KMB-IIT-MAD-29.12.22-04
The subject plant is located in district of and falls under NIC Category-17014. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2022.
General Info
Principal Product
Cardboard
Plant Area (Sq.ft)
25,000
No. of Employees
50
Production Hours
4,800
Annual Production
84,00,000
Annual Sales
₹18,90,000
Assessment Summary
Total Energy Costs(per year)
₹2,34,52,174
Total Recommended Investment(one time)
₹18,05,000
Total Recommended Savings(per year)
₹34,47,645
Energy Costs Calculation
Electricity
Annual Usage
9,54,328
Unit
kWh
Unit Cost
₹10
Annual Cost
₹95,43,280
Briquette
Annual Usage
14,95,580
Unit
kg
Unit Cost
₹9.3
Annual Cost
₹1,39,08,894
Solar
Annual Usage
4,06,648
Unit
kWh
Unit Cost
₹0
Annual Cost
₹
Total Energy Costs(per year)
₹2,34,52,174
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ineffective Combustion | Optimize the Air-Fuel Ratio | 1,71,152 | ₹15,91,714 | ₹3,00,000 | 2.3 | |
| Poor Thermal Insulation | Locate and Repair Defective Insulation on All Heating Plant Equipment and Piping | 5341 | ₹49,671 | ₹50000 | 12.1 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Current & Voltage Harmonics | Install Harmonic Filters | ₹ | ₹1200000 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Demand Underutilization | Surrender unutilized sanctioned demand | ₹5,28,000 | ₹ |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 1,11,384 | ₹11,13,840 | ₹75,000 | 0.8 | |
| VFD drive self-consumption is very high | Replace VFD drive with energy efficient VFD | 12,000 | ₹1,20,000 | ₹80,000 | 8.0 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Operated at Partial Load | Use variable speed drives for large variable blower loads. | 4,442 | ₹44,420 | ₹1,00,000 | 27.0 |