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)
₹1,44,18,869
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
| 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. | 1,94,880 | ₹16,64,271 | ₹88,000 | 1 | |
| Unloading time is high due to varying pressure demand | Existing screw compressor could be retrofitted with a VFD drive and optimize power consumption according to actual pressure demand | 43089 | ₹367,981 | ₹200,000 | 7 | |
| The existing Cut-off pressure is 6.5 bar. Whereas the maximum pressure requirement is 6 bar and same pressure is used for cleaning applications | Proposed to change the cutoff pressure from 6.5 bar to 6 bar. Run small capacity compressor to meet cleaning requirements | 17326 | ₹69,908 | ₹10,000 | 2 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 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 | ₹20,000 | 10 | |
| CT Range and Approach is very low at 1.4°C and 1.0°C respectively, due to which CT effectiveness is low | Improve 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 sensing | 135629 | ₹1,158,274 | ₹20,000 | 1 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency of Wood Pellet fired Melting furnace is low and Specific Energy Cost is high at Rs.5.5/kg | Switch 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 | ₹14,000,000 | 31 | |
| 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 charging | Optimize 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/kg | 215372 | ₹652,500 | ₹ | ||
| Excess thermal energy loss from Furnace Surfaces | Provide thermal insulation to furnace surfaces | 408270 | ₹1,236,911 | ₹300,000 | 3 | |
| Excess thermal energy loss from Furnace mouth, since it is open throughout the day | Close the Furnace mouth with a suitable lid | 331306 | ₹1,003,739 | ₹60,000 | 1 | |
| Excess thermal energy loss from ladle mouth, since it is open during transit | Close the ladle mouth with a suitable lid | 15436 | ₹46,765 | ₹20,000 | 6 | |
| 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 fuel | 87345 | ₹264,625 | ₹ | ||
| Holding Furnaces (1 to 15) are operated in ON/OFF control mode and full MD is consumed | Install PID controlled Thyristor Converter and reduce Maximum Demand by 25 kVA and save demand charges | ₹81,000 | ₹750,000 | 112 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Specific Energy Consumption of PDC - 3 and PDC - 14 are high | Reduce running idle time and increase casting rate with better labour quality to improve Specific Energy Consumption up to 0.25 kWh/Shot | 186150 | ₹1,589,721 | ₹ |
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 | 24090 | ₹205,729 | ₹50,000 | 3 | |
| Billed MD is low compared to minimum quota of CD allotted | Surrender CD from 425 to 350 kVA and save minimum demand charges | ₹254340 | ₹50000 | 3 |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Lights are switched ON at PDC Floor and Melting Areas even though daylight is sufficient | Install more skylights and switch OFF 20 Nos of 100W LED industrial down lights and flood lights | 5000 | ₹42,700 | ₹15,000 | 5 |
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 | 20462 | ₹161,996 | ₹500,000 | 38 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional Wall fans are used in the Office Spaces | Replace with Energy Efficient BLDC Wall fans | 1800 | ₹19,372 | ₹64,000 | 40 | |
| Conventional Ceiling fans are used in the Office Spaces | Replace with Energy Efficient BLDC Ceiling fans | 9234 | ₹90,258 | ₹182,400 | 25 |
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 380 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy | 456000 | ₹3,894,240 | ₹19,000,000 | 59 |