EAR/23-24/KISEM/IITI-14/02
The subject plant is located in district of and falls under NIC Category-13. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Textile Sizing, Weaving and Calendaring
Plant Area (Sq.ft)
2,00,000
No. of Employees
300
Production Hours
7,200
Annual Production
Annual Sales
₹30,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹3,56,00,000
Total Recommended Investment(one time)
₹52,64,400
Total Recommended Savings(per year)
₹36,80,680
Energy Costs Calculation
Electricity
Annual Usage
15,40,000
Unit
kWh
Unit Cost
₹7.2
Annual Cost
₹1,10,00,000
Fuel (Firewood, Coal & Agrowaste)
Annual Usage
33,49,000
Unit
kg
Unit Cost
₹7.5
Annual Cost
₹2,46,00,000
Total Energy Costs(per year)
₹3,56,00,000
Observations & Recommendations
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional Induction Motors with low efficiency is installed for calendaring machines | Replace with energy efficient IE4 or above Induction Motors | 28,174 | ₹2,24,896 | ₹2,25,000 | 13 | |
| For Fixed operating load VFD is used | By-pass the VFD from Calendaring motor and use soft starter for smoothing starting load | 2973 | ₹22148 | ₹40000 | 22 | |
| Conventional Induction Motors with low efficiency is installed for calendaring machines | Replace with energy efficient IE4 or above Induction Motors | 49633 | ₹347431 | ₹4,50,000 | 16 | |
| Conventional Induction Motors with low efficiency is installed for calendaring machine | Replace with energy efficient IE4 or above Induction Motors | 42261 | ₹2,95,826 | ₹2,25,000 | 10 | |
| Conventional Induction Motors with low efficiency is installed for Weaving machines | Replace with energy efficient IE4 or above Induction Motors | 15454 | ₹124178 | ₹300000 | 29 | |
| Specific Energy Consumed (kWh/kg) for some weaving machines found high. Terminal Voltage to motors found low. Conventional V- Belts are used | Undergo proper maintenance of machinery and reduce SEC (kWh/kg) near to 1.2 kWh/kg. Install Voltage Optimizer or Servo Stabilizer to improve voltage Replace conventional belts with Cogged V-Belts. | 10565 | ₹126000 | ₹60000 | 6 | |
| Conventional Induction Motors with low efficiency is installed for Weaving machines | Replace with energy efficient IE4 or above Induction Motors | 14488 | ₹113917 | ₹300000 | 32 | |
| Specific Energy Consumed (kWh/kg) for some weaving machines found high. Terminal Voltage to motors found low. Conventional VBelts are used. | Undergo proper maintenance of machinery and reduce SEC (kWh/kg) near to 1.2 kWh/kg. Install Voltage Optimizer or Servo Stabilizer to improve voltage Replace conventional belts with Cogged V-Belts. | 10253 | ₹71771 | ₹30000 | 6 | |
| Conventional Induction Motors with low efficiency is installed for Weaving machines | Replace with energy efficient IE4 or above Induction Motors | 13909 | ₹115360 | ₹330000 | 35 | |
| Specific Energy Consumed (kWh/kg) for some weaving machines found high. Terminal Voltage to motors found low. Conventional VBelts are used | Undergo proper maintenance of machinery and reduce SEC (kWh/kg) near to 1.2 kWh/kg. Install Voltage Optimizer or Servo Stabilizer to improve voltage Replace conventional belts with Cogged V-Belts. | 9843 | ₹68901 | ₹30000 | 6 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Steam leakages at various points | Arrest the steam leakages by properly sealing the gaps | 59301 | ₹77271 | ₹50000 | 8 | |
| Non insulated surfaces of steam distribution lines and condensate lines | Provide thermal insulation at the high temperature surfaces and save fuel | 17240 | ₹22464 | ₹50000 | 27 | |
| Thermal energy lost in condensate directly ejected out | Recover Condensate | 79070 | ₹103031 | ₹300000 | 35 | |
| Steam leakages at various points | Arrest the leakages by properly sealing the gaps | 92100 | ₹1,20,009 | ₹90,000 | 9 | |
| Non insulated surfaces of steam distribution lines and condensate lines | Provide thermal insulation at the high temperature surfaces and save fuel | 34491 | ₹45,243 | ₹1,00,000 | 27 | |
| Thermal energy lost in condensate directly ejected out | Recover Condensate | 162530 | ₹4,41,210 | ₹5,00,000 | 14 | |
| Steam leakages at various points | Arrest the leakages by properly sealing the gaps | 58500 | ₹76,227 | ₹70,000 | 12 | |
| Non insulated surfaces of steam distribution lines and condensate lines | Provide thermal insulation at the high temperature surfaces and save fuel | 42301 | ₹55,120 | ₹1,20,000 | 27 | |
| Thermal energy lost in condensate directly ejected out | Recover Condensate | 135000 | ₹1,95,450 | ₹5,00,000 | 31 | |
| Steam leakages at various points. | Arrest the leakages by properly sealing the gaps | 289534 | ₹377270 | ₹80000 | 3 | |
| Non insulated surfaces of steam distribution lines and condensate lines | Provide thermal insulation at the high temperature surfaces and save fuel | 115167 | ₹185225 | ₹200000 | 13 | |
| Efficiency of Boiler found to be slightly low | Optimize fuel feeding by cutting and chopping large piece of firewood using a suitable shredding equipment, improve combustion efficiency and save fuel | 144767 | ₹188635 | ₹200000 | 13 | |
| Steam generated is directly expanded from 8 bar to 2.5 bar using PRV as per process demand | Replace PRV with suitable Micro Turbine to reclaim lost energy as Electrical energy | 144768 | ₹188635 | ₹1000000 | 64 |
LT - Lighting
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Conventional low efficient CFL Lights are used | Install Energy Efficient LED Lights | 4147 | ₹29093 | ₹6400 | 3 | |
| Conventional low efficient FTL Lights are used | Install Energy Efficient LED Tube Lights | 5708 | ₹48,143 | ₹8,000 | 2 |
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| The Existing Compressor set pressure range is higher | Optimize the compressor set pressure range. | 2220 | ₹8880 | ₹ | ||
| The Existing Compressor set pressure range is higher. | Optimize the compressor set pressure range. | 1350 | ₹5400 | ₹ |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| For Fixed operating load VFD is used | By-pass the VFD from boiler ID fan. | 376 | ₹2946 | ₹ |