KMB-IIT-MAD-23.05.19-10
The subject plant is located in Chennai district of Tamil Nadu and falls under NIC Category-28. This assessment was carried out by the IEAC Center, IIT Madras, during the course of the year 2023.
General Info
Principal Product
Machining
Plant Area (Sq.ft)
10,000
No. of Employees
50
Production Hours
7,200
Annual Production
50,000
Annual Sales
₹1,00,00,000
Assessment Summary
Total Energy Costs(per year)
₹44,02,067
Total Recommended Investment(one time)
₹2,50,500
Total Recommended Savings(per year)
₹8,60,622
Energy Costs Calculation
Electricity
Annual Usage
5,64,760
Unit
kWh
Unit Cost
₹7.79
Annual Cost
₹44,02,067
Total Energy Costs(per year)
₹44,02,067
Observations & Recommendations
CR - Compressor
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Air Leakage | Eliminate leaks in inert gas and compressed air lines/ valves | 33,341 | ₹2,59,726 | ₹50,000 | 2.3 | |
| High Unloading losses | The actual plant CFM load should be calculated accurately and there should be one compressor meeting the base air load by running at full load and the other for meeting peak/fluctuating loads by operating it with a VFD; | 19,418 | ₹1,51,266 | ₹90,000 | 7.1 |
FN - Fans
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| Old Type Fans | Use BLDC fan with same velocity | 4327 | ₹33,707 | ₹56,000 | 19.9 |
HVC - Heating Ventilation & Cooling
| Observation | Recommendation | Unit Savings | Annual Savings | Investment | ROI | Status |
|---|---|---|---|---|---|---|
| High Power Consumption | Upgrade filter banks to reduce pressure drop and thus lower fan power requirements. | 46,428 | ₹3,61,674 | ₹10,000 | 0.3 | |
| High Power Consumption | Install Air Conditioning Units and Heat Pumps Having the Highest Practical Efficiency | 3942 | ₹30,708 | ₹0 | 0.0 | |
| High Specific power consumption | Install Air Conditioning Units and Heat Pumps Having the Highest Practical Efficiency | 3,022 | ₹23,541 | ₹44,500 | 22.7 |