KMB-IIT-BOM-190323
The subject plant is located in district of and falls under NIC Category-24319. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2023.
General Info
Principal Product
Continuous Casting & Re-rolling mills
Plant Area (Sq.ft)
2,00,000
No. of Employees
400
Production Hours
7,200
Annual Production
Annual Sales
₹1,00,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹49,55,00,000
Total Recommended Investment(one time)
₹44,00,000
Total Recommended Savings(per year)
₹5,89,28,663
Energy Costs Calculation
Electricity
Annual Usage
5,51,30,000
Unit
kWh
Unit Cost
₹9
Annual Cost
₹49,55,00,000
Total Energy Costs(per year)
₹49,55,00,000
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Some LT side capacitor banks are derated | The capacitors which are not working and derated should be replaced and the remaining should be maintained periodically | ₹ | ₹ | |||
| Reactive Power is both leading and lagging in supply side of plant | Go for HT Fixed Capacitors and LT APFC arrangement. Even separate 3 breakers can be provided for HT Capacitor banks (2 * 1200 kVAR + 600 kVAR.) | 5,07,619 | ₹45,58,415 | ₹10,00,000 | 2.6 | |
| Supply side current harmonics are high | Fifth Harmonics have the major role. Harmonic filter should be installed for suppressing 5th harmonic current. | ₹ | ₹ |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| No segregation and weighing of scraps. Also too long charging time even though shredder is used | Apart from shredder machine, Hydraulic presser can be used for bundling the scraps | 43,80,000 | ₹3,93,32,400 | ₹10,00,000 | 0.3 | |
| The ladle after pouring takes 32 – 35 mins for complete casting process and the ladle mouth temperature is above 900 deg C | Radiation losses after Pouring can be reduced by closing the ladle with thermal insulation lids on top of Ladle mouth. | 3,03,985 | ₹27,29,783 | ₹1,00,000 | 0.4 | |
| The effectiveness of Furnace 1 and 3 heat exchangers is not good | VFD should be installed in pump to optimise the flow for best effectiveness | ₹ | ₹ |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Both the mills were running almost full time even if there is no real need for the same | The line from CCM to mills can be doubled and used for both mills to increase productivity. Both nozzles of Tundish should be operated simultaneously by increasing the ladle discharge | 9,63,600 | ₹86,53,128 | ₹5,00,000 | 0.7 | |
| No automation in the mills and frequent breakdown also | Automate the mills | ₹10,00,000 | ₹8,00,000 | 9.6 | ||
| The conveyor slope is too high where many time break down occurs | Use hydraulic lift and rearrange the system so that break down can be reduced. | ₹ | ₹ |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Fume collector fan is running full time | Closed Loop VFD system should be installed. Where blower is common, individual dampers can be provided and operated in cooperation with the Sensing mechanism | 2,95,650 | ₹26,54,937 | ₹10,00,000 | 4.5 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Cooling tower 3 (common) is used to circulate the water and Both return from furnace and heat exchanger is jointly going to the cooling towers | Separate the inlets of cooling towers and use cooling tower 3 only for the DM water heat exchangers | ₹ | ₹ |