EAR/23-24/KISEM/IITI-05/02
The subject plant is located in Satna district of Madhya Pradesh and falls under NIC Category-17. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Paper Products Manufacturer
Plant Area (Sq.ft)
8,50,000
No. of Employees
110
Production Hours
7,200
Annual Production
1,67,00,000
Annual Sales
₹1,00,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹8,75,00,000
Total Recommended Investment(one time)
₹18,32,800
Total Recommended Savings(per year)
₹1,65,02,528
Energy Costs Calculation
Annual Usage
27,04,000
Unit
kWh
Unit Cost
₹9.02
Annual Cost
₹2,44,00,000
Annual Usage
296000
Unit
kWh
Unit Cost
₹9.02
Annual Cost
₹
Annual Usage
3655080
Unit
Kg
Unit Cost
₹9.6
Annual Cost
₹35100000
Annual Usage
5279020
Unit
Kg
Unit Cost
₹5.3
Annual Cost
₹28000000
Total Energy Costs(per year)
₹8,75,00,000
Observations & Recommendations
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are found to be high at different points of the circuit | Arrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit and fittings. | 74,214 | ₹6,02,618 | ₹54,000 | 2 | |
| Screw compressor (C1) - loading time is very high due to inefficient performance and high specific power consumption. Due to leakage and poor performance of C1, Reciprocating Compressor (C2) is also switched ON during peak demands | Replace inefficient C1 with new screw compressor of same capacity with VFD and keep C2 as standby only. | 39536 | ₹321823 | ₹700000 | 27 |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Mechanical power transmission slip found to be very high in Chest Agitator motors - 1,2 and 3, Turbo 600, Vacuum Pumps - 1 and 2 | Reduce slippage in belt and pulley system through replacement of conventional V-belts with Cogged V-belts and reduce motor speed using existing VFD | 528688 | ₹4303517 | ₹24000 | 1 | |
| Mechanical power transmission slip found to be very high in Chest Agitator motors - 5 and 6 | Reduce energy lost in transmission by direct coupling the machines | 6336 | ₹51575 | ₹80000 | 19 | |
| VFD is unnecesarily used to run Chest Pumps - 2,4,5 and 6 at full speed. Energy is lost as self power consumption in VFDs | Bypass VFD and save energy lost in VFDs | 42120 | ₹342857 | ₹8000 | 1 |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Thermal energy lost as flash steam at the rate of 7.4% | Recover condensate using a SOPT Pump and pumping condensate directly to feed water tank | 428400 | ₹2274804 | ₹700000 | 4 | |
| Steam leakages at various points (13 Nos x 15kg/hr) | Insulate steam lines and arrest the leakages by properly sealing the gaps | 334200 | ₹1774602 | ₹30000 | 1 | |
| Thermal energy lost in condensate circulating in steam traps (13Nos x 10kg/hr) | Recover Condensate | 27000 | ₹143370 | ₹50000 | 5 | |
| Thermal energy loss in Turbine and SOPT - PRV | Maintenance of Steam turbine shaft seals | 1217400 | ₹6464394 | ₹50000 | 1 |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Lighting used in the plant and office areas are low efficiency T8 and T12 fluorescent tube lights | Retrofitting 20 Nos of Conventional Tubelights - 36 W T8 FTL with 20W LED patterns | 2304 | ₹18755 | ₹12000 | 8 |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ceiling fans used in the plant and office areas are inefficient conventional type | Replace 24 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans | 7776 | ₹68097 | ₹76800 | 14 |
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Billed MD is low compared to minimum quota of CD allotted | Surrender CD from 900 to 800 kVA and save minimum demand charges | ₹136116 | ₹50000 | 5 |