EAR/22-23/KISEM/IITR-06
The subject plant is located in district of and falls under NIC Category-20. This assessment was carried out by the IEAC Center, IIT Ropar, during the course of the year 2023.
General Info
Principal Product
Chemicals
Plant Area (Sq.ft)
1,50,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹3,00,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹24,89,02,274.5
Total Recommended Investment(one time)
₹13,20,000
Total Recommended Savings(per year)
₹1,91,87,668
Energy Costs Calculation
Electricity
Annual Usage
3,09,85,014
Unit
kWh
Unit Cost
₹7.2
Annual Cost
₹22,04,16,073.5
Hydrogen
Annual Usage
1706880
Unit
kg
Unit Cost
₹167
Annual Cost
₹284862015
Total Energy Costs(per year)
₹24,89,02,274.5
Observations & Recommendations
CHR - Chiller
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Three primary pumps are used for two chillers (300 TR) | One pump (which consume more power) can be switched of | 1,54,439 | ₹12,35,510 | ₹ | ||
| Throttling control is used regulate the flow rate in both primary and secondary pump of the chiller | VFD technology can be used to regulate the water flow in pump with respect to the requirement | 9,19,070 | ₹76,06,871 | ₹3,50,000 | 0.6 | |
| Approach in the evaporator side is observed to be high | Do periodic chiller maintenance | ₹ | ₹ |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Screw compressors unloading time is high | Existing three screw compressors (One nitrogen and One Instrument air) can be operated with VFD drive | 2,85,613 | ₹22,84,900 | ₹1,50,000 | 0.8 | |
| Overall air leakages are high | Arrest air leakages regularly | 93,440 | ₹7,47,520 | ₹50,000 | 0.8 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High surface temperature on Boiler and Economiser | Provide proper thermal insulation | 1,543 | ₹2,57,763 | ₹50,000 | 2.3 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional energy inefficient fans are used in cooling towers | Existing inefficient fans can be replaced with energy efficient FRP fans | 95,677 | ₹7,65,414 | ₹4,00,000 | 6.3 | |
| Cooling tower fan is continuously operating without any control | On/Off control can be provided to CT fan with respect to atmospheric temperature | 12,775 | ₹1,02,200 | ₹20,000 | 2.3 | |
| Throttling control is used regulate the flow rate in circulation pump | VFD technology can be used to regulate the water flow in pump with respect to the requirement | 7,73,436 | ₹61,87,489 | ₹3,00,000 | 0.6 |