EAR/23-24/KISEM/IITR-07
The subject plant is located in district of and falls under NIC Category-13. This assessment was carried out by the IEAC Center, IIT Ropar, during the course of the year 2023.
General Info
Principal Product
Textiles
Plant Area (Sq.ft)
1,50,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹1,00,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹18,89,68,501
Total Recommended Investment(one time)
₹1,24,44,000
Total Recommended Savings(per year)
₹1,69,59,749
Energy Costs Calculation
Electricity
Annual Usage
2,53,22,400
Unit
kWh
Unit Cost
₹7.5
Annual Cost
₹18,89,68,501
Total Energy Costs(per year)
₹18,89,68,501
Observations & Recommendations
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| A variation in power consumption is observed in larger and smaller blowers in the OE machines compared with the same type of blowers in similar OE machines. | Do periodic maintenance to arrest all the leakages from the machine. Remove the waste periodically or use an automation system to remove the waste periodically from the OE machine. | 5,77,800 | ₹43,33,500 | ₹5,00,000 | 1.4 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| More than the required static pressure is given to the carding machine. | Adjust the speed of the fan in VXL machine with the vfd drive so as to get the required pressure at the extreme end of the duct without damper. | 1,14,408 | ₹8,58,060 | ₹50,000 | 0.7 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Four to Seven machines are connected with the same rotary for waste recovery and the rotary is observed as running at constant speed even when a few machines are in off condition. | Automation should be provided to close the main duct of idle machines and at the same time control the rotary speed based on static pressure. | 6,03,501 | ₹45,26,264 | ₹6,00,000 | 1.6 | |
| Energy-inefficient and re-winded motors are used in the machines | Conventional motors can be considered for replacement with energy efficient IE4 motors. | 1,03,167 | ₹7,73,750 | ₹43,84,000 | 68 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakage was observed to be very high | Arrest air leakages regularly | 83,082 | ₹6,23,118 | ₹10,000 | 0.2 | |
| In Screw Compressor 5 (40 HP), the unloading time is high | Operate this screw compressor with a VFD Drive. | 51,961 | ₹3,89,707 | ₹3,00,000 | 9.2 | |
| Compressed air at 7 bar is used for cleaning application in all over the plant. | Use dedicated compressors for cleaning applications with separate airlines and reset the cut-out pressure of the compressor to 3 bar for cleaning application. | 1,22,774 | ₹9,20,808 | ₹2,00,000 | 2.6 |
HF - Humidification Plant
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency of Humidifiers is observed to be very low. | Do periodic maintenance of the humidifier. | 3,02,280 | ₹22,67,099 | ₹4,00,000 | 2.1 | |
| The airflow rate through all the humidifiers is observed to be very high. | Optimise the air flow rate based on humidity requirements at the department by balancing supply and return air. | ₹ | ₹ |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Two Off-circuit tap changer (OCTC) Transformers of 1250 kVA and 3000 kVA capacity with an HV range of 9900 to 11550 Volts are installed in the plant | It is recommended to replace the existing transformer with 5 star rated On-load tap changer (OLTC) transformer with more position and wider range. | 2,26,359 | ₹16,97,689 | ₹60,00,000 | 31.8 | |
| To stabilise the voltage two servo transformers are installed at the secondary of both the transformers | It is recommended to replace the existing transformer with 5 star rated On-load tap changer (OLTC) transformer with more position and wider range. | 75,967 | ₹5,69,754 | ₹ |