KMB-IIT-GUW-230522-03
The subject plant is located in district of and falls under NIC Category-22209. This assessment was carried out by the IEAC Center, IIT Guwahati, during the course of the year 2023.
General Info
Principal Product
Thermoware,Plastic Industry
Plant Area (Sq.ft)
1,30,000
No. of Employees
300
Production Hours
7,200
Annual Production
Annual Sales
₹20,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,10,03,347
Total Recommended Investment(one time)
₹6,75,000
Total Recommended Savings(per year)
₹15,30,922
Energy Costs Calculation
Electricity
Annual Usage
12,92,805
Unit
kWh
Unit Cost
₹8.5
Annual Cost
₹1,10,03,347
Total Energy Costs(per year)
₹1,10,03,347
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Current harmonics is very high (16.5%) | Install harmonics filter to reduce the current harmonics | ₹5,00,000 | ₹ | |||
| In previous year, apart from the month (November 2022 & December 2022) the power factor is maintained below 0.97 | Improve the power factor to 0.97 to get rebate of 3% of total unit consumption | 19,378 | ₹1,68,589 | ₹50,000 | 3.6 | |
| Only 20 kVAR connected in 250 kVAR APFC | Replace the derated capacity of 130 kVAR | ₹ | ₹ | |||
| In APFC, feedback signal is taken from single phase | Install three phase sensing in the APFC | ₹ | ₹ |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall Air leakage is high (45 cfm). Nearly 89 air leak points were identified. | Arrest all the identified air leakages | 60,480 | ₹5,26,176 | ₹50,000 | 1.1 | |
| Compressor unloading hours is high (8 hours per day) | Install VFD to reduce the unloading losses | 31,080 | ₹2,70,396 | ₹75,000 | 3.3 | |
| Compressor current pressure setting is very high (8.9 - 9.6 bar) | Reduce the pressure setting to 6.5 - 7 bar | 29,750 | ₹2,58,825 | ₹ |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Nearly, 20 m3/hr of water is flowing through bypass from hot water tank to cold water tank. | Pump no 3 (5.5 kW) can be turned off and VFD can be installed to minimize and balance the excess water flow. | 35,280 | ₹3,06,936 | ₹1,50,000 | 5.9 |