EAR/23-24/KISEM/IITI-08/02
The subject plant is located in district of and falls under NIC Category-24319. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Coper strips and foils
Plant Area (Sq.ft)
2,00,000
No. of Employees
300
Production Hours
8,760
Annual Production
17,60,000
Annual Sales
₹20,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹2,66,00,000
Total Recommended Investment(one time)
₹57,80,700
Total Recommended Savings(per year)
₹54,77,538
Energy Costs Calculation
Electricity
Annual Usage
33,00,000
Unit
kWh
Unit Cost
₹8
Annual Cost
₹2,63,00,000
Diesel
Annual Usage
2700
Unit
kg
Unit Cost
₹112
Annual Cost
₹3,00,000
Total Energy Costs(per year)
₹2,66,00,000
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. | 76,927 | ₹6,07,725 | ₹1,20,000 | 3 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Specific Energy Consumption of the 80kW - Upcaster unit - 1 was found to be 0.709 kWh/kg of product drawn and Specific Energy Cost is Rs.5.6/kg, due to low draw rate | Optimize the loading of furnace by slightly increasing the draw rate from 20 m/hr to 26 m/hr and reduce specific energy consumption near to 0.5 kWh/kg and specific energy cost to Rs.3.95/kg | 107575 | ₹753022 | ₹ | ||
| Energy loss as heat through un-insulated surfaces of the melting chamber of Up-caster Units - 1 and 2 | Provide thermal insulation to the melting chamber | 84684 | ₹669001 | ₹200000 | 4 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Mechanical Power Transmission Slip found to be high in FPM - 3 machine | Reduce slip by changing conventional V-belt with cogged V - belt and reduce speed of drive in the existing VFD | 6351 | ₹50174 | ₹1500 | 1 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Losses are found to be higher than standard limits | Undergo routine maintenance, oil filtration, breather replacement, overall check-up etc. | 217073 | ₹1714875 | ₹40000 | 1 |
DG - Diesel Generator
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Specific Fuel Consumption is found very high than standard limits | Undergo routine maintenance, oil and oil filter change, coolant change, air filter cleaning or changing, diesel pump and injection tuning, overall lubing, overall check-up etc. | 1447 | ₹137554 | ₹30,000 | 3 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Upcaster Unit - 1 (80kW) is operated in ON/OFF control mode | Install a Thyristor based Power Converter with suitable controller for smooth ramp power modulation and integrate with the available PID Controllers to reduce Maximum Demand by 19 kVA and save demand charges. | ₹537300 | ₹2,00,000 | 5 |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Some Down Lights are switched ON unnecessarily in the daytime even though enough daylight is available (Upcasting and Extrusion areas) | Switch OFF the unwanted lights | 9500 | ₹75050 | ₹15000 | 3 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional Ceiling fans are used | Replace with Energy Efficient BLDC Ceiling fans | 5184 | ₹44154 | ₹51200 | 14 | |
| Conventional Wall fans are used in the Office Spaces | Replace with Energy Efficient BLDC Wall fans | 900 | ₹8110 | ₹16000 | 24 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Inefficient Pump in the Cooling Tower Circuit | Replace CT Pump without affecting water flow rate, which can maintain the Range temperature of the CT | 70882 | ₹559967 | ₹200000 | 5 | |
| Multiple Pump used in Single Circuit and same well is used for hot and cold water | Provide only one pump in the CT circuit before Heat Exchanger. Bypass hot well and pump, release hot water directly to input of CT | ₹ | ₹ | |||
| Bypassing of pressurised water from pump discharge line | Avoid bypassing of water from 120kW furnace coil discharge line and use appropriate pump for the required flow. Note: Bypassing of pressurised water is done in multiple pumps. | ₹ | ₹ | |||
| The cooling Tower fan operate 24X7 irrespective to load | Operate CT fan according to approach temperature. If approach drop below 2°C, then CT fan will be switched OFF | 2595 | ₹20502 | ₹7000 | 5 | |
| In the whole circuit of cooling tower RO Water is used. Ro water is used from Cooling tower to Extrusion and bench draw machine | Use Raw Water instead of RO water in Cooling Tower. Use raw water in the cooling tower side only (since heat exchanger is available) | 20576 | ₹162550 | ₹ |
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 98 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy | 117600 | ₹929040 | ₹4900000 | 64 |