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-13/02

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

Auto, Electrical and General Engineering Parts

Plant Area (Sq.ft)

26,900

No. of Employees

250

Production Hours

6,720

Annual Production

41,13,000

Annual Sales

₹20,00,00,000

Assessment Summary

Total Energy Costs(per year)

₹2,94,25,000

Total Recommended Investment(one time)

₹3,53,29,400

Total Recommended Savings(per year)

₹1,83,13,108

Energy Costs Calculation
Electricity

Annual Usage

4,35,000

Unit

kWh

Unit Cost

₹9

Annual Cost

₹39,15,000

Furnace oil

Annual Usage

435402

Unit

Ltr

Unit Cost

₹52

Annual Cost

₹2,26,00,000

Diesel

Annual Usage

27,720

Unit

Ltr

Unit Cost

₹105

Annual Cost

₹29,10,000

Total Energy Costs(per year)

₹2,94,25,000

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.1,94,880₹16,64,271₹88,0001
Unloading time is high due to varying pressure demandExisting screw compressor could be retrofitted with a VFD drive and optimize power consumption according to actual pressure demand43089₹367,981₹200,0007
The existing Cut-off pressure is 6.5 bar. Whereas the maximum pressure requirement is 6 bar and same pressure is used for cleaning applicationsProposed to change the cutoff pressure from 6.5 bar to 6 bar. Run small capacity compressor to meet cleaning requirements17326₹69,908₹10,0002
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The material of the cooling tower fan is Non- FRP type material.Proposed to use FRP type material for all cooling tower fan. FRP material is light in weight and Corrosion resistance properties.3075₹26,258₹20,00010
CT Range and Approach is very low at 1.4°C and 1.0°C respectively, due to which CT effectiveness is lowImprove range and approach by reducing waterflow rate by switching off two pumps and using existing VFD of CT fan in closed loop mode with temperature sensing135629₹1,158,274₹20,0001
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Efficiency of Wood Pellet fired Melting furnace is low and Specific Energy Cost is high at Rs.5.5/kgSwitch to Electrical induction melting furnace having low specific energy cost at Rs.2.8/kg (recommended only for 2 furnaces, since the furnaces are installed recently)3013684₹5,482,520₹14,000,00031
Specific Fuel Consumption of the furnaces were found slightly high at 0.38 kg/kg of melting and Specific Energy Cost is Rs.5.5/kg, due to improper chargingOptimize the charging to the design capacity by properly sizing, pressing of scrap and sizing the ingots appropriately and reduce specific fuel consumption near to 0.35 kg/kg of melt and specific energy cost to Rs.5/kg215372₹652,500
Excess thermal energy loss from Furnace SurfacesProvide thermal insulation to furnace surfaces408270₹1,236,911₹300,0003
Excess thermal energy loss from Furnace mouth, since it is open throughout the dayClose the Furnace mouth with a suitable lid331306₹1,003,739₹60,0001
Excess thermal energy loss from ladle mouth, since it is open during transitClose the ladle mouth with a suitable lid15436₹46,765₹20,0006
Holding time is high for certain batches on an average of 10 batches / day at an excess holding time of 1 hr/batch due to scarcity in production demand, causing additional fuel consumption for holding.Optimize production schedule and operate required number of furnaces only and reduce holding time as far as possible to save fuel87345₹264,625
Holding Furnaces (1 to 15) are operated in ON/OFF control mode and full MD is consumedInstall PID controlled Thyristor Converter and reduce Maximum Demand by 25 kVA and save demand charges₹81,000₹750,000112
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Specific Energy Consumption of PDC - 3 and PDC - 14 are highReduce running idle time and increase casting rate with better labour quality to improve Specific Energy Consumption up to 0.25 kWh/Shot186150₹1,589,721
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Daily Energy Losses are high compared to standard similar rating TransformerCarry out overall maintenance and oil filtration of the Transformer24090₹205,729₹50,0003
Billed MD is low compared to minimum quota of CD allottedSurrender CD from 425 to 350 kVA and save minimum demand charges₹254340₹500003
LT - Lighting
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Lights are switched ON at PDC Floor and Melting Areas even though daylight is sufficientInstall more skylights and switch OFF 20 Nos of 100W LED industrial down lights and flood lights5000₹42,700₹15,0005
ALS - Alternate Source of Power
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Diesel fuelled Conventional Forklifts are used for material handling.Switch to Energy Efficient Battery-operated Electric - Forklifts20462₹161,996₹500,00038
HVC - Heating Ventilation & Cooling
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Conventional Wall fans are used in the Office SpacesReplace with Energy Efficient BLDC Wall fans1800₹19,372₹64,00040
Conventional Ceiling fans are used in the Office SpacesReplace with Energy Efficient BLDC Ceiling fans9234₹90,258₹182,40025
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 380 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy456000₹3,894,240₹19,000,00059