EAR/23-24/KISEM-08/1st Draft
The subject plant is located in district of 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
Chemical and Intermediates
Plant Area (Sq.ft)
1,50,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹25,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹5,40,16,724
Total Recommended Investment(one time)
₹4,88,000
Total Recommended Savings(per year)
₹8,99,012
Energy Costs Calculation
Electricity
Annual Usage
7,57,882
Unit
kWh
Unit Cost
₹10
Annual Cost
₹75,54,400
Diesel Oxidation Catalyst
Annual Usage
552210
Unit
kg
Unit Cost
₹53
Annual Cost
₹29267130
Piped Natural Gas
Annual Usage
209902
Unit
SCM
Unit Cost
₹80.7
Annual Cost
₹16921194
Furnace oil
Annual Usage
38000
Unit
Lit
Unit Cost
₹7.3
Annual Cost
₹274000
Total Energy Costs(per year)
₹5,40,16,724
Observations & Recommendations
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 200 TR Cooling tower fan running 24 Hrs without When there is no load on cooling tower | Temperature indicator is already installed in cooling tower, a controller required to have ON/OFF controlling on CT Fan | 3,528 | ₹35,174 | ₹7,500 | 2.5 | |
| 200 TR Cooling tower pump running on High power consumption when no cooling water requirement in plant | Install a VFD in 7.5 kW Cooling tower Motor. | 12432 | ₹1,23,947 | ₹60,500 | 5.8 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Vacuum drop in Spray dryer to ID Fan line, Cyclone collector is without Air lock Rotary system | Install a Rotary Air lock system in spray dryer and VFD on ID fan to control Vacuum in System | 54235 | ₹5,40,731 | ₹4,20,000 | 9.3 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Actual Contract demand found marginally low than billing demand throughout the year | Reduction in Contract demand from 380 kW to 300 kW to reduce Demand charges (260 Rs/kW) | ₹1,99,160 | ₹ |