KMB-IIT-MAD-21.06.22-06
The subject plant is located in district of Tamil Nadu and falls under NIC Category-17013. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2022.
General Info
Principal Product
Manufacturing of Printing and Writing Papers, Calendar Posters
Plant Area (Sq.ft)
30,000
No. of Employees
100
Production Hours
7,200
Annual Production
50,00,000
Annual Sales
₹40,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹22,36,53,984
Total Recommended Investment(one time)
₹23,35,000
Total Recommended Savings(per year)
₹77,95,177
Energy Costs Calculation
Electricity
Annual Usage
1,73,58,840
Unit
kWh
Unit Cost
₹7.6
Annual Cost
₹13,19,27,184
Indonesian Coal & Biomass
Annual Usage
1,66,77,600
Unit
kgs
Unit Cost
₹5.5
Annual Cost
₹9,17,26,800
Total Energy Costs(per year)
₹22,36,53,984
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ineffective Combustion | Optimize the Air-Fuel Ratio | 6,02,280 | ₹33,12,540 | ₹2,00,000 | 0.7 | |
| Poor Thermal Insulation | Locate and Repair Defective Insulation on All Heating Plant Equipment and Piping | 8,557 | ₹47,064 | ₹1,00,000 | 25.5 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| TR 1 - High Current & Voltage Harmonics | Install Harmonic Filters | 17359 | ₹1,31,928 | ₹150000 | 13.6 | |
| TR 2 - High Current & Voltage Harmonics | Install Harmonic Filters | 17359 | ₹1,31,928 | ₹150000 | 13.6 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Good Power Factor | Replace the de-rated capacitors with new capacitors | 20,346 | ₹1,54,630 | ₹50,000 | 3.9 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 47,648 | ₹3,62,125 | ₹1,00,000 | 3.3 | |
| Capacity Underutilization | The compressor should be effectively operated in a manner that it should have minimum number of unloading cycles | 1,85,220 | ₹14,07,672 | ₹1,50,000 | 1.3 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Rewinded Motor | Replace rewound motors with energy efficient motors | 9,828 | ₹74,693 | ₹50,000 | 8.0 | |
| Rewinded Motor | Replace rewound motors with energy efficient motors | 5,376 | ₹40,858 | ₹50,000 | 14.7 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 3,093 | ₹23,507 | ₹40,000 | 20.4 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 2,419 | ₹18,384 | ₹40,000 | 26.1 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 4,216 | ₹32,042 | ₹40,000 | 15.0 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 1,642 | ₹12,479 | ₹40,000 | 38.5 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 2,989 | ₹22,716 | ₹40,000 | 21.1 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 4,009 | ₹30,468 | ₹40,000 | 15.8 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 26,611 | ₹2,02,244 | ₹1,00,000 | 5.9 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 1,434 | ₹10,898 | ₹40,000 | 44.0 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 3,784 | ₹28,758 | ₹40,000 | 16.7 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 3,767 | ₹28,629 | ₹40,000 | 16.8 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 5,167 | ₹39,269 | ₹40,000 | 12.2 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 3,888 | ₹29,549 | ₹40,000 | 16.2 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 8,726 | ₹66,318 | ₹50,000 | 9.0 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 4,061 | ₹30,864 | ₹40,000 | 15.6 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 6,221 | ₹47,280 | ₹40,000 | 10.2 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 6,324 | ₹48,062 | ₹40,000 | 10.0 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 14,360 | ₹1,09,136 | ₹50,000 | 5.5 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 3,681 | ₹27,976 | ₹40,000 | 17.2 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 4,182 | ₹31,783 | ₹50,000 | 18.9 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 6,998 | ₹53,185 | ₹40,000 | 9.0 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 6,929 | ₹52,660 | ₹40,000 | 9.1 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 5,046 | ₹38,350 | ₹40,000 | 12.5 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 60,480 | ₹4,59,648 | ₹1,00,000 | 2.6 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 4,596 | ₹34,930 | ₹40,000 | 13.7 | |
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 1,528 | ₹11,613 | ₹25,000 | 25.8 | |
| Rewinded Motor | Replace rewound motors with energy efficient motors | 16,800 | ₹1,27,680 | ₹50,000 | 4.7 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Flow Detoriated | Replace old low efficient pumps with IE3 energy efficient Submersible pumps | 6,450 | ₹49,020 | ₹50,000 | 12.2 | |
| Flow Detoriated | Replace old low efficient pumps with IE3 energy efficient Submersible pumps | 5,987 | ₹45,501 | ₹50,000 | 13.2 | |
| Manual Throttling of Valves | Modify pumping to minimize throttling. | 40,740 | ₹3,09,624 | ₹50,000 | 1.9 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| CT Not Necessary | Turn Off Unnecessary Cooling Tower Fans When Loads Are Reduced. | 14,364 | ₹1,09,166 | ₹0 | 0.0 |