KMB-IIT-MAD-21.11.22-14
The subject plant is located in Chennai district of Tamil Nadu and falls under NIC Category-20221. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2022.
General Info
Principal Product
Kumkuman manufacturing
Plant Area (Sq.ft)
3,000
No. of Employees
50
Production Hours
7,200
Annual Production
50,000
Annual Sales
₹2,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹85,64,303
Total Recommended Investment(one time)
₹18,60,000
Total Recommended Savings(per year)
₹13,09,480
Energy Costs Calculation
Electricity
Annual Usage
5,11,020
Unit
kWh
Unit Cost
₹10.3
Annual Cost
₹52,64,303
Rice Husk
Annual Usage
6,00,000
Unit
kgs
Unit Cost
₹5.5
Annual Cost
₹33,00,000
Total Energy Costs(per year)
₹85,64,303
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Fair Combustion | Optimize the Air-Fuel Ratio | 30,872 | ₹1,69,796 | ₹4,50,000 | 31.8 | |
| Poor Thermal Insulation | Locate and Repair Defective Insulation on All Heating Plant Equipment and Piping | 7,794 | ₹42,867 | ₹50,000 | 14.0 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Current Harmonics | Install Harmonic Filters | 6,930 | ₹71,379 | ₹2,00,000 | 33.6 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Fair Power Factor | Optimize plant power factor to unity | 1,500 | ₹15,450 | ₹20,000 | 15.5 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 21,432 | ₹2,20,750 | ₹50,000 | 2.7 | |
| Compressor 3 - Capacity Underutilization | The compressor should be effectively operated in a manner that it should have minimum number of unloading cycles | 9,720 | ₹1,00,116 | ₹0 | 0.0 | |
| Compressor 3 - Capacity Underutilization | The compressor should be effectively operated in a manner that it should have minimum number of unloading cycles | 10,500 | ₹1,08,150 | ₹1,00,000 | 11.1 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess Power Consumption | Replace induction based electrical heaters with equivalent capacity of Heat Pump | 24,623 | ₹2,53,617 | ₹5,00,000 | 23.7 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Operated at Partial Load | Properly size the motor to the load for optimum efficiency | 29,569 | ₹3,04,561 | ₹4,00,000 | 15.8 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Old Type Fans | Use BLDC fan with equivalent velocity | 3,713 | ₹38,244 | ₹90,000 | 28.2 |