EAR/23-24/KISEM/IITI-03/02
The subject plant is located in Pithampur district of Madhya Pradesh and falls under NIC Category-24202. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Aluminium Die Cast Products Manufacturer
Plant Area (Sq.ft)
46,985
No. of Employees
117
Production Hours
7,200
Annual Production
9,00,000
Annual Sales
₹
Assessment Summary
Total Energy Costs(per year)
₹2,24,55,000
Total Recommended Investment(one time)
₹1,04,72,800
Total Recommended Savings(per year)
₹72,36,907
Energy Costs Calculation
Electricity
Annual Usage
16,78,000
Unit
kWh
Unit Cost
₹8.2
Annual Cost
₹1,38,34,000
PNG
Annual Usage
156748
Unit
SCM
Unit Cost
₹55
Annual Cost
₹8621000
Total Energy Costs(per year)
₹2,24,55,000
Observations & Recommendations
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are found to be high at different points of the circuit | Arrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit and fittings | 1,75,867 | ₹14,49,146 | ₹1,50,000 | 2 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency and Loading of Induction Motor used in PDC Machines - 3,4,6 and 7 is low | Replace 30 HP Induction motor with 20 HP IE3 Efficiency class Induction Motor | 31232 | ₹257351 | ₹225000 | 11 | |
| Efficiency and Loading of Induction Motor used in PDC Machines - 2 and 5 is low | Replace 60 HP and 50 HP Induction motors with 40 HP IE3 Efficiency class Induction Motor | 19975 | ₹176779 | ₹180000 | 13 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The Cooling tower is underloaded and effectiveness is found low. Hot well and Cold Wells are mixed up | Improve range by reducing water flow rate by installing and operating the pump using VFD and intermediate operation of fan | 11092 | ₹91398 | ₹40000 | 6 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency of Gas fired Melting furnace is low and Specific Energy Cost is low at Rs.7.92/kg | Switch to Electrical resistance melting furnace having low specific energy cost at Rs.2.73/kg | ₹4656324 | ₹2500000 | 7 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Holding Furnaces 2,3,5,6 and 7 is operated in ON/OFF control mode and full MD is consumed | Install PID controlled Thyristor Converter and reduce Maximum Demand by 6 to 8 kVA and save demand charges | ₹259494 | ₹250000 | 12 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Billed MD is low compared to minimum quota of CD allotted | Surrender CD from 425 to 350 kVA and save minimum demand charges | ₹268650 | ₹50000 | 3 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Daily Energy Losses are high compared to standard similar rating Transformer | Carry out overall maintenance and oil filtration of the Transformer | 3504 | ₹28873 | ₹15000 | 7 |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Lights are switched ON at PDC Floor, even though daylight is sufficient | Install more skylights and switch OFF 10 Nos of 150W LED industrial down lights | 4500 | ₹37080 | ₹30000 | 10 | |
| Lighting used in the office and cabins are low efficiency T5 fluorescent tube lights | Retrofitting 12 Nos of Conventional Tube lights - 28W T5 FTL with 20W LED Patterns | 260 | ₹2202 | ₹7200 | 40 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ceiling fans used in the office and cabins are inefficient conventional type | Replace 8 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans | 972 | ₹9609 | ₹25600 | 32 |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Electricity is consumed from utility grid alone and there is no source of renewable energy in the plant | Install a Rooftop 140 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy | 168000 | ₹1384320 | ₹7000000 | 61 |