EAR/23-24/KISEM/IITR-03
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)
4,00,000
No. of Employees
300
Production Hours
7,200
Annual Production
Annual Sales
₹30,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹7,86,16,130
Total Recommended Investment(one time)
₹6,60,000
Total Recommended Savings(per year)
₹31,09,876
Energy Costs Calculation
Electricity
Annual Usage
1,14,00,880
Unit
kWh
Unit Cost
₹6.9
Annual Cost
₹7,86,16,130
Total Energy Costs(per year)
₹7,86,16,130
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Un-necessary superheating of metal is observed due to the faster heating rate. (During the final stage of melting, the temperature of molten metal rises at a rate of 7°C per minute) | Manually adjust the power of furnace during the final stage of melting. | 71,485 | ₹5,00,398 | ₹ | ||
| Radiation loss from the furnace during idle time | Furnace cover can be used during idle time | 68,615 | ₹4,80,302 | ₹100000 | 2.5 | |
| Scrap is loaded without weighing and thus the furnace is over loaded to adjust the composition by trial and error method | Proper weighing mechanism should be incorporated to avoid the overloading of furnace and reduce the testing time. | 2,52,000 | ₹17,64,000 | ₹500000 | 3.4 | |
| Scrap is charged with overhead crane in bulk quantity and is spread over the furnace surface, and not properly filling the furnace. | Scrap should be charged properly after converting in to bundles (size should be less than 1/3rd of furnace dia) | ₹ | ₹ | |||
| Idle time observed during charging | Scrap should be charged properly after converting in to bundles (size should be less than 1/3rd of furnace dia) | ₹ | ₹ |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess water flow was observed in cooling tower | Cooling water flow can be reduced with vfd drive in pumping system | 40,702 | ₹2,84,914 | ₹50,000 | 2.1 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Mould cooling fans where in continuous operation | Proper positioning of either fan or mould can reduce the operating hours | 11,466 | ₹80,262 | ₹10,000 | 1.5 |