IIT Madras

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Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras


The subject plant is located in district of and falls under NIC Category-24319. This assessment was carried out by the IEAC Center, IIT Indore, during the course of the year 2023.

General Info

Principal Product

Steel Billets and Ingots manufacturing

Plant Area (Sq.ft)


No. of Employees


Production Hours


Annual Production


Annual Sales


Assessment Summary

Total Energy Costs(per year)


Total Recommended Investment(one time)


Total Recommended Savings(per year)


Energy Costs Calculation

Annual Usage




Unit Cost


Annual Cost



Annual Usage




Unit Cost


Annual Cost


Total Energy Costs(per year)


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 fittings.6,173₹38,765₹30,00010
Inefficient Reciprocating Compressor with higher kW/CFM is usedInstall and operate energy efficient Permanent Magnet BLDC Screw Compressor27752₹174,281₹700,00049
The existing Cut-off pressure is 10 bar. whereas the maximum pressure requirement is 7.5 barProposed to change the cutoff pressure from 10 bar to 7.5 bar11131₹69,908₹10,0002
BR - Boiler & Steam Line
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Specific Energy Consumption of the 8T Induction Furnaces at 10270 kg were found 0.745 kWh/kg of melting and Specific Energy Cost is Rs.4.67/kg, due to high stock loadingOptimize the loading of 8T furnaces to the design capacity of 8000 kg/batch and reduce specific energy consumption near to 0.549 kWh/kg and specific energy cost to Rs.3.44/kg54,65,449₹3,43,23,022
Specific Energy Consumption of the 10T Induction Furnaces at 12580 kg were found 0.702 kWh/kg of melting and Specific Energy Cost is Rs.4.4/kg, due to high stock loadingOptimize the loading of 10T furnaces to the design capacity of 10000 kg/batch and reduce specific energy consumption near to 0.549 kWh/kg and specific energy cost to Rs.3.44/kg4254192₹29,779,342
Old and outdated type Coil Cradle assembly is used in 8T FurnacesReplace with latest energy efficient Coil Cradle Assembly in 8T Furnaces519184₹3,260,475₹2,500,00010
Excess thermal energy loss from ladle SurfacesProvide thermal insulation to ladle surface16799₹105,497₹50,0006
Excess thermal energy loss from ladle mouth, since it is open during transitClose the ladle mouth with a suitable lid during transit time472467₹2,967,093₹200,0001
MT - Motors
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Conventional Water resistance starting and braking system is used in Rolling Mill - Slip Ring Induction MotorReplace with energy efficient Rotor Control Drive with Slip Power Recovery Scheme (SPRS)415749₹2,610,907₹2,000,00010
Conventional Induction Motors with low efficiency is installed for conveyors, straightening machines, cooling beds, degree tables, pumps etc.Replace with energy efficient IE4 or above Induction Motors319350₹3,071,586₹3,810,00015
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The material of the cooling tower fan is non- FRP type material.Install FRP type CT fan. FRP material is light in weight and corrosion resistant53611₹339,359₹250,0009
The approach temperature of the Cooling tower is 6.5°CClean CT fills, allow uniform flow of water from the output of cooling tower and maintain the approach below 5°C35741₹226,239₹150,0008
CT operates throughout the day continuously without any control.Operate CT fan as per the load with respect to approach. Control the fan speed using by VFD in closed loop. (This is applicable when approach temperature drop below 5°C)
HVC - Heating Ventilation & Cooling
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
The efficiency of furnace cooling tower pump (Raw Water) is very low.Use efficient and correct sized pump in the cooling system.128330₹812,332₹200,0003
Cooling water is splashed in the idle strand alsoSwitch OFF the primary pump used for the idle strand103718₹656,537
In Cooling gate, the water flow remains continuous even when there is no production.Operate the secondary pump as per the water flow requirement in the system. Control the pump flow rate in using VFD in closed loop75686₹479,095₹100,0003
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 1100 kWp grid tied Solar PV power plant at the free space available on the top of the plant roofing to harvest clean renewable energy1320000₹8,289,600₹55,000,00080