KMB-IIT-BOM-150323
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)
1,50,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹5,00,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,18,03,71,013
Total Recommended Investment(one time)
₹52,70,000
Total Recommended Savings(per year)
₹11,74,41,982
Energy Costs Calculation
Electricity
Annual Usage
7,69,37,628
Unit
kWh
Unit Cost
₹8.8
Annual Cost
₹67,13,27,413
Coal
Annual Usage
5,69,40,000
Unit
kg
Unit Cost
₹8.94
Annual Cost
₹50,90,43,600
Total Energy Costs(per year)
₹1,18,03,71,013
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 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 kVAR | Go 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 | ₹2,00,000 | 4.9 | |
| Supply side harmonics is present | A 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
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ladle wall Temp is above 230 degree C | Use 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 lining | Use 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 | ₹13,00,000 | 0.3 | |
| The ladle after pouring takes 32 – 35 mins for complete casting process and the ladle mouth temperature is above 900 deg C | The radiation & convection losses can be decreased by closing the ladle with thermal insulation lids. | 3,95,180 | ₹35,32,909 | ₹50,000 | 0.2 | |
| ladle preheating | Use Laser preheating which is more efficient than using woods. | ₹ | ₹ | |||
| Flue gas temperature (above 270 deg C) & excess air (above 320%) is too high | Optimize the excess air by adjusting the speed of blower and use recuperator. | 3,84,000 | ₹38,40,000 | ₹2,00,000 | 0.6 | |
| Thermal insulation issues in reheating Furnace. | Insulate completely using cerawool | ₹ | ₹ |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Two mills will be running parallelly even if there is no real need for the same | The line from CCM to mills can be doubled and used for both mills to increase productivity. | 44,61,148 | ₹3,98,82,663 | ₹5,00,000 | 0.2 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 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 | ₹20,000 | 0.2 | |
| The current air compressors are vertical or double cylinder reciprocating compressors which are not energy efficient | Replace 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 | ₹7,00,000 | 18.6 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Patra Mill Cooling tower was observed working even when the Mill is not working | Switch off 10-15 mins after the mill shut down | 2,82,510 | ₹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 | ₹3,00,000 | 1.6 | |
| Many valves are leaking in cooling tower pumps. | Arrest the leakages | ₹ | ₹ |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Fume collection blowers are running full time | VFD 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 sensing | 4,27,050 | ₹38,17,827 | ₹20,00,000 | 6.3 | |
| Furnace 3 Fume collection blower is not working in good condition. | Replace the same with BLDC or Energy Efficient blowers. | ₹ | ₹ |