KMB-IIT-MAD-08.03.23-02
The subject plant is located in district of and falls under NIC Category-13111. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2023.
General Info
Principal Product
Dyeing Fabric
Plant Area (Sq.ft)
6,000
No. of Employees
50
Production Hours
7,200
Annual Production
36,96,000
Annual Sales
₹18,48,00,000
Assessment Summary
Total Energy Costs(per year)
₹1,54,66,329
Total Recommended Investment(one time)
₹18,72,600
Total Recommended Savings(per year)
₹17,58,816
Energy Costs Calculation
Electricity
Annual Usage
4,83,831
Unit
kWh
Unit Cost
₹8
Annual Cost
₹38,70,648
Wood
Annual Usage
26,96,670
Unit
kg
Unit Cost
₹4.3
Annual Cost
₹1,15,95,681
Total Energy Costs(per year)
₹1,54,66,329
Observations & Recommendations
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| No FD fan | Install FD fan | 2,18,188 | ₹9,38,208 | ₹8,00,000 | 10.2 | |
| Stream leaks | Locate and Repair Steam and Water Leaks at Appropriate Intervals | ₹ | ₹10000 | |||
| No Flow meter | Install Flow meter for feed water | ₹ | ₹200000 |
DM - Demand Management
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Demand Underutilization | Surrender unutilized sanctioned demand | ₹ | ₹57,600 |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Power Factor | Replace the de-rated capacitors with new capacitors | ₹ | ₹10000 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 7,506 | ₹60,048 | ₹20000 | 4.0 | |
| High specific energy consumption | Replace old compressor with energy efficient low specific energy consumption (kW/CFM) compressor; | 22,518 | ₹1,80,144 | ₹130000 | 8.7 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Power Consumption | Do proper maintenance for efficient operation | 21,600 | ₹1,72,800 | ₹75,000 | 5.2 | |
| High Bypass flow | Balance the system to minimize flows and reduce pump power requirements. | 7,200 | ₹57,600 | ₹10,000 | 2.1 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| VFD installed on full load blowers | Remove VFD for constant full load operations | 31,752 | ₹2,54,016 | ₹2,10,000 | 9.9 |
BL - Blower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| No automation of blowers | Turn blowers off when they are not needed | 12000 | ₹96,000 | ₹350000 | 43.8 |