EAR/23-24/KISEM-09/Final 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 & Intermediate
Plant Area (Sq.ft)
1,50,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹20,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,95,61,382
Total Recommended Investment(one time)
₹3,27,500
Total Recommended Savings(per year)
₹8,90,649
Energy Costs Calculation
Electricity
Annual Usage
8,70,473
Unit
kWh
Unit Cost
₹9.5
Annual Cost
₹82,27,590
Piped Natural Gas
Annual Usage
138156
Unit
SCM
Unit Cost
₹82
Annual Cost
₹1,13,33,792
Total Energy Costs(per year)
₹1,95,61,382
Observations & Recommendations
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 500 TR Cooling tower fan running 24 Hrs even when there is no load on cooling tower | Temperature Controller is already installed in cooling tower Auto Manual control is not working, we need to switch on the automatic control and Keep 28 deg setpoint in Controller | 6,325.2 | ₹59,773 | ₹ | ||
| 500 TR Cooling tower pump running on High power consumption when no cooling water requirement in plant | Install a VFD with PID controller in 15 kW Cooling tower Motor | 18765.6 | ₹1,77,335 | ₹95,500 | 6.2 |
CHR - Chiller
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Higher Condenser approach observed in chiller | Condenser Cleaning is recommended for chiller to reduce compressor power consumption | 6875 | ₹64968 | ₹40000 | 7.4 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Improper Insulation found in Steam lines | Insulation in Open uninsulated Steam lines | 2707 | ₹2,08,439 | ₹12000 | 1 | |
| No Condensate recovery system in plant | Replace TD Trap with float traps in FBD Dryer and install a condensate recovery tank | 4907 | ₹3,80,134 | ₹1,80,000 | 5 |