KMB-IIT-BOM-230825-16
The subject plant is located in Aurangabad district of Maharashtra and falls under NIC Category-29301. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2023.
General Info
Principal Product
Auto mobile parts
Plant Area (Sq.ft)
1,000
No. of Employees
200
Production Hours
7,200
Annual Production
Annual Sales
₹
Assessment Summary
Total Energy Costs(per year)
₹36,83,152
Total Recommended Investment(one time)
₹15,70,000
Total Recommended Savings(per year)
₹36,83,153
Energy Costs Calculation
Electricity
Annual Usage
3,54,906
Unit
kWH
Unit Cost
₹9.45
Annual Cost
₹36,83,152
Total Energy Costs(per year)
₹36,83,152
Observations & Recommendations
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Last year, In October and November month contract demand is exceeded. due to that penalty has been charged. | ₹ | ₹ |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Many capacitors are not working and Most of the time reactive power is negative. | Change the APFC into detuned, SCR based system and Add small capacitor for fine tuning | 21,389 | ₹2,02,126 | ₹2,00,000 | 11.9 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Three Furnaces are operating in ON/OFF control mode and consuming maximum demand. Only 1 furnace has SCR out of four remaining furnaces has only ON/OFF contactor, based temperature sensing by RTD. Power and demand consumption pattern of furnaces with SCR respectively | Install PID controlled thyristor converter and reduce maximum demand | ₹3,29,290 | ₹3,00,000 | 11 | ||
| Around 17 h per day the furnace mouth is open which can be closed to reduce radiation losses | Cover the furnace mouth with automated lid so that radiation loss can be reduced. | 79,948 | ₹7,55,509 | ₹2,00,000 | 3 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 28 major leakage points identified | Arrest all air leakages | 1,03,243 | ₹9,75,646 | ₹50,000 | 1 | |
| Mixing of high pressure and low pressure compressed air usages | Compressed air required to PDC plant is 4.5/6.5 bar and for product cleaning is 3 bar. separate the whole compressor | 87,350 | ₹8,25,458 | ₹20,000 | 0.3 | |
| All three compressor are without VFD and unloading hours of two compressors are high | Install VFD to both compressors wich are 133 & 134 CFM after seperating the compressor line for PDC machine. | 42,450 | ₹4,01,153 | ₹3,00,000 | 9 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Hot water and cold water is getting mixed in sump | Install VFD for the pump so that the flow/pressure should be maintained. | 20,526 | ₹1,93,971 | ₹5,00,000 | 31 | |
| The cooling tower is not maintained properly (cooling water contains too much algae). | Maintain the cooling tower properly and should be cleaned regularly | ₹ | ₹ |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Solar panel are not cleaned properly | Cleaning of solar panel should be done regularly. Install water drainer clip | ₹ | ₹ |