EAR/22-23/KISEM-IITGN-06
The subject plant is located in Ahmedabad district of Gujarat and falls under NIC Category-20. This assessment was carried out by the IEAC Center, IIT Gandhinagar, during the course of the year 2023.
General Info
Principal Product
Dyes & Intermediates
Plant Area (Sq.ft)
1,00,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹5,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,06,07,036
Total Recommended Investment(one time)
₹94,290
Total Recommended Savings(per year)
₹4,64,546
Energy Costs Calculation
Electricity
Annual Usage
5,11,260
Unit
kWh
Unit Cost
₹8
Annual Cost
₹39,53,974
Gas
Annual Usage
82,749
Unit
SCM
Unit Cost
₹81
Annual Cost
₹66,53,062
Total Energy Costs(per year)
₹1,06,07,036
Observations & Recommendations
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Power factor at LT side during load time is 0.74 | Install a fixed capacitor of 20 kVAR | ₹ | ₹6,290 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Some Hydrogen (ppm) traces reflect in flue gas due to frequent burner on and off | From On Off operation switch to low-high modulation | ₹ | ₹ | 7 | ||
| High excess air in the system | First modulate the burner and then again check the excess air | 4061 | ₹2,88,362 | ₹ | 7 | |
| Heat loss from flue gas duct & supply line from APH to blower (Air preheater) | Proper insulation is required | 2481 | ₹1,76,184 | ₹70,000 | 5 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 3 capacitor of 15 kVAR are derated (APFC) | Replace all the derated capacitor | ₹ | ₹12,000 | |||
| 2 capacitor of 10 kVAR are derated (APFC) | Replace all the derated capacitor | ₹ | ₹6,000 |