EAR/23-24/KISEM/IITI-02/02
The subject plant is located in Indore district of Madhya Pradesh and falls under NIC Category-17. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.
General Info
Principal Product
Paper Products Manufacturer
Plant Area (Sq.ft)
40,000
No. of Employees
500
Production Hours
7,200
Annual Production
90,00,000
Annual Sales
₹2,00,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹4,17,26,000
Total Recommended Investment(one time)
₹7,46,400
Total Recommended Savings(per year)
₹23,22,796
Energy Costs Calculation
Electricity
Annual Usage
22,38,492
Unit
kWh
Unit Cost
₹8.8
Annual Cost
₹1,98,18,000
Coal
Annual Usage
1503141
Unit
Kg
Unit Cost
₹10.2
Annual Cost
₹15380000
Firewood
Annual Usage
2309098
Unit
Kg
Unit Cost
₹2.8
Annual Cost
₹6528000
Total Energy Costs(per year)
₹4,17,26,000
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 | 26,290 | ₹2,32,665 | ₹1,00,000 | 6 | |
| Screw compressor (Comp 1) - unloading time is high due to varying pressure demand | Existing screw compressor - 1 could be retrofitted with a VFD drive and optimize power consumption according to actual pressure demand | 6705 | ₹59339 | ₹75000 | 16 | |
| Reciprocating Compressor (Comp 3) is operated intermediately to support certain equipments alone, even though Comp 1 alone is sufficient to meet compressed air demand in the plant | Switch OFF the Reciprocating Compressor (Comp 3) and operate Comp 1 alone | 18327 | ₹162194 | ₹25000 | 2 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Efficiency of Induction Motor used in Rewinding Machine is low due to ageing and underloaded operation | Replace 45 HP Induction motor with 12.5 HP IE3 Efficiency class Induction Motor | 2246 | ₹19876 | ₹32000 | 20 | |
| Energy loss in VFDs were found high in Rewinder | Undergo maintenance of heat sinks in VFDs | 6330 | ₹56021 | ₹50000 | 11 | |
| Mechanical power transmission slip found to be slightly high in 1st Belt of Rewinder Machine | Reduce slippage in belt and pulley system through replacement of conventional V-belts with Cogged Vbelts and reduce motor speed using existing VFD | 202 | ₹1784 | ₹1200 | 9 | |
| Efficiency of Induction Motor used in Boiler ID Fan is low due to ageing and underloaded operation | Replace 20 HP Induction motor with 12.5 HP IE3 Efficiency class Induction Motor | 4298 | ₹38034 | ₹32000 | 11 | |
| Efficiency of Induction Motor used in Boiler FD Fan is low due to ageing and underloaded operation | Replace 20 HP Induction motor with 5 HP IE3 Efficiency class Induction Motor | 2146 | ₹18994 | ₹17000 | 11 | |
| Efficiency of Induction Motor used in Vacuum Pump 1 is low due to ageing and underloaded operation | Operate comparatively efficient Vacuum Pump - 2 throughout and keep Vacuum - Pump - 1 as stand by | 26976 | ₹238738 | ₹ | ||
| Mechanical power transmission slip found to be slightly high in Vacuum Pump 1 and 2 | Reduce slippage in belt and pulley system through replacement of conventional V-belts with Cogged Vbelts and reduce motor speed using existing VFD | 3905 | ₹34557 | ₹9600 | 4 | |
| Mechanical power transmission slip found to be slightly high in Pulper | Reduce slippage in belt and pulley system through replacement of conventional V-belts with Cogged Vbelts and reduce motor speed using existing VFD | 7615 | ₹67395 | ₹9000 | 2 | |
| Loading of Motors driving Tertiary Centricleaner and Thickener is found to be very low | Operate the Motors in Star Connection using a suitable Delta / Star Connertor unit and improve loading and save energy | 2153 | ₹19054 | ₹20000 | 13 | |
| Energy loss in VFDs were found high in Post Drier Roll, 1st Press, Mould Roll - 1,2,4 and Rewinder | Replace high power consuming VFDs with modern low loss VFDs and do maintenance of heat sinks in certain VFDs | 35781 | ₹316662 | ₹250000 | 10 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| ₹ | ₹50000 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Heat lost through leakages and non insulated surfaces of steam pipe distribution line - to Predrier Roll, condensate collection tank to predrier roll and MG roll | Seal the leak points and Provide thermal insulation at the high temperature surfaces and save fuel | 16451 | ₹46392 | ₹50000 | 13 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Ceiling fans used in the plant area and office are inefficient conventional type | Replace 16 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans | 858 | ₹7593 | ₹25600 | 41 |