fully loaded motors | 19,548 | ₹1,07,514 | ₹50,000 | 5.6 | |
| Operated at Full Load | Install Soft Starter cum Energy saver for fully loaded motors | 20,587 | ₹1,13,229 | ₹50,000 | 5.3 | |
| Operated at Full Load | Install Soft Starter cum Energy saver for fully loaded motors | 23,912 | ₹1,31,516 | ₹50,000 | 4.6 | |
| Operated at Full Load | Install Soft Starter cum Energy saver for fully loaded motors | 19,276 | ₹1,06,018 | ₹50,000 | 5.7 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 3,546 | ₹19,503 | ₹30,000 | 18.5 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 2,945 | ₹16,198 | ₹30,000 | 22.2 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 2,054 | ₹11,297 | ₹30,000 | 31.9 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 3,875 | ₹21,313 | ₹50,000 | 28.2 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 3,478 | ₹19,129 | ₹50,000 | 31.4 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 3,056 | ₹16,808 | ₹50,000 | 35.7 | |
| VFD Self Consumption is High | Use appropriate VFD that consumes less power | 28,800 | ₹1,58,400 | ₹1,50,000 | 11.4 | |
| Poor Maintenance | Establish a preventive maintenance program | 1,11,000 | ₹6,10,500 | ₹50,000 | 1.0 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 4,000 | ₹22,000 | ₹20,000 | 10.9 | |
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 5,500 | ₹30,250 | ₹20,000 | 7.9 | |
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 9,000 | ₹49,500 | ₹50,000 | 12.1 | |
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 4,500 | ₹24,750 | ₹20,000 | 9.7 | |
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 12,000 | ₹66,000 | ₹25,000 | 4.5 | |
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 11,000 | ₹60,500 | ₹50,000 | 9.9 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Maintenance | Schedule Periodic Cooling Tower Fan Maintenance Program | 19152 | ₹105336 | ₹20000 | 2.3 | |
| Mix of Hot & Cold Well | Improving Cooling Tower Performance by separating Hot well and Coldwell | 15000 | ₹82500 | ₹5000 | 0.7 |