IIT Madras

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Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras


The subject plant is located in district of 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

Steel rolling

Plant Area (Sq.ft)


No. of Employees


Production Hours


Annual Production

Annual Sales


Assessment Summary

Total Energy Costs(per year)


Total Recommended Investment(one time)


Total Recommended Savings(per year)


Energy Costs Calculation

Annual Usage




Unit Cost


Annual Cost



Annual Usage




Unit Cost


Annual Cost


Total Energy Costs(per year)


Observations & Recommendations
CPF - Capacitor & Power Factor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
There is No APFC in the plant. All are HT and LT Fixed Capacitors. Many capacitors are not working properly due to ageing & derating. CCM LT Capacitor Bank-1 was found low kVARGo for HT Fixed Capacitors and LT APFC arrangement. Even HT Capacitors can be arranged to 2 * 600 kVAR instead of single 1200 kVAR and switch on the same as per operationrequirement. Rphase of CCM LT Capacitor Bank-1 was not getting continuity because of problem in MCCB.55,029₹4,91,955₹2,00,0004.9
Supply side harmonics is presentA properly designed Harmonics Filter should be implemented to eliminate the same so that the problems due to harmonics will be reduced
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Ladle wall Temp is above 230 degree CUse ceramic fiber materials for lining the Laddle instead of Ramming Mass.7,46,484₹66,73,567
Molten metal temperature is high (1600 – 1680 deg C) and low life of furnace liningUse ceramic fiber materials for lining the Induction Furnace instead of Ramming Mass
Scraps are not segregation & handled properly. Slag is too high in some period. There is no weighing of scraps.Clean, segregate the scraps and use Hydraulic presser for bundling the scraps.56,94,000₹5,09,04,360₹13,00,0000.3
The ladle after pouring takes 32 – 35 mins for complete casting process and the ladle mouth temperature is above 900 deg CThe radiation & convection losses can be decreased by closing the ladle with thermal insulation lids.3,95,180₹35,32,909₹50,0000.2
ladle preheatingUse Laser preheating which is more efficient than using woods.
Flue gas temperature (above 270 deg C) & excess air (above 320%) is too highOptimize the excess air by adjusting the speed of blower and use recuperator.3,84,000₹38,40,000₹2,00,0000.6
Thermal insulation issues in reheating Furnace.Insulate completely using cerawool
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Two mills will be running parallelly even if there is no real need for the sameThe line from CCM to mills can be doubled and used for both mills to increase productivity.44,61,148₹3,98,82,663₹5,00,0000.2
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
2 out of 4 compressor lines has high leakages.Arrest all the air leak points in all the sections and periodically check for air leaks.1,42,824₹12,76,849₹20,0000.2
The current air compressors are vertical or double cylinder reciprocating compressors which are not energy efficientReplace compressor with energy efficient VFD installed screw compressor and link whole the air line to same with receiver tank as already exist.50,418₹4,50,738₹7,00,00018.6
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Patra Mill Cooling tower was observed working even when the Mill is not workingSwitch off 10-15 mins after the mill shut down2,82,510₹25,25,639
All the three pumps of Patra mill cooling tower are working full time.Switch off the additional pump.2,04,400₹18,27,336
Patra mill cooling tower input and output heat exchange takes place.Change the position of inlet pipe
16” rolling mill Cooling Tower hot sump and cold sumps were mixed.Separate the sumps.2,48,114₹22,18,139₹3,00,0001.6
Many valves are leaking in cooling tower pumps.Arrest the leakages
BL - Blower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Fume collection blowers are running full timeVFD with sensor or timer based system should be installed. Where blower is common, individual dampers can be provided and operated in corporation with the VFD sensing4,27,050₹38,17,827₹20,00,0006.3
Furnace 3 Fume collection blower is not working in good condition.Replace the same with BLDC or Energy Efficient blowers.