EAR/23-24/KISEM/IITI-12/01
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
Steel Billets and Ingots manufacturing
Plant Area (Sq.ft)
77,294
No. of Employees
220
Production Hours
8,760
Annual Production
5,50,00,000
Annual Sales
₹1,00,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹37,40,15,000
Total Recommended Investment(one time)
₹6,50,00,000
Total Recommended Savings(per year)
₹7,89,14,437.88
Energy Costs Calculation
Electricity
Annual Usage
5,92,00,000
Unit
kWh
Unit Cost
₹6.3
Annual Cost
₹37,37,00,000
Firewood
Annual Usage
1,12,560
Unit
kg
Unit Cost
₹2.8
Annual Cost
₹3,15,000
Total Energy Costs(per year)
₹37,40,15,000
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. | 6,173 | ₹38,765 | ₹30,000 | 10 | |
| Inefficient Reciprocating Compressor with higher kW/CFM is used | Install and operate energy efficient Permanent Magnet BLDC Screw Compressor | 27752 | ₹174,281 | ₹700,000 | 49 | |
| The existing Cut-off pressure is 10 bar. whereas the maximum pressure requirement is 7.5 bar | Proposed to change the cutoff pressure from 10 bar to 7.5 bar | 11131 | ₹69,908 | ₹10,000 | 2 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Specific Energy Consumption of the 8T Induction Furnaces at 10270 kg were found 0.745 kWh/kg of melting and Specific Energy Cost is Rs.4.67/kg, due to high stock loading | Optimize the loading of 8T furnaces to the design capacity of 8000 kg/batch and reduce specific energy consumption near to 0.549 kWh/kg and specific energy cost to Rs.3.44/kg | 54,65,449 | ₹3,43,23,022 | ₹ | ||
| Specific Energy Consumption of the 10T Induction Furnaces at 12580 kg were found 0.702 kWh/kg of melting and Specific Energy Cost is Rs.4.4/kg, due to high stock loading | Optimize the loading of 10T furnaces to the design capacity of 10000 kg/batch and reduce specific energy consumption near to 0.549 kWh/kg and specific energy cost to Rs.3.44/kg | 4254192 | ₹29,779,342 | ₹ | ||
| Old and outdated type Coil Cradle assembly is used in 8T Furnaces | Replace with latest energy efficient Coil Cradle Assembly in 8T Furnaces | 519184 | ₹3,260,475 | ₹2,500,000 | 10 | |
| Excess thermal energy loss from ladle Surfaces | Provide thermal insulation to ladle surface | 16799 | ₹105,497 | ₹50,000 | 6 | |
| Excess thermal energy loss from ladle mouth, since it is open during transit | Close the ladle mouth with a suitable lid during transit time | 472467 | ₹2,967,093 | ₹200,000 | 1 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional Water resistance starting and braking system is used in Rolling Mill - Slip Ring Induction Motor | Replace with energy efficient Rotor Control Drive with Slip Power Recovery Scheme (SPRS) | 415749 | ₹2,610,907 | ₹2,000,000 | 10 | |
| Conventional Induction Motors with low efficiency is installed for conveyors, straightening machines, cooling beds, degree tables, pumps etc. | Replace with energy efficient IE4 or above Induction Motors | 319350 | ₹3,071,586 | ₹3,810,000 | 15 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The material of the cooling tower fan is non- FRP type material. | Install FRP type CT fan. FRP material is light in weight and corrosion resistant | 53611 | ₹339,359 | ₹250,000 | 9 | |
| The approach temperature of the Cooling tower is 6.5°C | Clean CT fills, allow uniform flow of water from the output of cooling tower and maintain the approach below 5°C | 35741 | ₹226,239 | ₹150,000 | 8 | |
| CT operates throughout the day continuously without any control. | Operate CT fan as per the load with respect to approach. Control the fan speed using by VFD in closed loop. (This is applicable when approach temperature drop below 5°C) | ₹ | ₹ |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The efficiency of furnace cooling tower pump (Raw Water) is very low. | Use efficient and correct sized pump in the cooling system. | 128330 | ₹812,332 | ₹200,000 | 3 | |
| Cooling water is splashed in the idle strand also | Switch OFF the primary pump used for the idle strand | 103718 | ₹656,537 | ₹ | ||
| In Cooling gate, the water flow remains continuous even when there is no production. | Operate the secondary pump as per the water flow requirement in the system. Control the pump flow rate in using VFD in closed loop | 75686 | ₹479,095 | ₹100,000 | 3 |
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 1100 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy | 1320000 | ₹8,289,600 | ₹55,000,000 | 80 |