IIT Madras

IIT Hyderabad

IIT Bombay

IIT Indore

IIT Gandhinagar

IIT Guwahati

IIT Ropar

Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras


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


Plant Area (Sq.ft)


No. of Employees


Production Hours


Annual Production

Annual Sales


Assessment Summary

Total Energy Costs(per year)


Total Recommended Investment(one time)


Total Recommended Savings(per year)


Energy Costs Calculation

Annual Usage




Unit Cost


Annual Cost


Total Energy Costs(per year)


Observations & Recommendations
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
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 timeFurnace cover can be used during idle time68,615₹4,80,302₹1000002.5
Scrap is loaded without weighing and thus the furnace is over loaded to adjust the composition by trial and error methodProper weighing mechanism should be incorporated to avoid the overloading of furnace and reduce the testing time.2,52,000₹17,64,000₹5000003.4
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 chargingScrap should be charged properly after converting in to bundles (size should be less than 1/3rd of furnace dia)
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Excess water flow was observed in cooling towerCooling water flow can be reduced with vfd drive in pumping system40,702₹2,84,914₹50,0002.1
FN - Fans
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Mould cooling fans where in continuous operationProper positioning of either fan or mould can reduce the operating hours11,466₹80,262₹10,0001.5