EAR/23-24/KISEM/IITR-05
The subject plant is located in Ludhiana district of Punjab 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)
3,00,000
No. of Employees
150
Production Hours
7,200
Annual Production
Annual Sales
₹30,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,44,55,770
Total Recommended Investment(one time)
₹2,78,88,077
Total Recommended Savings(per year)
₹24,33,121
Energy Costs Calculation
Electricity
Annual Usage
20,18,895
Unit
kWh
Unit Cost
₹7.2
Annual Cost
₹1,44,55,770
Total Energy Costs(per year)
₹1,44,55,770
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Un-necessary super-heating of metal is observed in the furnace (127°C difference is observed between tapping temperature to first box pouring temperature) | It is recommended to provide proper insulation of the ladle including its cover and preheat ladle in each cycle to the required temperature | 76,936 | ₹5,38,553 | ₹2,00,000 | 4.5 | |
| Ladle is preheated with molten metal once in day | Ladle can be heated by energy efficient LPG pre-heater | 64,839 | ₹4,53,872 | ₹500000 | 13.2 | |
| Idle time is observed after the molten metal is ready for pouring | Mould should be ready prior to molten material. Reduce the power to half after reaching maximum temperature | 51,878 | ₹3,63,145 | ₹1,00,000 | 3.3 | |
| 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. Also, adjust the power input to the furnace to avoid superheating during the idle operation in between charging | ₹ | ₹ | |||
| Radiation loss through furnace opening is very high | It is recommended to provide a door to the furnace and it should be closed during idle operation of furnace and in between charging to minimise the radiation heat loss. | 33,066 | ₹2,31,462 | ₹25,000 | 1.3 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are high | Arrest all air leakages regularly in the compressed air lines | 33,066 | ₹2,31,462 | ₹25,000 | 1.3 | |
| Pressure setting is higher (Loading pressure 7 bar and Unloading pressure 8 bar) | It is recommended to reduce 1 bar pressure. (Unloading pressure 7 bar) | 3,059 | ₹21,415 | ₹5,000 | 2.8 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| One excess pump is in operation to pump soft water to the cooling tower. | Modify the pipe line, so that hot water can directly go to the cooling tower and remove the excess pump in operation | 19,434 | ₹1,36,039 | ₹10,000 | 0.9 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Power factor maintained in the utility transformer is observed as very low (0.84) | Replace the faulty capacitors from the APFC panel install additional 55 kVAR to the APFC panel | 82,703 | ₹5,78,925 | ₹25,000 | 0.5 |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Source of Electricity is only utility grid. There is no any renewable energy source is available | Install roof-top 538 kWp grid tied Solar PV power plant at the free space available on the top of the plant | 6,46,154 | ₹45,23,077 | ₹2,69,23,077 | 71.4 |