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)
₹65,27,160
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
| 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. | 11,685 | ₹1,87,530 | ₹52,000 | 4 | |
| Inefficient Reciprocating Compressor with higher kW/CFM is used | Operate comparatively efficient screw compressor already available in the plant | 15137 | ₹1,28,061 | ₹20,000 | 2 | |
| Reciprocating Compressor suction -discharge operation is not happing properly, and air is leaked through suction valve | Undergo maintenance | 7096 | ₹60,029 | ₹20,000 | 4 | |
| At compressor suction side, the temperature of air is 40°C to 42°C observed | Proposed to shift the compressor to open space and allow to suction the air at space temperature | 710 | ₹6,003 | ₹6,000 | 12 | |
| The existing Cut-off pressure is 7.5 bar. Whereas the maximum pressure requirement is 6 bars | Proposed to change the cut-off pressure from 7.5 bar to 6.5 bar | 2365 | ₹20,010 | ₹ |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional Electric Resistance heaters are used in Thermic Fluid Heaters at Composite Pressing Unit | Switch to Energy Efficient Induction Heaters | 249134 | ₹21,07,677 | ₹12,00,000 | 7 | |
| In the Calendering Unit - Heat gained by a roll is lost by adding cooling water without reclaiming it for consecutive heating roll | Cascade the flow of water from one roll to another for completely reclaiming the heat gain | 47304 | ₹4,00,192 | ₹5,00,000 | 15 | |
| Conventional Wall fans are used in the Office Spaces | Replace with Energy Efficient BLDC Wall fans | 1620 | ₹14,112 | ₹28,800 | 25 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 1250 kVA Servo Stabilizer - Losses are found to be higher than standard limits | Operate comparatively energy efficient OLTC - Voltage Controller already available with the existing Transformer which is in non-operative condition | 156375 | ₹13,22,932 | ₹1,00,000 | 1 | |
| 750 kVA Isolation Transformer - Losses are found to be higher than standard limits | Operate comparatively energy efficient OLTC - Voltage Controller already available with the existing Transformer which is in non-operative condition | 57970 | ₹4,90,424 | ₹1,00,000 | 3 | |
| Purchased Contract Demand is not properly utilized | Surrender Contract Demand | ₹2,11,500 | ₹50,000 | 3 |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Diesel fuelled Conventional Forklifts are used for material handling | Switch to Energy Efficient Battery-operated Electric - Forklifts | 25577 | ₹2,02,495 | ₹5,00,000 | 30 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 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 | ₹50,000 | 2 | |
| In CT- 2 bypass of pressurised water from the discharge line and overflow of pressurised water observed | Proposed to use corrected rated pump and Cooling tower. Avoid bypass and overflow of pressurized water. | ₹ | ₹ | |||
| CT-1 the fan is operating continuously irrespective to load | Operate fan as per the approach temperature. | 3716 | ₹31,434 | ₹15,000 | 6 | |
| 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 | ₹30,000 | 1 | |
| In existing condition, the material of the CT fan is non-FRP material | Proposed to use FRP material type fan in both cooling tower | 10841 | ₹91,711 | ₹50,000 | 7 |
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 660 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy | 792000 | ₹67,00,320 | ₹3,30,00,000 | 60 |