ENERGY CONSERVATION &

RENEWABLE ENERGYRENEWABLE ENERGY

An OMAX case study

Overview

� Amongst top three companies in Automotive Stamping and two wheeler & Commercial vehicle Chassis manufacturing-(Process 85k Tons Steel pa)

� Largest Sprocket manufacturing capacity (11 Million pa) in South East Asia.

Facilities

� Largest Tri Nickel Chrome Plating facility (120 Million DM2)

� Largest & full spectrum welding facility in India with robots & 800 MIG welding sets (100 Km welding capacity per day)

� Largest consolidated Piston Rod manufacturing facility with super finishing capability catering to Europe & United States.

� Designing

� Automotive Stampings

� Two Wheel & Commercial Vehicle Chassis manufacturing

ONE STOP SOLUTION:

Process Capability � Machined Parts – Sprockets/ Piston Rods/ Oil Pumps/

Transmission Shafts

� Full spectrum welding process- Robotic MIG, spot and friction

� Powder Coating & Liquid Painting

� Zn Plating, Tri Nickel Chrome Painting & Hard Chrome Plating

– To protect Earth– To reduce costs and be competitive– To survive power and fuel unavailability and cost increase

Why conserve Energy?

15

20

25

30

35

NG Price

17% 61%

30

40

50

HSD Price

9% 25%

0

5

10

15

FY 10-11 FY 11-12 FY 12-13

Till Nov'12

17%

0

10

20

FY 10-11 FY 11-12 FY 12-13

Till Nov'12

0

1

2

3

4

5

6

7

FY 10-11 FY 11-12 FY 12-13…

Grid Power

13% 38%

Why conserve energy?

FY 08-09 FY 09-10 FY 10-11 FY 11-12 FY 12-13…

Actual

If unattended

Power & Fuel Cost Power & Fuel Cost would be

almost double!!

FY 08-09 FY 09-10 FY 10-11 FY 11-12 FY 12-13…

0

2

4

6

8

10

12

14

Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12

Daily Average Power Cut Hours

Daily Average Power

Cut Hours

~ 6 hrs of power cut

everyday (25%)

Energy Saving Strategy

PHASE I

Reduce Energy

PHASE II

Reduce Energy

PHASE III

Move towards Renewable

Energy Conservation Strategy

Reduce Energy Consumption

Energy Audits and Optimization

Waste Heat RecoveryFuel Saver Devices

Monitoring and Management

Reduce Energy Cost

Reduction in Contract Demand

Power TradingCheaper Alternate

Fuels (Pet coke, Rice

husk, briquettesetc.)

Renewable Energy

Rooftop Solar

Future Plan1 MW Rooftop Solar for

Captive Power

Power Factor• P is the Active power (kW)

• S is the apparent power (kVA)

• Q is the reactive power

• Reactive power is necessary to generate the magnetic

field needed to run certain types of loads like lighting,

induction motors, electric furnacesinduction motors, electric furnaces

• But it also tends to increase the difference between P

and S.

If PF is not close to 1, we will be paying for more power than we actually use.

Dharuhera 0.99

Speedomax 0.98

Binola 0.99

Manesar 0.99

Conventional vs Waste Heat Recovery

Exhaust

Exhaust

Steam generation

Air Conditioning

HRU

DG SET

Cooling Tower

FUEL

Jacket Water

DG SETFUEL

Jacket WaterAir

Conditioning

Waste Heat Recovery at OMAX

• Omax Dharuhera :

• 1.5 MW Gas Genset

• HRU installed

• Replaces Hot water generator at powder coating facility

• 400 SCM/day savings in PNG

• ~Rs. 2.5 Lac/month savings

• Omax Manesar:

• 1.5 MW Gas Genset

• HRU under planning

• Exhaust heat will be used to heat ovens at powder coating

• Jacket water heat will be used for Air conditioning using VAM

HAREDA provides subsidy for waste heat recovery projects.

Both the above projects have been selected

Fuel Saving Techniques

Catalytic Fuel Saver device

• Installed at the diesel line inlet of DG, burners

• Simple catalytic device

• Results in savings of about 6 - 9% in fuel consumption

Diesel Additive

• 250 ml of additive for every 1000 ltr of Diesel

• Improves the fuel properties

• Results in savings of 5 -10%

• Modular type IGBT rectifier to replace old

technology rectifiers in Electroplating

• Approx 20% higher efficiency

• Easy to maintain and upgrade

Technology Upgrade

• Innovative method to utilize Sun’s visible light indoors

• No heat addition

• project in process

Innovative Day-lighting system

WATERLESS URINAL

• Water and Energy are inter linked

• Saving water saves energy and reduces cost

• Savings by means of reduction in:

• Pumping power

• Treatment cost

Omax Renewable Energy• 2 x 100 kWp rooftop solar power plants have been installed for captive use

• 2 x 1.25 MW Grid Connected, Wind Turbine Generators have been commissioned at Jaisalmer, Rajasthan in 2012.

• Further 1 MW Rooftop Solar has been planned in FY 13-14 for captive use across our manufacturing units.

Omax Renewable Energy

200 kWp

2.5 MW

Mega Watt scale Solar Projects

• Omax is venturing into the Solar EPC sector

• Installation of MW scale rooftop Solar Power Plants for

Captive use

• Easy to adapt financial model

CLEAN ENERGY GREEN ENERGY

• Long term hedging against power cost increase

• Added benefits through Renewable Energy Certificates (REC).

Gallery

SOLAR 100 kWp SOLAR 100 kWp

LED

HRU

FUEL SAVER

LED

Gallery

Powerless exhaust

VFD on compressors

Servo Voltage Stabilizer

Timers

NEED OF THE HOUR

ACTION!!

Thank you!!

Save Energy Save Earth