IIT Madras

IIT Hyderabad

IIT Bombay

IIT Indore

IIT Gandhinagar

IIT Guwahati

IIT Ropar

Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras

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
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Ineffective CombustionOptimize the Air-Fuel Ratio6,02,280₹33,12,540₹2,00,0000.7
Poor Thermal InsulationLocate and Repair Defective Insulation on All Heating Plant Equipment and Piping8,557₹47,064₹1,00,00025.5
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
TR 1 - High Current & Voltage HarmonicsInstall Harmonic Filters17359₹1,31,928₹15000013.6
TR 2 - High Current & Voltage HarmonicsInstall Harmonic Filters17359₹1,31,928₹15000013.6
CPF - Capacitor & Power Factor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Good Power FactorReplace the de-rated capacitors with new capacitors20,346₹1,54,630₹50,0003.9
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
High Air LeakageEliminate leaks in inert gas and compressed air lines/ valves47,648₹3,62,125₹1,00,0003.3
Capacity UnderutilizationThe compressor should be effectively operated in a manner that it should have minimum number of unloading cycles1,85,220₹14,07,672₹1,50,0001.3
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Rewinded MotorReplace rewound motors with energy efficient motors9,828₹74,693₹50,0008.0
Rewinded MotorReplace rewound motors with energy efficient motors5,376₹40,858₹50,00014.7
Operated at Partial LoadProperly size the motor to the load for optimum efficiency3,093₹23,507₹40,00020.4
Operated at Partial LoadProperly size the motor to the load for optimum efficiency2,419₹18,384₹40,00026.1
Operated at Partial LoadProperly size the motor to the load for optimum efficiency4,216₹32,042₹40,00015.0
Operated at Partial LoadProperly size the motor to the load for optimum efficiency1,642₹12,479₹40,00038.5
Operated at Partial LoadProperly size the motor to the load for optimum efficiency2,989₹22,716₹40,00021.1
Operated at Partial LoadProperly size the motor to the load for optimum efficiency4,009₹30,468₹40,00015.8
Operated at Partial LoadProperly size the motor to the load for optimum efficiency26,611₹2,02,244₹1,00,0005.9
Operated at Partial LoadProperly size the motor to the load for optimum efficiency1,434₹10,898₹40,00044.0
Operated at Partial LoadProperly size the motor to the load for optimum efficiency3,784₹28,758₹40,00016.7
Operated at Partial LoadProperly size the motor to the load for optimum efficiency3,767₹28,629₹40,00016.8
Operated at Partial LoadProperly size the motor to the load for optimum efficiency5,167₹39,269₹40,00012.2
Operated at Partial LoadProperly size the motor to the load for optimum efficiency3,888₹29,549₹40,00016.2
Operated at Partial LoadProperly size the motor to the load for optimum efficiency8,726₹66,318₹50,0009.0
Operated at Partial LoadProperly size the motor to the load for optimum efficiency4,061₹30,864₹40,00015.6
Operated at Partial LoadProperly size the motor to the load for optimum efficiency6,221₹47,280₹40,00010.2
Operated at Partial LoadProperly size the motor to the load for optimum efficiency6,324₹48,062₹40,00010.0
Operated at Partial LoadProperly size the motor to the load for optimum efficiency14,360₹1,09,136₹50,0005.5
Operated at Partial LoadProperly size the motor to the load for optimum efficiency3,681₹27,976₹40,00017.2
Operated at Partial LoadProperly size the motor to the load for optimum efficiency4,182₹31,783₹50,00018.9
Operated at Partial LoadProperly size the motor to the load for optimum efficiency6,998₹53,185₹40,0009.0
Operated at Partial LoadProperly size the motor to the load for optimum efficiency6,929₹52,660₹40,0009.1
Operated at Partial LoadProperly size the motor to the load for optimum efficiency5,046₹38,350₹40,00012.5
Operated at Partial LoadProperly size the motor to the load for optimum efficiency60,480₹4,59,648₹1,00,0002.6
Operated at Partial LoadProperly size the motor to the load for optimum efficiency4,596₹34,930₹40,00013.7
Operated at Partial LoadProperly size the motor to the load for optimum efficiency1,528₹11,613₹25,00025.8
Rewinded MotorReplace rewound motors with energy efficient motors16,800₹1,27,680₹50,0004.7
PP - Pumps
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Flow DetoriatedReplace old low efficient pumps with IE3 energy efficient Submersible pumps6,450₹49,020₹50,00012.2
Flow DetoriatedReplace old low efficient pumps with IE3 energy efficient Submersible pumps5,987₹45,501₹50,00013.2
Manual Throttling of ValvesModify pumping to minimize throttling.40,740₹3,09,624₹50,0001.9
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
CT Not NecessaryTurn Off Unnecessary Cooling Tower Fans When Loads Are Reduced.14,364₹1,09,166₹00.0