EAR/23-24/KISEM/IITGN-01/Rev-01(25/07/2023)
The subject plant is located in Ahmedabad district of Gujarat and falls under NIC Category-37003. This assessment was carried out by the IEAC Center, IIT Gandhinagar, during the course of the year 2023.
General Info
Principal Product
Common Effluent Treatment Plant
Plant Area (Sq.ft)
30,000
No. of Employees
45
Production Hours
7,200
Annual Production
Annual Sales
₹1,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹2,04,43,743
Total Recommended Investment(one time)
₹11,00,000
Total Recommended Savings(per year)
₹24,04,725
Energy Costs Calculation
Electricity
Annual Usage
20,81,870
Unit
kWh
Unit Cost
₹9.81
Annual Cost
₹2,04,43,743
Total Energy Costs(per year)
₹2,04,43,743
Observations & Recommendations
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Some of the sludge transfer pumps(2& 6) running under load | Clean NRV and impeller along with casing and also check impeller diameter | ₹ | ₹ | |||
| Some of the sludge transfer pumps(2& 6) running under load | Use VFD for both pumps with pressure transmitter/transducer | 68,031 | ₹6,12,281 | ₹2,00,000 | 4 | |
| Bypassing the flow due to increase in the inlet pressure of Filter press (calculation excludes for pump 2 & 6., Filter press 1 & 4) | Use VFD with Filter press pump and take input from Pressure transducer for controlling motor speed. (Rated power=30 kW) and if any spare impeller is available replace with pump 4 and run on VFD | 1,02,047 | ₹9,18,421 | ₹3,00,000 | 4 | |
| Lime Transfer pump 7A & 7B are running under load | Check the impeller size, any choking near NRV and impeller casing. After cleaning ,check the flow ,pressure and current, if no choking found replace with smaller pump | ₹ | ₹ | |||
| Recycling pumps of 14 A & B are running under load and on Efficiency of 66% while the design efficiency of pump is 70%.(Running time for all the pumps are considered as 24 hrs of operation for 360 day ) | Use VFD with motor and pump so that efficiency will increase | 7,603 | ₹68,429 | ₹1,50,000 | 24 | |
| Recycling pumps 0f 15 A & B are running under load and on Efficiency of 54% while the design efficiency of pump is 70%.(Running time for all the pumps are considered as 24 hrs of operation for 360 day ) | Use VFD with motor and pump so that efficiency will increase | 39,830 | ₹3,58,474 | ₹1,50,000 | 5 | |
| All recycling pumps of 16 are running under load and on Efficiency of 55-60% while the design efficiency of pump is 70%.(Running time for all the pumps are considered as 24 hrs of operation for 360 day ) | Use VFD with motor and pump so that efficiency will increase | 32,400 | ₹2,91,600 | ₹1,50,000 | 6 | |
| All recycling pumps 0f 16 are running under load and on Efficiency of 55-60% while the design efficiency of pump is 70%.(Running time for all the pumps are considered as 24 hrs of operation for 360 day ) | Use VFD with motor and pump so that efficiency will increase | 17,280 | ₹1,55,520 | ₹1,50,000 | 12 | |
| Transfer pump running under load (Rated power=37 kW and Actual Power= 27 kW) | Replace the motor with 30 kW | ₹ | ₹ |