EAR/22-23/KISEM-IITB-06
The subject plant is located in district of and falls under NIC Category-20. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2022.
General Info
Principal Product
Chemicals
Plant Area (Sq.ft)
2,00,000
No. of Employees
Production Hours
7,200
Annual Production
Annual Sales
₹20,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹10,74,89,340
Total Recommended Investment(one time)
₹12,00,000
Total Recommended Savings(per year)
₹3,88,34,029
Energy Costs Calculation
Electricity
Annual Usage
20,30,524
Unit
kWh
Unit Cost
₹9.5
Annual Cost
₹1,92,11,962
Diesel Generator
Annual Usage
19,114
Unit
Ltr
Unit Cost
₹92
Annual Cost
₹17,58,488
Coal
Annual Usage
99,44,700
Unit
kg
Unit Cost
₹8.7
Annual Cost
₹8,65,18,890
Total Energy Costs(per year)
₹10,74,89,340
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Reactive power is negative most of the time. | APFC mechanism of Plant is not working well and it should be rectified with the AMC | 12,900 | ₹1,16,100 | ₹30,000 | 5.17 | |
| APFC controlling is by using single phase sensing only | The sensing mechanism should be upgraded to Three phase sensing | ₹ | ₹ |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 26 out of 81 motors were studied out of which 6 pumps were underloaded | VFD is recommended which will save more power | 2,34,100 | ₹21,06,904 | ₹6,00,000 | 3.42 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess air is too high around 190-200%. | Install Oxygen sensor and give feedback to VFD for controlling FD and ID fan | 5,68,700 | ₹49,47,690 | ₹3,00,000 | 0.71 | |
| VFD controlling of ID fan by using temperature setting only | Install Oxygen sensor and give feedback to VFD for controlling FD and ID fan | ₹ | ₹ | |||
| FD fan is working at full speed irrespective of the quantity of supply air. | VFD should be installed in FD fan and it should be controlled as above | 12,700 | ₹1,14,300 | ₹ | ||
| Thermal insulation is not maintained proper at some places | Thermal insulation should be done at circulation pipes and boiler walls. | 64,400 | ₹5,60,280 | ₹50,000 | 1.1 | |
| Dry flue gas temperature is too high | This can be utilised for Preheating of process Raw material. | ₹ | ₹ | |||
| Coal is used as fuel for Boiler | Cashew nut shell fuel substitution is recommended which has more GCV | 48,19,200 | ₹3,01,38,755 | ₹1,00,000 | 0.04 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Poor Effectiveness & Approach of the Cooling Tower | Change the fins which were not in good condition and frequent maintenance of cooling tower is required | ₹ | ₹ |
CHR - Chiller
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Chiller line Insulation is not complete and proper. | Need proper and complete insulation. | 96,000 | ₹8,50,000 | ₹1,00,000 | 1.4 | |
| The effectiveness of 6 heat exchangers is below 60%. Some heat exchangers whenever not functional, then also water circulation is there. | The flow of cooling water should be optimised to get best effectiveness and circulation of water can be stopped when heat exchanger is not operating | ₹ | ₹ |