EAR/23-24/KISEM/IITI-07/02
The subject plant is located in Ujjain district of Madhya Pradesh and falls under NIC Category-24319. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Auto Casting Products Manufacturer
Plant Area (Sq.ft)
50,000
No. of Employees
600
Production Hours
7,200
Annual Production
62,06,000
Annual Sales
₹1,00,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹5,72,18,000
Total Recommended Investment(one time)
₹2,10,85,800
Total Recommended Savings(per year)
₹90,57,169
Energy Costs Calculation
Electricity
Annual Usage
80,79,000
Unit
kWh
Unit Cost
₹7.02
Annual Cost
₹5,67,79,000
PNG
Annual Usage
6920
Unit
Kg
Unit Cost
₹63.5
Annual Cost
₹439000
Total Energy Costs(per year)
₹5,72,18,000
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 | 173230 | ₹1212608 | ₹30000 | 1 | |
| Compressor - 1 (A) is fully loaded throughout the day but in Compressor - 3 (C) unloading time is high compared to loading time | Optimize loading of Compressor by Operate Compressor - 1 (A) as slave and Compressor-2 (B) as a master by installing VFD and Keep Compressor -3 (C) as standby | 106596 | ₹746172 | ₹200000 | 4 | |
| For cleaning and low-pressure applications, high rated compressor used. The requirement for low pressure is 2 bar, but the compressor used 8 bar set pressure. | Provide appropriate size of compressor for low pressure applications. Use 2 to 2.5 bar dedicated compressor for low pressure applications. | 28627 | ₹200390 | ₹25000 | 2 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Specific Energy Consumption of the Induction Furnaces at 600 kg were found 0.67 kWh/kg of melting and Specific Energy Cost is Rs.4.7/kg, due to high stock loading | Optimize the loading of furnaces to the design capacity of 500 kg/batch and reduce specific energy consumption near to 0.562 kWh/kg and specific energy cost to Rs.3.9/kg | 670965 | ₹4696756 | ₹ | ||
| Specific Energy Consumption of the Induction Furnaces were found high at 0.562 kWh/kg of melting and Specific Energy Cost is Rs.3.9/kg, due to inefficient conventional SCR based Power Converter with Pulse firing scheme | Replace the existing SCR / Diode based Power Converter Unit with Modern IGBT based Power Converter with Vector Controlled PWM Firing scheme and reduce specific energy consumption near to 0.515 kWh/kg and specific energy cost to Rs.3.6/kg | 294939 | ₹2064570 | ₹1000000 | 6 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| In the existing stage cooling tower fan operate 24X7 and L/G ratio is high | Installed VFD for better optimization of cooling tower fan. Operate fan according to approach temperature and improve L/G ratio | 9936 | ₹69552 | ₹40000 | 7 | |
| In the existing condition, hot and cold well used in the circuit. The hot well used for the furnace coil water circuit and the cold well used in the cooling tower circuit | Bypass the hot well and cold well from the existing circuit. Provide close loop circuit to use of potential head produced by the pump. The return water line of the furnace coil will be directly connected to the suction side of the pump instead of to drop the water in hot well. In cooling tower, the sump exit line will be directly connected to the suction side of the pump instead of water flow to the cold well. Provide make up water arrangement directly to the sump side of the cooling tower | 8424 | ₹8424 | ₹50000 | 72 |
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 44 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans | 7128 | ₹58696 | ₹140800 | 29 |
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 392 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy | 470400 | ₹3292800 | ₹19600000 | 72 |