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)
₹2,49,89,262
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
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are found to be high at different points of the circuit | Arrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit and fittings. | 1,03,086 | ₹9,89,630 | ₹5,00,000 | 6 | |
| Screw compressors – 1 & 2 - unloading time is high due to varying pressure demand | Existing screw compressor could be retrofitted with a VFD drive and optimize power consumption according to actual pressure demand | ₹ | ₹ |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Cooling Tower 1 – Cold and Hot wells mixed together reducing range and performance of system, demanding more water flow rate | Separate cold well and hot well and switch off two outlet water pumps to improve cooling tower range through optimization of water circulation rate | 201882 | ₹18,49,238 | ₹5,00,000 | 3 | |
| Cooling Tower 2 – Cold and Hot wells mixed together reducing range and performance of system, demanding more water flow rate | Separate cold well and hot well and speed control of water pumps using VFD to improve cooling tower range through optimization of water circulation rate | 69075 | ₹6,32,449 | ₹5,00,000 | 5 | |
| Cooling Tower 3 – Cold and Hot wells mixed together reducing range and performance of system, demanding more water flow rate | Separate cold well and hot well and speed control of water pumps using VFD to improve cooling tower range through optimization of water circulation rate | 57516 | ₹5,26,842 | ₹5,00,000 | 6 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Mechanical power transmission slip found to be slightly high in certain blocks of the wire drawing machines in the plant | Reduce 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 VFD | 9134 | ₹87,683 | ₹1,20,000 | 17 |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Majority of lighting used in the plant area are inefficient fluorescent tube lights | Retrofitting 69 Nos of Conventional Tubelights (FTL) with LED Tubelights or Batterns | 318 | ₹3,053 | ₹2,400 | 10 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ceiling fans used in the plant area and office are inefficient conventional type | Replacing 46 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC fans | 7585 | ₹72,816 | ₹1,92,000 | 32 | |
| Some Split air conditioners are aged and inefficient | Replacing 2 Nos of 1.5 TR Conventional Split AC with BEE 5 Star Label Inverter split type | 3684 | ₹35,366 | ₹1,20,000 | 41 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess air drawn by Muffle furnace – 1, 2 and 3 at annealing process | Reduce speed of ID Fan motor through existing VFD to optimize excess air demand and save CNG fuel as well as Electricity. | 7951 | ₹699775 | ₹0 | 0 | |
| Excess heat lost through furnace walls, ceiling, and flue gas pipe surfaces of Muffle furnaces -1, 2 and 3 | Insulate 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 | ₹1,50,00,000 | 9 | |
| 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 | ₹3,00,000 | 22 |