KMB-IIT-MAD-18.04.22-01
The subject plant is located in Tiruppur district of Tamil Nadu and falls under NIC Category-37003. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2022.
General Info
Principal Product
Dyeing
Plant Area (Sq.ft)
30,000
No. of Employees
70
Production Hours
7,200
Annual Production
6,00,000
Annual Sales
₹20,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹13,29,55,760
Total Recommended Investment(one time)
₹14,35,000
Total Recommended Savings(per year)
₹20,07,553
Energy Costs Calculation
Electricity
Annual Usage
1,18,78,368
Unit
kWh
Unit Cost
₹7.5
Annual Cost
₹8,90,87,760
Coal
Annual Usage
20,28,000
Unit
kgs
Unit Cost
₹11
Annual Cost
₹2,23,08,000
Wood
Annual Usage
38,50,000
Unit
kgs
Unit Cost
₹5.6
Annual Cost
₹2,15,60,000
Total Energy Costs(per year)
₹13,29,55,760
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Good Combustion | Optimize the Air-Fuel Ratio | 2,02,170 | ₹15,16,275 | ₹1,75,000 | 1.4 | |
| Fuel Weighing System Not Available | Install Fuel Weighing System | ₹ | ₹ | |||
| Poor Condensate Removal | Test and Repair Steam Traps on a Continuing Basis | 10,531 | ₹78,983 | ₹25,000 | 3.8 | |
| Poor Thermal Insulation | Locate and Repair Defective Insulation on All Heating Plant Equipment and Piping | 54,650 | ₹4,09,875 | ₹1,00,000 | 2.9 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| TR 1 - High Current Harmonics | Install Harmonic Filters | 38,115 | ₹2,85,863 | ₹1,75,000 | 7.3 | |
| TR 2 - Current harmonics is high | Install Harmonic Filters | 38,115 | ₹2,85,863 | ₹1,75,000 | 7.3 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Panel 1 - Low Power Factor | Replace the de-rated capacitors with new capacitors | 28,000 | ₹2,10,000 | ₹90,000 | 5.1 | |
| Panel 2 - Low Power Factor | Replace the de-rated capacitors with new capacitors | 29,000 | ₹2,17,500 | ₹92,000 | 5.1 | |
| Panel 3 - Low Power Factor | Replace the de-rated capacitors with new capacitors | 30951 | ₹232133 | ₹93000 | 4.8 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 34,000 | ₹2,55,000 | ₹35,000 | 1.6 | |
| Capacity Underutilization | The compressor should be effectively operated in a manner that it should have minimum number of unloading cycles | 20,000 | ₹1,50,000 | ₹75,000 | 6.0 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess Power Consumption | Use energy-efficient motors | 12,960 | ₹97,200 | ₹75,000 | 9.3 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Flow Detoriated | Operate Standby pumps having better flow and efficiency | 36,000 | ₹2,70,000 | ₹0 | 0.0 | |
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 43,200 | ₹3,24,000 | ₹50,000 | 1.9 | |
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 23,750 | ₹1,78,125 | ₹50,000 | 3.4 | |
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 23,765 | ₹1,78,238 | ₹50,000 | 3.4 | |
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 21,985 | ₹1,64,888 | ₹50,000 | 3.6 | |
| Manual Throttling of Valves | Operate pumps with VFD to avoid manual valve throttling | 23,125 | ₹1,73,438 | ₹50,000 | 3.5 | |
| Poor Maintenance | Establish Preventive Maintenance Schedule for effective pump operation | 51,840 | ₹3,88,800 | ₹75,000 | 2.3 |