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

EAR/22-23/KISEM/IITI-02/01

The subject plant is located in district of and falls under NIC Category-25. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2022.

General Info

Principal Product

G.I welded mesh, MS welded mesh, brass stitching wire, etc.

Plant Area (Sq.ft)

2,00,000

No. of Employees

700

Production Hours

7,224

Annual Production

9,00,00,000

Annual Sales

₹5,00,00,000

Assessment Summary

Total Energy Costs(per year)

₹22,66,50,000

Total Recommended Investment(one time)

₹24,34,400

Total Recommended Savings(per year)

₹2,52,59,757

Energy Costs Calculation
Electricity

Annual Usage

1,16,45,000

Unit

kWh

Unit Cost

₹10

Annual Cost

₹11,64,50,000

CNG

Annual Usage

512890

Unit

kg

Unit Cost

₹214.87

Annual Cost

₹11,02,00,000

Total Energy Costs(per year)

₹22,66,50,000

Observations & Recommendations
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Overall air leakages are found to be high at different points of the circuitArrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit and fittings.1,03,086₹9,89,630₹5,00,0006
Screw compressors – 1 & 2 - unloading time is high due to varying pressure demandExisting screw compressor could be retrofitted with a VFD drive and optimize power consumption according to actual pressure demand
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Cooling Tower 1 – Cold and Hot wells mixed together reducing range and performance of system, demanding more water flow rateSeparate cold well and hot well and switch off two outlet water pumps to improve cooling tower range through optimization of water circulation rate201882₹18,49,238₹5,00,0003
Cooling Tower 2 – Cold and Hot wells mixed together reducing range and performance of system, demanding more water flow rateSeparate cold well and hot well and speed control of water pumps using VFD to improve cooling tower range through optimization of water circulation rate69075₹6,32,449₹5,00,0005
Cooling Tower 3 – Cold and Hot wells mixed together reducing range and performance of system, demanding more water flow rateSeparate cold well and hot well and speed control of water pumps using VFD to improve cooling tower range through optimization of water circulation rate57516₹5,26,842₹5,00,0006
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Mechanical power transmission slip found to be slightly high in certain blocks of the wire drawing machines in the plantReduce slippage in belt and pulley system of certain motor driven blocks through replacement of conventional V-belts with Cogged V-belts and reduce motor speed using existing VFD9134₹87,683₹1,20,00017
LT - Lighting
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Majority of lighting used in the plant area are inefficient fluorescent tube lightsRetrofitting 69 Nos of Conventional Tubelights (FTL) with LED Tubelights or Batterns318₹3,053₹2,40010
HVC - Heating Ventilation & Cooling
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Ceiling fans used in the plant area and office are inefficient conventional typeReplacing 46 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC fans7585₹72,816₹1,92,00032
Some Split air conditioners are aged and inefficientReplacing 2 Nos of 1.5 TR Conventional Split AC with BEE 5 Star Label Inverter split type3684₹35,366₹1,20,00041
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Excess air drawn by Muffle furnace – 1, 2 and 3 at annealing processReduce speed of ID Fan motor through existing VFD to optimize excess air demand and save CNG fuel as well as Electricity.7951₹699775₹00
Excess heat lost through furnace walls, ceiling, and flue gas pipe surfaces of Muffle furnaces -1, 2 and 3Insulate the furnace walls, ceiling and flue gas pipe external surface using glass mineral wool insulation and thereby reduce heat lost from surface and save CNG fuel.229530₹2,01,98,643₹1,50,00,0009
Heat lost through flue gas from muffle furnaces and zinc bath furnaces.After optimizing excess air demand, the heat lost in flue gas is recovered using a suitable recuperator and can be used to preheat feed water of hot water generator to reduce LPG fuel consumed.2161₹1,64,262₹3,00,00022