KMB-IIT-GUW-230817-07
The subject plant is located in Guwahati district of Assam and falls under NIC Category-20. This assessment was carried out by the IEAC Center, IIT Guwahati, during the course of the year 2023.
General Info
Principal Product
Mosquito repellant Refills, Anti Roach Gel, Hair dye
Plant Area (Sq.ft)
30,000
No. of Employees
45
Production Hours
7,200
Annual Production
Annual Sales
₹10,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹2,42,85,999
Total Recommended Investment(one time)
₹16,00,000
Total Recommended Savings(per year)
₹30,51,028
Energy Costs Calculation
Electricity
Annual Usage
17,97,624
Unit
kWh
Unit Cost
₹7.9
Annual Cost
₹1,41,33,999
Diesel
Annual Usage
1,12,800
Unit
Ltr
Unit Cost
₹90
Annual Cost
₹1,01,52,000
Total Energy Costs(per year)
₹2,42,85,999
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Boiler feed water temperature is only 35 °C | Collect condensate recovery properly and use it as boiler feed water | 5,520 | ₹4,96,800 | ₹2,00,000 | 4.8 | |
| Condensate recovery is not collected and utilized. | Collect condensate recovery properly and use it as boiler feed water | ₹ | ₹ |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Maximum Demand that has been reached in the previous year is 392 kVA while the sanctioned demand is 530 kVA | Surrender the excess demand of 100 kVA | ₹3,36,000 | ₹ |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Only 94 kVAR connected in 160 kVAR APFC panel | Replace the derated capacitor | ₹ | ₹15,000 | |||
| PF correction is based on feedback from single phase only | Install three phase sensing to bring PF to unity. | ₹ | ₹ |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall transformer loss is high - 1.89% | Install Harmonics filter to avoid distortion in harmonics and to reduce the transformer loss | 19,523 | ₹1,63,017 | ₹7,00,000 | 51.5 | |
| Transformer current harmonics (8.5%) is higher than the IEEE Standard of 8% | Install Harmonics filter to avoid distortion in harmonics and to reduce the transformer loss | ₹ | ₹ |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Plant overall Air leakage is high - 103 CFM | Arrest all the identified air leakages | 1,42,663 | ₹11,91,236 | ₹50,000 | 0.5 | |
| Compressor current pressure setting is very high ( 7.5 bar) | Reduce the pressure setting to 6 - 6.5 bar | 40,068 | ₹3,34,568 | ₹ |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| In cooling tower, the water flow is uneven and the CT fan is running even during the non cooling time | Proper maintenance should be done regularly. Turn off CT fan when not in use. | 6,480 | ₹54,108 | ₹1,00,000 | 22.2 |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| UPS 1 & UPS 2 is operated only at 35% & 25% loading | Operate the UPS at maximum load to get maximum efficiency | 8,250 | ₹68,888 | ₹ |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Power consumption of the 30 old exhaust fans (0.5 kW) are higher than the power consumption of new exhaust fan (0.3 kW) | Replace the old exhaust fans with new exhaust fans | 21,600 | ₹1,80,360 | ₹3,00,000 | 20 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Totally, there are 94 conventional ceiling fan in the plant running for 24 hours and power consumption by each fan is 70 W | Replace the conventional ceiling fan with BLDC fans which consumes only 30 W | 27,072 | ₹2,26,051 | ₹2,35,000 | 12.5 |