Bureau of Energy Efficiency (BEE) - ?· Bureau of Energy Efficiency (BEE) ... We are sincerely thankful…

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<ul><li><p>REPORT </p><p>ON </p><p>ENERGY COST REDUCTION WITH ENERGY </p><p>EFFI.IENT MR </p><p>(ALWAR OIL MILL CLUSTER) </p><p>Bureau of Energy Efficiency (BEE) </p><p>Prepared By Reviewed By </p><p>DETAILED PROJECT REPORT ON </p><p>ENERGY EFFICIENT MOTOR FOR EXPELLER (50 HP) </p><p>(ALWAR OIL MILL CLUSTER) </p></li><li><p>ENERGY EFFICIENT MOTOR FOR EXPELLER (50 HP) </p><p>ALWAR OIL MILL CLUSTER </p></li><li><p> BEE, 2010 </p><p>Detailed Project Report on Energy Efficient Motor for Expeller </p><p>(50 HP) </p><p> Oil Mill SME Cluster, Alwar (Rajasthan) (India) New Delhi: Bureau of Energy Efficiency; </p><p> Detail Project Report No.: </p><p> For more information </p><p>Bureau of Energy Efficiency (BEE) </p><p>(Ministry of Power, Government of India) </p><p>4th Floor, Sewa Bhawan </p><p>R. K. Puram, New Delhi 110066 </p><p>Telephone +91-11-26179699 </p><p>Fax+91-11-26178352 </p><p>Websites: www.bee-india.nic.in </p><p>Email: jsood@beenet.in/ pktiwari@beenet.in </p><p>http://www.bee-india.nic.in/mailto:jsood@beenet.in/mailto:pktiwari@beenet.in</p></li><li><p>Acknowledgement </p><p>We are sincerely thankful to the Bureau of Energy Efficiency, Ministry of Power, for giving us </p><p>the opportunity to implement the BEE SME Project in Alwar Oil Mill Cluster, Alwar. We </p><p>express our sincere gratitude to all concerned officials for their support and guidance during </p><p>the conduct of this exercise. </p><p>Dr. Ajay Mathur, Director General, BEE </p><p>Smt. Abha Shukla, Secretary, BEE </p><p>Shri Jitendra Sood, Energy Economist, BEE </p><p>Shri Pawan Kumar Tiwari, Advisor (SME), BEE </p><p>Shri Rajeev Yadav, Project Economist, BEE </p><p>CII AVANTHA Centre for Competitiveness for SMEs, Confederation of Indian Industry (CII) </p><p>is also thankful to Industry Associations for their valuable inputs, cooperation, support and </p><p>facilitating the implementation of BEE SME program in Alwar Oil Mill Cluster. </p><p>We take this opportunity to express our appreciation for the excellent support provided by </p><p>Foundry Unit Owners, Local Service Providers, and Equipment Suppliers for their active </p><p>involvement and their valuable inputs in making the program successful and in completion of </p><p>the Detailed Project Report (DPR). </p><p>CII AVANTHA Centre for Competitiveness for SMEs, Confederation of Indian Industry (CII) </p><p>is also thankful to all the SME owners, plant in charges and all workers of the SME units for </p><p>their support during the energy use and technology audit studies and in implementation of the </p><p>project objectives. </p><p>CII AVANTHA Centre for Competitiveness for SMEs Confederation of Indian Industry </p><p>Chandigarh </p></li><li><p>Contents List of Annexure vii </p><p>List of Tables vii </p><p>List of Figures viii </p><p>List of Abbreviation viii </p><p>Executive summary ix </p><p>About BEES SME program xi </p><p>1 INTRODUCTION ........................................................................................................1 </p><p>1.1 Brief Introduction about cluster ...................................................................................1 </p><p>1.1.1 Production process .....................................................................................................2 </p><p>1.2 Energy performance in existing situation ....................................................................4 </p><p>1.2.1 Average production by a typical unit ...........................................................................4 </p><p>1.2.2 Energy consumption ...................................................................................................4 </p><p>1.2.3 Specific Energy Consumption .....................................................................................4 </p><p>1.3 Existing technology/equipment ...................................................................................4 </p><p>1.3.1 Description of existing technology ...............................................................................4 </p><p>1.3.2 Its role in the whole process .......................................................................................5 </p><p>1.4 Establishing the baseline for the equipment ................................................................5 </p><p>1.4.1 Design and operating parameters ...............................................................................5 </p><p>1.4.2 Operating efficiency of the existing motor ...................................................................5 </p><p>1.5 Barriers for adoption of new and energy efficient technology / equipment ...................5 </p><p>1.5.1 Technological Barriers ................................................................................................5 </p><p>1.5.2 Financial Barrier ..........................................................................................................6 </p><p>1.5.3 Skilled manpower .......................................................................................................6 </p><p>1.5.4 Other barrier(s) ...........................................................................................................6 </p><p>2. TECHNOLOGY/EQUIPMENT FOR ENERGY EFFICIENCY IMPROVEMENTS .........7 </p><p>2.1 Detailed description of technology/equipment selected ...............................................7 </p><p>2.1.1 Description of equipment ............................................................................................7 </p><p>2.1.2 Technology /Equipment specifications ........................................................................7 </p></li><li><p>2.1.3 Justification of the technology selected &amp; Suitability ...................................................8 </p><p>2.1.4 Superiority over existing technology/equipment ..........................................................9 </p><p>2.1.5 Availability of the proposed technology/equipment ......................................................9 </p><p>2.1.6 Source of technology/equipment for the project .......................................................... 10 </p><p>2.1.7 Service/technology providers .................................................................................... 10 </p><p>2.1.8 Terms of sales .......................................................................................................... 10 </p><p>2.1.9 Process down time during implementation ................................................................ 10 </p><p>2.2 Life cycle assessment and risks analysis .................................................................. 10 </p><p>2.3 Suitable unit/plant size in terms of capacity/production ............................................. 10 </p><p>3. ECONOMIC BENEFITS OF NEW ENERGY EFFICIENT TECHNOLOGY ................ 11 </p><p>3.1 Technical benefits ..................................................................................................... 11 </p><p>3.1.1 Fuel savings per year................................................................................................ 11 </p><p>3.1.2 Electricity savings per year ....................................................................................... 11 </p><p>3.1.3 Improvement in product quality ................................................................................. 11 </p><p>3.1.4 Increase in production............................................................................................... 11 </p><p>3.1.5 Reduction in raw material consumption .................................................................... 11 </p><p>3.1.6 Reduction in other losses .......................................................................................... 11 </p><p>3.2 Monetary benefits ..................................................................................................... 11 </p><p>3.3 Social benefits .......................................................................................................... 11 </p><p>3.3.1 Improvement in working environment in the plant ..................................................... 11 </p><p>3.3.2 Improvement in skill set of workers ........................................................................... 11 </p><p>3.4 Environmental benefits ............................................................................................. 12 </p><p>3.4.1 Reduction in effluent generation ............................................................................... 12 </p><p>3.4.2 Reduction in GHG emission such as CO2, NOx, etc ................................................. 12 </p><p>3.4.3 Reduction in other emissions like SOx ...................................................................... 12 </p><p>4. INSTALLATION OF NEW ENERGY EFFICIENT MOTOR ........................................ 13 </p><p>4.1 Cost of technology/equipment implementation .......................................................... 13 </p><p>4.1.1 Cost of technology/equipments ................................................................................. 13 </p></li><li><p>4.1.2 Other costs ............................................................................................................... 13 </p><p>4.2 Arrangement of funds ............................................................................................... 13 </p><p>4.2.1 Entrepreneurs contribution ....................................................................................... 13 </p><p>4.2.2 Loan amount ............................................................................................................. 13 </p><p>4.2.3 Terms &amp; conditions of loan ....................................................................................... 13 </p><p>4.3 Financial indicators ................................................................................................... 13 </p><p>4.3.1 Cash flow analysis .................................................................................................... 13 </p><p>4.3.2 Simple payback period .............................................................................................. 14 </p><p>4.3.3 Net Present Value (NPV) .......................................................................................... 14 </p><p>4.3.4 Internal rate of return (IRR) ....................................................................................... 14 </p><p>4.3.5 Return on investment (ROI) ...................................................................................... 14 </p><p>4.4 Sensitivity analysis in realistic, pessimistic and optimistic scenarios ......................... 14 </p><p>4.5 Procurement and implementation schedule .............................................................. 14 </p></li><li><p>vii </p><p>List of Annexure </p><p>Annexure 1: Energy audit data used for baseline establishment ............................................ 15 </p><p>Annexure 2: Detailed technology assessment report EE Motor ........................................... 16 </p><p>Annexure 3: Detailed financial calculations &amp; analysis ........................................................... 17 </p><p>Annexure 4: Details of procurement and implementation plan ................................................ 21 </p><p>Annexure 6: Details of technology/equipment and service providers ...................................... 22 </p><p>Annexure 7: Quotation or techno-commercial bid ................................................................... 23 </p><p>List of Table </p><p>Table 1.1 production wise unit breakups ................................................................................... 2 </p><p>Table 1.2 Product Manufactured ............................................................................................... 2 </p><p>Table 1.3 Energy consumption .................................................................................................. 4 </p><p>Table 1.4 Existing motor specifications...................................................................................... 5 </p><p>Table 2.1: Energy Efficient motor Specifications ........................................................................ 8 </p><p>Table 4.1: Project detail cost ................................................................................................... 13 </p><p>Table 4.2: Sensitivity analysis ................................................................................................. 14 </p></li><li><p>viii </p><p>List of Figure </p><p>Figure 1.1: General Process Flowchart of a Typical Oil Mill...3 </p><p>Lists of Abbreviations </p><p> BEE - Bureau of Energy Efficiency </p><p>DPR - Detailed Project Report </p><p>DSCR - Debt Service Coverage Ratio </p><p>GHG - Green House Gases </p><p>HP - Horse Power </p><p>IRR - Internal Rate of Return </p><p>MSME - Micro Small and Medium Enterprises </p><p>MoP - Ministry of Power </p><p>NPV - Net Present Value </p><p>ROI - Return on Investment </p><p>MoMSME - Ministry of Micro Small and Medium Enterprises </p><p>SIDBI - Small Industrial Development Bank of India </p></li><li><p>ix </p><p>EXECUTIVE SUMMARY </p><p>Confederation of Indian Industry is executing BEE-SME program in Alwar Oil Mill Cluster, </p><p>supported by Bureau of Energy Efficiency (BEE) with an overall objective of improving the </p><p>energy efficiency in cluster units. </p><p>Alwar Oil Mill cluster is one of the largest Oil Mill clusters in India; accordingly this cluster was </p><p>chosen for energy efficiency improvements by implementing energy efficient measures / </p><p>technologies, so as to facilitate maximum replication in other Oil Mill clusters in India. The </p><p>main energy forms used in the cluster units are grid electricity. In Oil Mill plant, electricity bill is </p><p>almost 100% of total plant energy bill. </p><p>Most of the Industrial installations in the country have large electrical loads which are severely </p><p>inductive in nature, such as motors, large machines etc which results in a high power </p><p>consumption. This means loss and wastage of energy by electricity boards as well as for Oil </p><p>Mill units. This can be taken care by Energy Efficient Motors in place of Old / Re-winded </p><p>Motors. </p><p>In any oil mill, Kolhu and Expellers motors are the main energy consumers. During energy </p><p>audit, it was observed that the maximum of such motors are very old and re-winded more </p><p>than 5 times which leads to lower operating efficiency and higher power consumption. </p><p>Operating Efficiency of old motors is in the range of 70 - 85%. </p><p>Installation of new energy efficient motor of 50 HP capacity for existing expeller having </p><p>efficiency more than existing motor would lead to power saving upto 10199 kW per year due </p><p>to improve efficiency. </p><p>The DPR highlights the details of the study conducted for assessing the potential for reducing </p><p>electricity consumption in expeller machine by installing new efficient motor in various units of </p><p>the cluster, possible energy savings and its monetary benefit, availability of the </p><p>technologies/design, local service providers, technical features and proposed equipment </p><p>specifications, various barriers in implementation, environmental aspects, estimated GHG </p><p>reductions, capital cost, financial analysis, and schedule of project Implementation. </p><p>This bankable DPR also found eligible for subsidy scheme of MoMSME for Technology and </p><p>Quality Upgradation Support to Micro, Small and Medium Enterprises under National </p><p>Manufacturing and Competitiveness Programme. The key indicators of the DPR including the </p><p>Project cost, debt equity ratio, monetary benefit and other necessary parameters are given in </p><p>table below: </p></li><li><p>x </p><p>Sr. No. Particular Unit Value </p><p>1 Project cost (` in Lakh) 1.07 </p><p>2 Electricity Savings kWh/annum 10199 </p><p>3 Monetary ben...</p></li></ul>

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