EAR/23-24/KISEM/IITGN-03/Final
The subject plant is located in district of and falls under NIC Category-24319. This assessment was carried out by the IEAC Center, IIT Gandhinagar, during the course of the year 2023.
General Info
Principal Product
Foundry
Plant Area (Sq.ft)
1,30,000
No. of Employees
350
Production Hours
7,200
Annual Production
Annual Sales
₹30,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹3,94,36,752
Total Recommended Investment(one time)
₹17,82,500
Total Recommended Savings(per year)
₹20,53,718
Energy Costs Calculation
Electricity
Annual Usage
49,14,320.7
Unit
kWh
Unit Cost
₹8
Annual Cost
₹3,94,36,752.23
Total Energy Costs(per year)
₹3,94,36,752
Observations & Recommendations
CPF - Capacitor & Power Factor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Frequent On & Off of Capacitor connected with APFC | Use fixed capacitor of 25 kVAR | ₹92,726 | ₹7,500 | 1 |
TR - Transformer
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Average voltage at each phase is 440 V and machines are rated for 415 V | Change the tapping of transformer | ₹ | ₹ |
BR - Boiler & Steam Line
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Current harmonics present in the system | Install passive harmonic filter | 95,834 | ₹7,37,924 | ₹1,00,000 | 2 |
PP - Pumps
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Furnace pumps are running at low efficiency | Use VFD with one pump and take input from pressure transmitter for controlling the speed of pump with its head | 18000 | ₹1,38,600 | ₹60,000 | 6 | |
| Panel Cooling Water pump running at high head due to heat exchanger choking issue | Use VFD with one pump and take input from Pressure transmitter for controlling the speed of pump with head, this will improve the efficiency of operating pump | 14000 | ₹1,07,800 | ₹40,000 | 5 |
CT - Cooling Tower
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Effectiveness of Panel cooling heat exchanger are reduced | Clean the heat exchanger | ₹ | ₹ | |||
| High TDS at Cooling tower sump water | Maintain the TDS in range of 1000-1500 ppm-do proper blowdown | ₹ | ₹ | |||
| Approach, effectiveness and range of Cooling tower increase. | Properly clean the nozzle and also check the layer formation on fills and also reduce the flow of cooling tower water. | 28,080 | ₹2,16,216 | ₹50,000 | 3 | |
| Continuous operation of cooling tower fan | Use VFD with cooling tower fan motor (vfd input is sump temperature) | 5,543 | ₹5,543 | ₹25,000 | 7 | |
| Use CLCT for furnace cooling of capacity 100 TR | Install CLCT and remove one 7.5 kW pump and 5.5 kW pump | 93,180 | ₹7,17,486 | ₹15,00,000 | 24 | |
| No insulation on cooling tower pipeline | Proper insulation of all the incoming pipe line required as sump temperature is 28deg C but at furnace heat exchanger it is 31.5 and at panel heat exchanger it is 37 deg C | ₹ | ₹ |