IIT Madras

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IIT Bombay

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IIT Gandhinagar

IIT Guwahati

IIT Ropar

Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras


The subject plant is located in district of and falls under NIC Category-20. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2022.

General Info

Principal Product


Plant Area (Sq.ft)


No. of Employees

Production Hours


Annual Production

Annual Sales


Assessment Summary

Total Energy Costs(per year)


Total Recommended Investment(one time)


Total Recommended Savings(per year)


Energy Costs Calculation

Annual Usage




Unit Cost


Annual Cost


Diesel Generator

Annual Usage




Unit Cost


Annual Cost



Annual Usage




Unit Cost


Annual Cost


Total Energy Costs(per year)


Observations & Recommendations
CPF - Capacitor & Power Factor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Reactive power is negative most of the time.APFC mechanism of Plant is not working well and it should be rectified with the AMC12,900₹1,16,100₹30,0005.17
APFC controlling is by using single phase sensing onlyThe sensing mechanism should be upgraded to Three phase sensing
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
26 out of 81 motors were studied out of which 6 pumps were underloadedVFD is recommended which will save more power2,34,100₹21,06,904₹6,00,0003.42
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Excess air is too high around 190-200%.Install Oxygen sensor and give feedback to VFD for controlling FD and ID fan5,68,700₹49,47,690₹3,00,0000.71
VFD controlling of ID fan by using temperature setting onlyInstall Oxygen sensor and give feedback to VFD for controlling FD and ID fan
FD fan is working at full speed irrespective of the quantity of supply air.VFD should be installed in FD fan and it should be controlled as above12,700₹1,14,300
Thermal insulation is not maintained proper at some placesThermal insulation should be done at circulation pipes and boiler walls.64,400₹5,60,280₹50,0001.1
Dry flue gas temperature is too highThis can be utilised for Preheating of process Raw material.
Coal is used as fuel for BoilerCashew nut shell fuel substitution is recommended which has more GCV48,19,200₹3,01,38,755₹1,00,0000.04
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Poor Effectiveness & Approach of the Cooling TowerChange the fins which were not in good condition and frequent maintenance of cooling tower is required
CHR - Chiller
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Chiller line Insulation is not complete and proper.Need proper and complete insulation.96,000₹8,50,000₹1,00,0001.4
The effectiveness of 6 heat exchangers is below 60%. Some heat exchangers whenever not functional, then also water circulation is there.The flow of cooling water should be optimised to get best effectiveness and circulation of water can be stopped when heat exchanger is not operating