EAR/23-24/KISEM/IITR-02
The subject plant is located in district of and falls under NIC Category-24319. This assessment was carried out by the IEAC Center, IIT Ropar, during the course of the year 2023.
General Info
Principal Product
Casting
Plant Area (Sq.ft)
4,00,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹30,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹14,85,99,941
Total Recommended Investment(one time)
₹3,91,000
Total Recommended Savings(per year)
₹41,58,104
Energy Costs Calculation
Electricity
Annual Usage
2,13,54,198
Unit
kWh
Unit Cost
₹6.95
Annual Cost
₹14,85,99,941
Total Energy Costs(per year)
₹14,85,99,941
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Un-necessary superheating of metal is observed due to the faster heating rate. (During the final stage of melting, the temperature of molten metal rises at a rate of 7°C per minute) | Manually adjust the power of furnace during the final stage of melting. | 3,55,395 | ₹24,87,768 | ₹1,00,000 | 0.5 | |
| Scrap is loaded without weighing and thus the furnace is over loaded to adjust the composition by trial and error method | Proper weighing mechanism should be incorporated to avoid the overloading of furnace and reduce the testing time. | ₹ | ₹ | |||
| Radiation loss from the furnace during idle time | Furnace cover can be used during idle time | 58,342 | ₹408,394 | ₹100000 | 2.9 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Screw compressor unloading time is high | The screw compressor can be operated with VFD drive and reciprocating compressors can keep as standby. | 51,230 | ₹358,607 | ₹100,000 | 3.3 | |
| Overall air leakages are high | Arrest air leakages regularly in the compressed air lines | 30,012 | ₹210,086 | ₹10,000 | 0.6 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overflow of water in the cooling tower is observed | VFD technology can be used to regulate the water flow in pump with respect to the requirement | 45,687 | ₹3,19,811 | ₹50,000 | 1.9 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Mould cooling fans where operated 24 hrs | Proper positioning of either fan or mould can reduce the operating hours | 25,200 | ₹176,400 | ₹10000 | 0.7 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Three faulty and three derated capacitors found | Replace the faulty capacitors | 28,148 | ₹1,97,038 | ₹21000 | 1.3 |