Analysis of Energy Use and Energy Savings: A Case Study of a Condiment Industry in India

Electric motors and boilers lead the industrial components which consume the largest portion of energy in an industry. This study explores the energy audit data of the condiment industry in India. The study mainly focuses on the estimation of the load factor, energy use, energy savings and annual bill savings with payback period of the electric motors of the plant. During the audit, it was found that there were several motors running under loaded conditions despite non-availability of variable speed drives installed in the plant. Therefore, variable speed drives are recommended to be installed to save energy by reducing the motors speed by up to 60%. According to the estimation, about 276 MWh, 551 MWh and 827 MWh electrical energy can be saved for 20%, 40% and 60% speed reduction of the motors using variable speed drives, respectively, where in most of the cases the payback period remains below 1 year. Furthermore, some suggestions are made to improve the poor power factor of running motors by using capacitor banks to save the reactive power. Besides, an estimation of energy saving is performed with a 2-ton capacity boiler. Since, there was no heat recovery system in the boiler; an air-preheater is suggested to be installed at the end of flue gas exhausting path of the boiler with the purpose of saving 68 tons of fuel per annum and having a payback period of 12 months. Moreover, a digital monitoring system, namely, “The Smart Joules” has been proposed to be installed in the plant aiming at saving about 3–5% of total energy per annum and having a payback period of 19 months. Finally, a summarization is made concluding in the fact that about 90 MWh energy and 95 tons of fuel can be saved (excluding motor energy savings) per annum by implementing proposed measures with a payback period of 15 months.