IIT Madras

IIT Hyderabad

IIT Bombay

IIT Indore

IIT Gandhinagar

IIT Guwahati

IIT Ropar

Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras

EAR/23-24/KISEM/IITI-11/01

The subject plant is located in district of 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

ACP, APP, Metalam sheets

Plant Area (Sq.ft)

1,50,000

No. of Employees

350

Production Hours

8,760

Annual Production

2,50,00,000

Annual Sales

₹15,00,00,000

Assessment Summary

Total Energy Costs(per year)

₹5,05,46,000

Total Recommended Investment(one time)

₹3,57,21,800

Total Recommended Savings(per year)

₹1,32,27,481

Energy Costs Calculation
Electricity

Annual Usage

60,00,000

Unit

kWh

Unit Cost

₹8.4

Annual Cost

₹5,02,00,000

Diesel

Annual Usage

3600

Unit

kg

Unit Cost

₹96.2

Annual Cost

₹3,46,000

Total Energy Costs(per year)

₹5,05,46,000

Observations & Recommendations
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Overall air leakages are found to be high at different points of the circuitArrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit and fittings.11,685₹1,87,530₹52,0004
Inefficient Reciprocating Compressor with higher kW/CFM is usedOperate comparatively efficient screw compressor already available in the plant15137₹1,28,061₹20,0002
Reciprocating Compressor suction -discharge operation is not happing properly, and air is leaked through suction valveUndergo maintenance7096₹60,029₹20,0004
At compressor suction side, the temperature of air is 40°C to 42°C observedProposed to shift the compressor to open space and allow to suction the air at space temperature710₹6,003₹6,00012
The existing Cut-off pressure is 7.5 bar. Whereas the maximum pressure requirement is 6 barsProposed to change the cut-off pressure from 7.5 bar to 6.5 bar2365₹20,010
HVC - Heating Ventilation & Cooling
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Conventional Electric Resistance heaters are used in Thermic Fluid Heaters at Composite Pressing UnitSwitch to Energy Efficient Induction Heaters249134₹21,07,677₹12,00,0007
In the Calendering Unit - Heat gained by a roll is lost by adding cooling water without reclaiming it for consecutive heating rollCascade the flow of water from one roll to another for completely reclaiming the heat gain47304₹4,00,192₹5,00,00015
Conventional Wall fans are used in the Office SpacesReplace with Energy Efficient BLDC Wall fans1620₹14,112₹28,80025
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
1250 kVA Servo Stabilizer - Losses are found to be higher than standard limitsOperate comparatively energy efficient OLTC - Voltage Controller already available with the existing Transformer which is in non-operative condition156375₹13,22,932₹1,00,0001
750 kVA Isolation Transformer - Losses are found to be higher than standard limitsOperate comparatively energy efficient OLTC - Voltage Controller already available with the existing Transformer which is in non-operative condition57970₹4,90,424₹1,00,0003
Purchased Contract Demand is not properly utilizedSurrender Contract Demand₹2,11,500₹50,0003
ALS - Alternate Source of Power
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Diesel fuelled Conventional Forklifts are used for material handlingSwitch to Energy Efficient Battery-operated Electric - Forklifts25577₹2,02,495₹5,00,00030
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
In Cooling Towers-1 and Cooling Tower- 2, the load return hot water is discharged to hot well and the same is pumped to CT inlet.Deliver process return water directly to CT inlet.54207₹4,58,590₹50,0002
In CT- 2 bypass of pressurised water from the discharge line and overflow of pressurised water observedProposed to use corrected rated pump and Cooling tower. Avoid bypass and overflow of pressurized water.
CT-1 the fan is operating continuously irrespective to loadOperate fan as per the approach temperature.3716₹31,434₹15,0006
The overall efficiency of the CT Pump is low (5% to 10%).Replace the pump with optimal size energy efficient pump.93908₹7,94,461₹30,0001
In existing condition, the material of the CT fan is non-FRP materialProposed to use FRP material type fan in both cooling tower10841₹91,711₹50,0007
ALS - Alternate Source of Power
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Electricity is consumed from utility grid alone and there is no source of renewable energy in the plantInstall a Rooftop 660 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy792000₹67,00,320₹3,30,00,00060