KMB-IIT-BOM-080523-15
The subject plant is located in Jalna district of Maharashtra and falls under NIC Category-24105. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2023.
General Info
Principal Product
Re-Rolling Mill
Plant Area (Sq.ft)
5,00,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹50,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹3,43,00,000
Total Recommended Investment(one time)
₹18,50,000
Total Recommended Savings(per year)
₹24,50,145
Energy Costs Calculation
Electricity
Annual Usage
13,38,895
Unit
kWh
Unit Cost
₹11.5
Annual Cost
₹1,54,00,000
Coal
Annual Usage
1264000
Unit
Kg
Unit Cost
₹15
Annual Cost
₹1,89,00,000
Total Energy Costs(per year)
₹3,43,00,000
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Many Capacitors are Derated. Thyristor failiure is there in 50kVAR. During night grid is feed around 15kVAR | Replace Derated Capacitors. Fixed Capacitors should be decreased. | 30,474 | ₹3,51,498 | ₹1,50,000 | 5.1 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 3 Big (2 for 12 Hrs & one for 5 Hrs) cutting machines are there | Install VFD for 2 out of 3 cutting machines which are being operated 12 hours and tune the VFD for the same purpose | 19,152 | ₹2,20,906 | ₹2,70,000 | 14.7 | |
| There are 5 (three 5hp & two 3hp) small cutting machines which are operating whole 12 hours. | Install pedal switch which will be cost effective method for 3 cutting machines which are near rolling mill | 4,770 | ₹55,019 | ₹10,000 | 2.2 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Coal Crushing machine is working at variable load | Install VFD and tune the VFD for the same purpose | 44,064 | ₹5,08,250 | ₹2,00,000 | 4.7 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Pump bypass valve is open full time. Out of 13.81 m3/hr only 9 m3/hr is required in plant | Install VFD for the pump so that the flow/pressure should be maintained | 17,022 | ₹1,96,342 | ₹1,20,000 | 7.3 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The exhaust temperature is too high (~600 deg.C) | Install recuperator to preheat the air from 35 deg.C to 120 deg.C | 45,566 | ₹6,83,490 | ₹10,00,000 | 17.6 | |
| Thermal insulation is not good enough in many areas in the furnace wall | Insulate perfectly, give double insulation if required | 28,976 | ₹4,34,640 | ₹1,00,000 | 2.8 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Rolling Mill is manually operating | Automise the rolling mill so that production can be increased | ₹ | ₹ |