KMB-IIT-BOM-070423
The subject plant is located in district of and falls under NIC Category-24319. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2023.
General Info
Principal Product
Foundry
Plant Area (Sq.ft)
2,00,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹15,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹4,52,00,000
Total Recommended Investment(one time)
₹13,00,000
Total Recommended Savings(per year)
₹77,10,670
Energy Costs Calculation
Electricity
Annual Usage
44,36,000
Unit
kWh
Unit Cost
₹10.2
Annual Cost
₹4,52,00,000
Total Energy Costs(per year)
₹4,52,00,000
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Plant Reactive Power is both leading as well as lagging and many capacitors in capacitor bank were derated | APFC mechanism should be rechecked and corrected. Similarly all the derated capacitors should be replaced with 3 phase sensing. | 5,198 | ₹53,015 | ₹50,000 | 11.3 | |
| Supply side Current Harmonics are high around 18 % where std is 8% | Fifth Harmonics have the major role. Harmonics filter can be installed | ₹ | ₹ |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ladle wall Temp is above 260 deg C and nozzle wall temperature is above 350 deg C | Use ceramic fiber materials for lining the Laddle. | 9,918 | ₹1,01,164 | ₹20,000 | 2.4 | |
| Furnace 1 Wall temperature is too high | Use ceramic fiber materials for lining the furnace. | 3,603 | ₹36,751 | ₹20,000 | 6.5 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Leakage in compressor is too high | Arrest air leakages periodically | 1,29,600 | ₹13,21,920 | ₹10,000 | 0.1 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Sand mixer machine load is varying. | VFD is recommended for the whole system | 47,629 | ₹4,85,820 | ₹2,00,000 | 4.9 | |
| Moulding machine is Semi automatic and most of the time metal is waiting for Mould. | Fully automatic moulding machine with mold handling system is recommended. | 5,60,000 | ₹57,12,000 | ₹10,00,000 | 2.1 |