KMB-IIT-GN-16.11.22-01
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 2022.
General Info
Principal Product
Common Effluent Treatment
Plant Area (Sq.ft)
20,000
No. of Employees
250
Production Hours
8,400
Annual Production
5,21,10,400
Annual Sales
₹95,81,20,000
Assessment Summary
Total Energy Costs(per year)
₹32,07,27,746
Total Recommended Investment(one time)
₹30,70,365
Total Recommended Savings(per year)
₹3,11,23,815
Energy Costs Calculation
Electricity
Annual Usage
1,18,37,400
Unit
kWh
Unit Cost
₹9
Annual Cost
₹10,67,20,746
Coal
Annual Usage
2,14,00,700
Unit
kg
Unit Cost
₹10
Annual Cost
₹21,40,07,000
Total Energy Costs(per year)
₹32,07,27,746
Observations & Recommendations
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Dissolved Oxygen level in aeration unit is greater than the standard decided by GPCB | Stop the 5-aerator motor and its blower keeping all the parameter as per GPCB norm (for saving calculation we only consider that blowers will remain stop for 18 hours/day) | 10,73,023 | ₹96,57,207 | ₹ | 0 | |
| Excess Air in Spray Dryer 3 | Optimize the flow by taking input to Flue gas Analyzer. Power Saving in FD fan 1 & 2 by optimizing the flow of air (already connected with VFD) | 25,920 | ₹2,33,280 | ₹0 | 0 | |
| Scrubber Water pump running on under load (25%) for Spray Dryer 1 (15 kW motor) | Check the nozzle opening and do cleaning after that if it is taking less power, it is recommended to use VFD or to go with delta to star connection to reduce the power consumption (Rated kW:15 kW motor and Actual kW:5.5 kW ) | 0 | ₹0 | ₹11000 | ||
| Excess air at Spray Dryer-1 | Power Saving in FD fan by optimizing the flow of air (Use VFD), use VFD at 45 Hz and optimize it (Motor+VFD) (Motor Rated P=75kW, Actual power=51.6kW) | 1,20,960 | ₹10,88,640 | ₹500000 | 6 | |
| Excess air at Spray Dryer-1 | Power Saving in SFD fan by optimizing the flow of air (Use VFD) (Motor Rated P=18.5kW, Actual power=11 kW | 34,560 | ₹3,11,040 | ₹1,50,000 | 6 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Surface Temperature at some points are higher than allowable temperature in spray dryer 1 | Proper Insulation Required | 87,120 | ₹8,71,200 | ₹2,50,000 | 4 | |
| Surface Temperature at some points are higher than allowable temperature in spray dryer 3 | Proper Insulation Required | 7,92,000 | ₹79,20,000 | ₹7,00,000 | 1 | |
| Excess air inside the Combustion chamber -Spray Dryer-1 | Use Oxygen Analyzer and give its feedback to control Forced draft fan speed by using VFD | 7,92,000 | ₹79,20,000 | ₹5,00,000 | 1 | |
| Excess air inside the Combustion chamber -Spray Dryer-3 | Use Oxygen Analyzer and give its feedback to control Forced draft fan speed by using VFD | 2,37,600 | ₹2376000 | ₹500000 | 3 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Some of the aerator capacitors are derated (Floating Aerator 3, Aerator motor 17,18,19 and aerator blower 16,17,18,19 | Need to change the derated capacitor to improve PF for specific motor and decrease the load current | ₹ | ₹32,000 | |||
| Collection tank pump all seven pumps’ capacitors are derated | Need to change the derated capacitor to improve PF for specific motor and decrease the load current | ₹ | ₹14,000 | |||
| Fixed capacitor and APFC 2500 kVAr transformer ,6 capacitors are derated | Need to change the derated capacitor to improve PF | ₹ | ₹33,000 | |||
| APFC, 2500 kVAr transformer ,3 capacitors are derated | Need to change the derated capacitor to improve PF | ₹ | ₹14,000 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Contract Demand | Case 1: Reduced Contract Demand to 2000 kW from 2500 kW. Since Oct-21 the average demand is 1750kW but as per norms billing demand is 2125 kW at 2500 kW | 1500 | ₹5,77,500 | ₹2,67,365 | 6 | |
| TOU load is 35% | Time of Usage (Shifting the peak time load to night) (Final pumping station pumps and borewell and Raw water pump) for 4 hours (Total Power cons. 90.25kW) | 129960 | ₹1,29,960 | ₹ | ||
| TOU load is 35% | Night Concession (30 paise per unit) | 129960 | ₹38,988 | ₹ |