KMB-IIT-BOM-070523-14
The subject plant is located in Aurangabad district of Maharashtra and falls under NIC Category-24105. This assessment was carried out by the IEAC Center, IIT Bombay, during the course of the year 2023.
General Info
Principal Product
Re-rolling mills
Plant Area (Sq.ft)
3,00,000
No. of Employees
150
Production Hours
7,200
Annual Production
Annual Sales
₹30,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹2,11,60,000
Total Recommended Investment(one time)
₹15,50,000
Total Recommended Savings(per year)
₹31,74,828
Energy Costs Calculation
Electricity
Annual Usage
15,10,000
Unit
kWh
Unit Cost
₹11.7
Annual Cost
₹1,76,00,000
Coal
Annual Usage
206380
Unit
Kg
Unit Cost
₹17.2
Annual Cost
₹3560000
Total Energy Costs(per year)
₹2,11,60,000
Observations & Recommendations
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Plant is operating from 8 am to 8 pm | Shift the timing to 6am – 6pm instead of 8am – 8pm | 2,56,784 | ₹2,82,462 | ₹ |
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| All APFC are contactor type and many derated capacitors are found | Replace derated capacitors. Fixed capacitors should be decreased and install thyristor controlled APFC instead of contactor based | 19,958 | ₹2,32,402 | ₹2,50,000 | 12.9 | |
| APFC controlling is by single phase sensing | The sensing mechanism should be upgraded to Three phase sensing | ₹ | ₹ |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Coal Crushing machine is working at variable load | Install VFD and tune the VFD for the same purpose | 81,504 | ₹9,49,063 | ₹2,00,000 | 2.5 |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| 3 Big cutting machines are there. One was not working during the visit | Install VFD for cutting machines which are being operated 12 hours and tune the VFD for the same purpose | 63,245 | ₹7,36,446 | ₹3,50,000 | 6 | |
| 2 small cutting machines which are operating whole 12 hours were studied | Install pedal switch which will be cost effective method for the small cutting machines | 3,690 | ₹42,968 | ₹10,000 | 3 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Delivering 41 m3/hr, where the pump is bypassing | Install VFD for the pump so that the flow/pressure should be maintained | 8,594 | ₹1,00,073 | ₹2,00,000 | 24 |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Excess air is too high (~200 %) | Oxygen sensor should be checked and FD & ID fan should be optimized according to that | 41,763 | ₹7,22,006 | ₹5,00,000 | 8 | |
| Thermal insulation is not good enough in many areas in the furnaces wall | Insulate perfectly, give double insulation if required | 6,329 | ₹1,09,408 | ₹40,000 | 4.39 | |
| The outlet door is half open full time | Apply pedal operated opening system | ₹ | ₹ |
MT - Motors
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Rolling Mill is manually operating | Automize the rolling mill so that production can be increased | ₹ | ₹ |