EAR/23-24/KISEM/IITR-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 Ropar, during the course of the year 2023.
General Info
Principal Product
Casting
Plant Area (Sq.ft)
1,00,000
No. of Employees
150
Production Hours
7,200
Annual Production
Annual Sales
₹5,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,62,35,600
Total Recommended Investment(one time)
₹7,90,000
Total Recommended Savings(per year)
₹33,26,057
Energy Costs Calculation
Electricity
Annual Usage
20,78,740
Unit
kWh
Unit Cost
₹7.63
Annual Cost
₹1,58,67,020
LPG
Annual Usage
4047
Unit
Kg
Unit Cost
₹91
Annual Cost
₹3,68,580
Total Energy Costs(per year)
₹1,62,35,600
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Idle time is observed after the molten metal is ready for pouring | Mould should be ready prior to molten material. Furnace lid can be used during idle time of operation to reduce radiation heat loss. Power settings should be adjusted during this period. | 1,73,000 | ₹13,14,800 | ₹1,00,000 | 0.9 | |
| Idle time is observed in between charging | The raw material must be weighed and arranged on melt floor near to furnace before starting the melting and the maximum size of single piece of metal/scrap should not be more than 1/3rd. of diameter of furnace crucible. | ₹ | ₹ | |||
| Furnace is charged beyond the coil level. 300 kg capacity furnace is charged with more than 350 kg and 500 kg capacity furnace is charged with more than 600 kg | Charge the furnace to its capacity only | ₹ | ₹ | |||
| Un-necessary superheating of metal is observed in both the furnaces | Temperature measurement should be done frequently | 90,215 | ₹6,85,631 | ₹25,000 | 0.4 | |
| Ladle is pre-heated with molten metal once in day | Ladle can be heated by energy efficient LPG pre-heater | 28,833 | ₹2,19,133 | ₹5,00,000 | 27.4 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are high | Arrest air leakages regularly in the compressed air lines | 81,052 | ₹6,15,999 | ₹30,000 | 0.6 | |
| Screw compressors unloading time is high | Compressor 1 and Compressor 3 can be operated with vfd drive. Compressor 2 can be kept as standby | 27,437 | ₹2,08,517 | ₹1,00,000 | 5.8 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High surface temperature on the chemical reservoir | Provide proper thermal insulation to the chemical reservoir | 4,742 | ₹36,038 | ₹5000 | 1.7 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Contract demand with PSPCL in over utilised | Increase contract demand to 1000 kVA | ₹1,54,967 | ₹10000 | 0.8 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Two faulty and One disconnected capacitors found | Replace the faulty capacitors | 11,970 | ₹90,972 | ₹20000 | 2.6 |