EAR/23-24/KISEM/IITI-06/01
The subject plant is located in Pithampur district of Madhya Pradesh and falls under NIC Category-24202. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Aluminium Die Cast and Extrusion Products Manufacturer
Plant Area (Sq.ft)
43,000
No. of Employees
40
Production Hours
7,200
Annual Production
15,26,000
Annual Sales
₹30,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹2,70,16,000
Total Recommended Investment(one time)
₹1,59,77,400
Total Recommended Savings(per year)
₹79,44,371
Energy Costs Calculation
Electricity
Annual Usage
9,29,000
Unit
kWh
Unit Cost
₹9.03
Annual Cost
₹83,97,000
Furnace Oil
Annual Usage
237530
Unit
Kg
Unit Cost
₹45
Annual Cost
₹10698000
LPG
Annual Usage
102030
Unit
Kg
Unit Cost
₹77.6
Annual Cost
₹7921000
Total Energy Costs(per year)
₹2,70,16,000
Observations & Recommendations
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Overall air leakages are found to be high at different points of the circuit | Arrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit and fittings. | 14,000 | ₹1,92,011 | ₹25,000 | 2 | |
| Reciprocating Compressor - Specific Power Consumption (SPC) is high and engagement is for full day delivering 18 CFM at 74% loading | Replace with comparatively efficient Screw Compressor with better SPC of 13 to 14 CFM at optimum loading | 10524 | ₹94716 | ₹120000 | 16 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency of Induction Motor used in Pressing machine is low due to ageing and underloaded operation | Replace 150 HP Induction motor with 100 HP IE3 Efficiency class Induction Motor | 30966 | ₹285815 | ₹400000 | 17 | |
| Efficiency of Induction Motor used in Cooling Tower - 1 out flow is low due to ageing | Replace 15 HP Induction motor with 15 HP IE3 Efficiency class Induction Motor | 13470 | ₹124329 | ₹100000 | 10 | |
| Efficiency of Induction Motor used in Cooling Tower - 2 out flow is low due to ageing | Replace 7.5 HP Induction motor with 7.5 HP IE3 Efficiency class Induction Motor | 2624 | ₹24217 | ₹50000 | 25 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency of FO fired Melting furnace is low and Specific Energy Cost is high at Rs.4.4/kg | Switch to Electrical resistance melting furnace having low specific energy cost at Rs.2.98/kg | 1104647 | ₹1222326 | ₹5000000 | 50 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency of LPG fired Billet Preheating Oven is low and Specific Energy Cost is high at Rs.5.49/kg | Switch to Electrical resistance Oven having low specific energy cost at Rs.2.7/kg | 1043358 | ₹4211760 | ₹4000000 | 12 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Heat lost through air gaps near front door edges, rear door edges and bottom railings. | Seal the air gaps and provide thermal insulation at the high temperature surfaces | 5156 | ₹46401 | ₹10000 | 3 | |
| Oven is operated in ON/OFF control mode, even though smooth ramp PID controlled Thyristor Converter based heater modulating system is available | Install and Operate using PID controlled Thyristor Converter and thereby optimize heating quality by smooth ramp using PID and thereby reduce Maximum Demand by 14 kVA and save demand charges | ₹773712 | ₹200000 | 4 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The Cooling tower effectiveness is found low performance | Improve range and approach by reducing waterflow rate by installing and operating the pump using VFD and intermediate operation of fan | 106386 | ₹957478 | ₹300000 | 4 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ceiling fans used in the plant and office areas are inefficient conventional type | Replace 7 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans | 1134 | ₹11606 | ₹22400 | 24 |
ALS - Alternate Source of Power
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Electricity is consumed from utility grid alone and there is no source of renewable energy in the plant | Install a Rooftop 115 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy | 138000 | ₹1242000 | ₹5750000 | 56 |