IIT Madras

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Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras

EAR/23-24/KISEM/IITI-03/02

The subject plant is located in Pithampur district of Madhya Pradesh and falls under NIC Category-24202. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.

General Info

Principal Product

Aluminium Die Cast Products Manufacturer

Plant Area (Sq.ft)

46,985

No. of Employees

117

Production Hours

7,200

Annual Production

9,00,000

Annual Sales

Assessment Summary

Total Energy Costs(per year)

₹2,24,55,000

Total Recommended Investment(one time)

₹1,04,72,800

Total Recommended Savings(per year)

₹86,21,226

Energy Costs Calculation
Electricity

Annual Usage

16,78,000

Unit

kWh

Unit Cost

₹8.2

Annual Cost

₹1,38,34,000

PNG

Annual Usage

156748

Unit

SCM

Unit Cost

₹55

Annual Cost

₹8621000

Total Energy Costs(per year)

₹2,24,55,000

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 fittings1,75,867₹14,49,146₹1,50,0002
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Efficiency and Loading of Induction Motor used in PDC Machines - 3,4,6 and 7 is lowReplace 30 HP Induction motor with 20 HP IE3 Efficiency class Induction Motor31232₹257351₹22500011
Efficiency and Loading of Induction Motor used in PDC Machines - 2 and 5 is lowReplace 60 HP and 50 HP Induction motors with 40 HP IE3 Efficiency class Induction Motor19975₹176779₹18000013
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The Cooling tower is underloaded and effectiveness is found low. Hot well and Cold Wells are mixed upImprove range by reducing water flow rate by installing and operating the pump using VFD and intermediate operation of fan11092₹91398₹400006
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Efficiency of Gas fired Melting furnace is low and Specific Energy Cost is low at Rs.7.92/kgSwitch to Electrical resistance melting furnace having low specific energy cost at Rs.2.73/kg₹4656324₹25000007
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Holding Furnaces 2,3,5,6 and 7 is operated in ON/OFF control mode and full MD is consumedInstall PID controlled Thyristor Converter and reduce Maximum Demand by 6 to 8 kVA and save demand charges₹259494₹25000012
DM - Demand Management
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Billed MD is low compared to minimum quota of CD allottedSurrender CD from 425 to 350 kVA and save minimum demand charges₹268650₹500003
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Daily Energy Losses are high compared to standard similar rating TransformerCarry out overall maintenance and oil filtration of the Transformer3504₹28873₹150007
LT - Lighting
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Lights are switched ON at PDC Floor, even though daylight is sufficientInstall more skylights and switch OFF 10 Nos of 150W LED industrial down lights4500₹37080₹3000010
Lighting used in the office and cabins are low efficiency T5 fluorescent tube lightsRetrofitting 12 Nos of Conventional Tube lights - 28W T5 FTL with 20W LED Patterns260₹2202₹720040
FN - Fans
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Ceiling fans used in the office and cabins are inefficient conventional typeReplace 8 Nos of Conventional ceiling fans with BEE 5 Star Label BLDC ceiling fans972₹9609₹2560032
ALS - Alternate Source of Power
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Electricity is consumed from utility grid alone and there is no source of renewable energy in the plantInstall a Rooftop 140 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy168000₹1384320₹700000061