EAR/22-23/KISEM-IITB-05
The subject plant is located in district of and falls under NIC Category-13. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2023.
General Info
Principal Product
TEXTILE
Plant Area (Sq.ft)
15,000
No. of Employees
500
Production Hours
8,600
Annual Production
Annual Sales
₹
Assessment Summary
Total Energy Costs(per year)
₹12,77,55,481
Total Recommended Investment(one time)
₹22,25,000
Total Recommended Savings(per year)
₹48,68,488
Energy Costs Calculation
GRID ELECTRICITY
Annual Usage
64,82,703
Unit
kWh
Unit Cost
₹5.66
Annual Cost
₹3,66,92,099
Fuel
Annual Usage
86,72,703
Unit
kg
Unit Cost
₹10.5
Annual Cost
₹9,10,63,382
Total Energy Costs(per year)
₹12,77,55,481
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess air is too high around 250 %. Allowable excess air is 70 % Maximum | Install Oxygen analyser and give feedback to existing FD and ID fan VFD. | 52,560 | ₹5,51,880 | ₹3,00,000 | 6.5 | |
| PRV used to decrease the pressure from 10 bar to 5 bar. | Install steam expander which can generate electricity of 19.57 kW/hr for 1 Ton steam from 10 to 5 bar. | 1,71,433 | ₹8,10,879 | ₹14,00,000 | 20.7 | |
| Temperature in boiler walls in certain area are high. | Insulate the walls | 37,150 | ₹3,90,075 | ₹50,000 | 1.5 | |
| Many steam line insulations are not proper. | Complete steam line insulation to reduce heat loss in the line | 7,687 | ₹80,714 | ₹10,000 | 1.5 | |
| Steam trap is not working in good condition | Connect the pipeline to water tank | 730 | ₹7,665 | ₹5,000 | 7.8 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Unloading hours for certain compressors | Install VFD for unloaded compressors | 73,809 | ₹3,49,117 | ₹1,00,000 | 3.44 | |
| Leakage cfm is high in many loom machines | Arrest leakages in Loom machine | 33,271 | ₹1,57,371 | ₹10,000 | 0.8 | |
| Pressure setting in looms is high around 5.5 bar. Recommended for cotton is 4.8 to max 5 bar and for polyester 5 to 5.2 bar | Adjust regulator so that 0.2-0.4 bar pressure can be decreased which will give minimum 3 cfm savings per machine. | 2,47,534 | ₹11,70,837 | ₹ | ||
| Many compressor suction filters are choked | Recommended to maintain filters periodically | ₹ | ₹ |
HF - Humidification Plant
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Supply cfm is less than Return cfm | Install VFD in return fan and optimize the speed according to the supply cfm. | 2,61,836 | ₹12,38,486 | ₹2,50,000 | 2.4 | |
| Return ducts of Looms are choked. It should be cleaned | It should be optimized by including VFD in Supply and Return fans | 23,565 | ₹1,11,464 | ₹1,00,000 | 10.8 |