EAR/22-23/KISEM-IITGN-05
The subject plant is located in district of and falls under NIC Category-24105. This assessment was carried out by the IEAC Center, IIT Gandhinagar, during the course of the year 2022.
General Info
Principal Product
Steel Rolling
Plant Area (Sq.ft)
1,00,000
No. of Employees
300
Production Hours
7,200
Annual Production
Annual Sales
₹10,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹5,90,01,110
Total Recommended Investment(one time)
₹64,75,000
Total Recommended Savings(per year)
₹69,45,548
Energy Costs Calculation
Electricity
Annual Usage
20,87,080
Unit
kWh
Unit Cost
₹5
Annual Cost
₹98,00,543
Wind Power
Annual Usage
12,92,749
Unit
kWh
Unit Cost
₹8
Annual Cost
₹1,02,34,168
Coal
Annual Usage
11,02,523
Unit
kg
Unit Cost
₹11
Annual Cost
₹1,21,27,756
Furnace oil
Annual Usage
6,42,624
Unit
kg
Unit Cost
₹42
Annual Cost
₹2,68,38,643
Total Energy Costs(per year)
₹5,90,01,110
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Excess Air | Control the flow of air by using VFD (input may be manual or automatic by taking input from Oxygen Gas analyzer) and pack the furnace i.e., cover the opening from different furnace area | 45,241 | ₹18,09,652 | ₹6,00,000 | 4 | |
| High Chimney Temperature (on average 244 deg C) | Reduce the Chimney temperature by using air preheater in the path of flue gas | 29591 | ₹11,83,660 | ₹7,00,000 | 7.1 | |
| High Chimney Temperature (on average 244 deg C) | Using Air preheater in flue gas path increase the fresh air temperature nearly by 200 deg C and helps in reducing the fuel consumption | ₹ | ₹6,00,000 | |||
| Heat loss from hot surface of Furnace & its ducts | Proper Insulation required | 25622 | ₹10,24,885 | ₹5,00,000 | 6 | |
| Manual Furnace Temperature Monitoring | Use Modulating burner for a particular temperature band (as per your set point) | ₹ | ₹3,00,000 | |||
| High Excess Air | Control the flow of air by using VFD (input may be manual or automatic by taking input from Oxygen Gas analyser) and pack the furnace i.e., cover the opening from different furnace area | 45241 | ₹18,09,652 | ₹6,00,000 | 4 | |
| Recuperator is not working effectively | Install it in the path of Flue gas so that fresh air temperature will increase by 200 deg C which in turn reduce the fuel consumption | 14952 | ₹5,98,086 | ₹2,00,000 | 4 | |
| Heat loss from hot surface of Furnace its ducts | Proper Insulation required | 12990 | ₹5,19,613 | ₹1,00,000 | 2 | |
| Manual Furnace Temperature Monitoring | Use Modulating burner for a particular temperature band (as per your set point) | ₹ | ₹3,00,000 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Current & Voltage Harmonics (@ 450 HP motor) | Install Harmonic Filter | ₹ | ₹5,00,000 | |||
| Current & Voltage Harmonics (@ 400 HP motor) | Install Harmonic Filter | ₹ | ₹5,00,000 | |||
| Current & Voltage Harmonics (@ 500 HP motor) | Install Harmonic Filter | ₹ | ₹5,00,000 | |||
| Current & Voltage Harmonics (@ 800 HP motor) | Install Harmonic Filter | ₹ | ₹5,00,000 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Current & Voltage Harmonics-LT side Transformer | Install Harmonic Filter | ₹ | ₹5,00,000 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Derated Capacitor (25 kVAR) | Replace the derated capacitor (11 nos) | ₹ | ₹71,500 | |||
| Derated Capacitor (10 kVAR) | Replace the derated capacitor (1 nos) | ₹ | ₹3,500 |