EAR/23-24/KISEM/IITI-09/02
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 2023.
General Info
Principal Product
Copper and Copper alloys components
Plant Area (Sq.ft)
5,300
No. of Employees
64
Production Hours
8,760
Annual Production
4,57,000
Annual Sales
₹2,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹40,63,737
Total Recommended Investment(one time)
₹43,46,200
Total Recommended Savings(per year)
₹14,67,329
Energy Costs Calculation
Electricity
Annual Usage
4,18,444
Unit
kWh
Unit Cost
₹9.7
Annual Cost
₹40,30,872
Diesel
Annual Usage
301
Unit
kg
Unit Cost
₹110
Annual Cost
₹32,865
Total Energy Costs(per year)
₹40,63,737
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. | 9,791 | ₹94,968 | ₹18,000 | 3 | |
| 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 | 24570 | ₹238329 | ₹200,000 | 11 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Specific Energy Consumption of the Bright Annealing Furnaces were found to be high at 0.136 kWh/kg of the product and Specific Energy Cost is Rs.1.31/kg, due to low loading | Optimize the loading of furnace by increasing the loading per batch and reduce specific energy consumption near to 0.088 kWh/kg and specific energy cost to Rs.0.85/kg | 64512 | ₹625766 | ₹100000 | 2 |
DG - Diesel Generator
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Specific Fuel Consumption is found very high than standard limits | Undergo routine maintenance, oil and oil filter change, coolant change, air filter cleaning or changing, diesel pump and injection tuning, overall lubing, overall checkup etc. | 108 | ₹56848 | ₹30,000 | 7 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Bright Annealing Furnaces are operated in ON/OFF control mode | Install a Thyristor based Power Converter with suitable controller for smooth ramp power modulation and integrate with the available PID Controllers and reduce Maximum Demand by 29 kVA and save demand charges | ₹153310 | ₹50,000 | 4 |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Some Down Lights are switched ON unnecessarily in the daytime even though enough daylight is available (Bright annealing furnace area) | Switch OFF the unwanted lights | 3000 | ₹23700 | ₹15,000 | 8 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional Ceiling fans are used | Replace with Energy Efficient BLDC Ceiling fans | 1944 | ₹16558 | ₹19,200 | 14 | |
| Conventional Wall fans are used in the Office Spaces | Replace with Energy Efficient BLDC Wall fans | 3600 | ₹32440 | ₹64,000 | 24 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Inefficient Pump in the Cooling Tower Circuit | Replace CT Pump without affecting water flow rate, which will maintain the Range temperature of the CT | 23407 | ₹225410 | ₹100,000 | 6 | |
| Multiple Pump used in Single Circuit and same well is used for hot and cold water | Provide only one pump in the CT circuit before Heat Exchanger. By pass hot well and release hot water directly to inlet of CT | ₹ | ₹ | |||
| Inefficient Pump in the Cooling Circuit | Provide proper size of pump in the circuit | ₹ | ₹ |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Electricity is consumed from utility grid alone and there is no source of renewable energy in the plant | Install a Rooftop 98 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy | 90000 | ₹711000 | ₹3750000 | 64 |