EAR/23-24/KISEM/IITGN-02/REV-01
The subject plant is located in district of 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
Final Effluent Treatment Plant
Plant Area (Sq.ft)
1,00,000
No. of Employees
200
Production Hours
7,200
Annual Production
Annual Sales
₹1,00,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹15,77,08,712
Total Recommended Investment(one time)
₹47,00,000
Total Recommended Savings(per year)
₹2,43,62,952
Energy Costs Calculation
Electricity
Annual Usage
1,77,20,080
Unit
kWh
Unit Cost
₹8.9
Annual Cost
₹15,77,08,712
Total Energy Costs(per year)
₹15,77,08,712
Observations & Recommendations
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Contract Demand (average demand last year is 2400 kVA) | Reduced the contract demand by 2700 kVA | ₹13,53,000 | ₹3,00,000 | 3 | ||
| Leading Power Factor in the plant | Switch off some capacitor will also help to reduce the Contract Demand (100 kVA) | ₹3,00,000 | ₹ |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Aeration (A1 & A2) area motor are running on 50 Hz with VFD | Reduce the frequency of aeration motor by 2 Hz | 227760 | ₹18,22,080 | ₹24,00,000 | 1 | |
| Aeration (B1 & B2) area motor are running on 50 Hz with VFD | Reduce the frequency of aeration motor by 2 Hz | 245280 | ₹19,62,240 | ₹ | ||
| Aeration (C1 & C2) area motor are running on 50 Hz with VFD | Reduce the frequency of aeration motor by 2 Hz | 341640 | ₹27,33,120 | ₹ | ||
| VFD of aeration tank (A3 & A4) running in manual mode although they have sensors | Take feedback back from dissolved oxygen sensor and give it to VFD for controlling the speed of motor | 353520 | ₹28,28,160 | ₹ | ||
| VFD of aeration tank (B3 & B4) running in manual mode although they have sensors | Take feedback back from dissolved oxygen sensor and give it to VFD for controlling the speed of motor | 1005120 | ₹80,40,960 | ₹ | ||
| VFD of aeration tank (C3) running in manual mode although they have sensors | Take feedback back from dissolved oxygen sensor and give it to VFD for controlling the speed of motor | 258480 | ₹20,67,840 | ₹ | ||
| Some Aeration Blowers are not capable to deliver the flow | Replace with highly efficient blowers (details are provided in the report) | ₹ | ₹ |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency of filter press feed pump is low (nearly 50%) | Replace with highly efficient pumps (70%) | 69,360 | ₹5,54,880 | ₹6,00,000 | 13 | |
| Feed pump motor is overrated (45kW) | When low efficient pump is replaced by highly efficient pump helps to reduce the motor rated power to 30 kW | 37,584 | ₹3,00,672 | ₹6,00,000 | 24 | |
| Bypassing the flow due to back pressure of filter press | Use VFD with Pressure transmitter in line so that VFD control the speed of motor as pressure increase | 3,00,000 | ₹24,00,000 | ₹8,00,000 | 4 |