IIT Madras

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IIT Bombay

IIT Indore

IIT Gandhinagar

IIT Guwahati

IIT Ropar

Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras

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)

₹13,19,298

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
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Overall air leakages are found to be high at different points of the circuitArrest air leakages regularly by conducting maintenance of compressed air system consisting of the plant, circuit and fittings26,290₹2,32,665₹1,00,0006
Screw compressor (Comp 1) - unloading time is high due to varying pressure demandExisting screw compressor - 1 could be retrofitted with a VFD drive and optimize power consumption according to actual pressure demand6705₹59339₹7500016
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 plantSwitch OFF the Reciprocating Compressor (Comp 3) and operate Comp 1 alone18327₹162194₹250002
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Efficiency of Induction Motor used in Rewinding Machine is low due to ageing and underloaded operationReplace 45 HP Induction motor with 12.5 HP IE3 Efficiency class Induction Motor2246₹19876₹3200020
Energy loss in VFDs were found high in RewinderUndergo maintenance of heat sinks in VFDs6330₹56021₹5000011
Mechanical power transmission slip found to be slightly high in 1st Belt of Rewinder MachineReduce slippage in belt and pulley system through replacement of conventional V-belts with Cogged Vbelts and reduce motor speed using existing VFD202₹1784₹12009
Efficiency of Induction Motor used in Boiler ID Fan is low due to ageing and underloaded operationReplace 20 HP Induction motor with 12.5 HP IE3 Efficiency class Induction Motor4298₹38034₹3200011
Efficiency of Induction Motor used in Boiler FD Fan is low due to ageing and underloaded operationReplace 20 HP Induction motor with 5 HP IE3 Efficiency class Induction Motor2146₹18994₹1700011
Efficiency of Induction Motor used in Vacuum Pump 1 is low due to ageing and underloaded operationOperate comparatively efficient Vacuum Pump - 2 throughout and keep Vacuum - Pump - 1 as stand by26976₹238738
Mechanical power transmission slip found to be slightly high in Vacuum Pump 1 and 2Reduce slippage in belt and pulley system through replacement of conventional V-belts with Cogged Vbelts and reduce motor speed using existing VFD3905₹34557₹96004
Mechanical power transmission slip found to be slightly high in PulperReduce slippage in belt and pulley system through replacement of conventional V-belts with Cogged Vbelts and reduce motor speed using existing VFD7615₹67395₹90002
Loading of Motors driving Tertiary Centricleaner and Thickener is found to be very lowOperate the Motors in Star Connection using a suitable Delta / Star Connertor unit and improve loading and save energy2153₹19054₹2000013
Energy loss in VFDs were found high in Post Drier Roll, 1st Press, Mould Roll - 1,2,4 and RewinderReplace high power consuming VFDs with modern low loss VFDs and do maintenance of heat sinks in certain VFDs35781₹316662₹25000010
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
₹50000
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Heat lost through leakages and non insulated surfaces of steam pipe distribution line - to Predrier Roll, condensate collection tank to predrier roll and MG rollSeal the leak points and Provide thermal insulation at the high temperature surfaces and save fuel16451₹46392₹5000013
FN - Fans
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Ceiling fans used in the plant area and office are inefficient conventional typeReplace 16 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans858₹7593₹2560041