Energy Audit Case Study: Magnum Ventures Ltd - Achieving 29% Energy Savings in Thermal Power Plant Operations
- Dr. Anubhav Gupta
- Jun 14
- 6 min read
How SARK Engineers & Consultants (formerly Ansh Energy Solutions) helped a leading paper manufacturer optimize their 6.6 MW cogeneration power plant for maximum energy efficiency and cost savings
Executive Summary
In the competitive landscape of industrial energy management, power plant efficiency optimization has become crucial for sustainable operations [1]. SARK Engineers & Consultants conducted a comprehensive energy audit of Magnum Ventures Ltd.'s 6.6 MW thermal captive power plant in Shaibabad, Uttar Pradesh, identifying potential annual savings of ₹2.90 crores through strategic energy conservation measures [2].
This case study demonstrates how professional energy auditing services can transform industrial operations, achieving remarkable improvements in boiler efficiency, pump performance, and electrical systems while maintaining production standards [3].
About Magnum Ventures Ltd
Magnum Ventures Ltd stands as one of Northern India's smartest paper manufacturing mills, with an impressive installed capacity of 85,000 TPA [2]. The company specializes in producing:
Cream wove Paper
Maplitho
Copier Paper
Coated Duplex Board
The facility operates from a sprawling 65,000 square meter infrastructure with five lacs square feet of building area in Sahibabad Industrial Area, Ghaziabad [2].
Power Plant Specifications
Parameter | Specification |
Total Capacity | 6.6 MW |
Commissioning | 2004 (4.4 MW), 2008 (expanded to 6.6 MW) |
Boiler Type | Thermax, Bi-drum, Natural Circulation |
Boiler Capacity | 31 TPH |
Turbine Configuration | 4.4 MW Extraction cum Condensing + 2.2 MW Condensing |
Cooling Towers | 2 x Paharpur (1200 m³/hr each) |
Energy Consumption Profile Analysis
The energy audit revealed critical insights into the plant's operational efficiency patterns [2]. Monthly power production averaged 39 lac units, with 33.87 lac units supplied to the paper plant and 4.84 lac units consumed as auxiliary power.
Auxiliary Power Breakdown
Equipment Category | Power Consumption | Percentage |
Water Pumping System | 10,754 kWh/day | 59% |
Boiler Auxiliaries | - | 25% |
Cooling Tower Fans | - | 11% |
Others | - | 5% |
This distribution highlights the significant impact of pumping systems on overall energy consumption, making them a primary target for optimization [1].
Key Audit Findings and Performance Assessment
Boiler Performance Analysis
The boiler efficiency evaluation using indirect heat loss methods revealed an operational efficiency of 80.91% against the design efficiency of 83±2% [2]. This 2-3% efficiency gap presented substantial opportunities for improvement through operational and maintenance interventions.
Critical Loss Components Identified:
Loss Type | Current Performance | Improvement Potential |
Dry Flue Gas Losses | 5.52% | Optimization possible |
Moisture in Fuel | 0.86% | Reducible to 0.20% |
Radiation Losses | 2.2% | Reducible to 1% |
Unburnt Carbon | 0.67% | Optimization possible |
Steam and Power Generation Metrics
Month | Steam Generation (Tons) | Power Generated (kWh) | Heat Rate 4.4MW (Kcal/kg) | Heat Rate 2.2MW (Kcal/kg) |
February | 25,103 | 37,59,000 | 4,780 | 2,980 |
March | 25,283 | 38,54,500 | 4,753 | 2,772 |
April | 24,994 | 38,28,000 | 4,683 | 2,815 |
May | 26,169 | 40,45,000 | 4,638 | 2,846 |
The analysis revealed that steam temperature was consistently below design parameters (445°C vs. 490°C±5°C), directly impacting turbine cycle efficiency [2].
Water Pumping System Efficiency
The comprehensive pump performance analysis uncovered significant inefficiencies across the water circulation systems [3]. Major pumps analyzed included:
Condensate extraction pumps
Boiler feed water pumps
RO/DM water plant pumps
Cooling water circulation pumps
Raw water pumps
Pump Efficiency Assessment:
Pump Type | Design Flow (m³/hr) | Measured Efficiency | Industry Standard |
BFP-1 | 40 | 64.5% | 78-80% |
BFP-2 | 40 | 68.9% | 78-80% |
CT Pump-1 (4.4MW) | 400 | 55.3% | 60-75% |
CT Pump-2 (4.4MW) | 390 | 58.6% | 60-75% |
Cooling Tower Performance Issues
The cooling tower evaluation revealed concerning performance degradation affecting overall plant efficiency [1]:
Parameter | CT-1 Performance | CT-2 Performance | Design Standard |
Range | 7.9°C | 11.6°C | 8°C |
Approach | 10.73°C | 8.8°C | 4°C |
Effectiveness | 42.40% | 56.86% | 66.66% |
Electrical System Analysis
The electrical system audit identified multiple areas requiring attention for optimal performance [3]:
Key Electrical Findings:
Total transformation capacity: 8,500 KVA for 4,300 MW alternator
Overall power factor maintained above 0.93 lagging
Individual feeder power factors below satisfactory levels
Average voltage harmonic distortion: 6.45%
Average current harmonic distortion: 9.3%
Comprehensive Energy Saving Recommendations
Boiler Optimization Strategy
Primary Recommendation: Superheater Modification
Investment Required: ₹25,00,000
Annual Savings: ₹1,56,58,500
Payback Period: 58 days
Upgrading the superheater section to achieve design steam temperature of 490°C±5°C would result in 8 tons daily coal savings and reduce boiler loading by 1.8 TPH [2].
Secondary Measures:
Improvement Area | Investment | Annual Savings | Payback |
Insulation Enhancement | Included above | ₹27,50,000 | Immediate |
Flash Steam Recovery | ₹4,50,000 | ₹2,94,690 | 18.5 months |
Flue Gas Heat Recovery | ₹3,00,000 | ₹19,15,465 | 2 months |
Water Pumping System Upgrades
Replacing inefficient cooling water circulation pumps with energy-efficient alternatives offers substantial benefits [1]:
Pump Replacement Analysis:
Scenario | Annual Energy Savings | Investment | Payback Period |
Case 1: Pump + Motor | 190,895 kWh | ₹2,27,560 | 87 days |
Case 2: Pump Only | 113,880 kWh | ₹2,27,560 | 146 days |
Cooling Tower Fan Optimization
Upgrading to energy-efficient FRP hollow fan blades presents significant energy savings opportunities [3]:
Fan Blade Upgrade Benefits:
Configuration | Energy Savings | Cost per Set | Payback |
Blade + Motor | 52,560 kWh | ₹85,000 | 4 months |
Blade Only | 26,280 kWh | ₹85,000 | 8 months |
Electrical System Improvements
Motor Replacement Program:
The audit identified 12 motors requiring replacement with energy-efficient alternatives [2]:
Total Investment: ₹6,77,700
Annual Energy Savings: 681,959 kWh
Monetary Savings: ₹34,09,797
Payback Period: 3 months
Power Factor Correction:
Installing 750 kVAr capacitors would reduce transmission and distribution losses:
Investment: ₹3,59,950
Annual Savings: ₹36,44,160
Payback: 1.2 months
Overall Investment and Savings Summary
Energy Saving Measure | Annual Savings (₹) | Investment (₹) | Payback (Months) |
Superheater R&M | 1,56,58,500 | 25,00,000 | 2 |
Insulation Improvement | 27,50,000 | Included above | Immediate |
Flash Steam Recovery | 2,94,690 | 4,50,000 | 18.5 |
Flue Gas Heat Recovery | 19,15,465 | 3,00,000 | 2 |
Pump Replacement | 9,54,475 | 5,69,400 | 3-5 |
CT Fan Upgrade | 15,76,800 | 5,10,000 | 4 |
Capacitor Installation | 36,44,160 | 3,60,000 | 1.2 |
Motor Replacement | 34,09,797 | 6,77,700 | 3 |
TOTAL | 2,90,30,412 | 50,25,260 | 2.1 |
Implementation Strategy and Benefits
The comprehensive energy audit conducted by SARK Engineers & Consultants demonstrates the transformative potential of professional energy management services [1]. The recommended measures would achieve:
Quantified Benefits
29% reduction in energy costs through systematic optimization
Overall plant efficiency improvement of 5-8%
Reduced carbon footprint through enhanced fuel efficiency
Enhanced equipment reliability through systematic upgrades
Strategic Implementation Approach
Phase 1: High-impact, low-investment measures (capacitors, motor replacements)
Phase 2: Medium-term improvements (pump and fan upgrades)
Phase 3: Major infrastructure modifications (boiler superheater upgrade)
Why Choose Professional Energy Auditing Services?
This case study exemplifies how specialized energy audit services can unlock substantial value for industrial operations [3]. Professional energy auditors bring:
Advanced diagnostic equipment for precise measurements
Industry expertise in identifying optimization opportunities
Proven methodologies following international standards
Comprehensive analysis covering all energy-consuming systems
Detailed financial modeling for investment decisions
Conclusion: Transforming Industrial Energy Efficiency
The Magnum Ventures energy audit demonstrates that systematic energy management can deliver remarkable results when approached professionally [2]. With a total investment of ₹50.25 lakhs generating annual savings of ₹2.90 crores, the project achieves an outstanding payback period of just 2.1 months [1].
For industrial facilities seeking to optimize their energy performance, this case study provides compelling evidence of the value proposition offered by comprehensive energy auditing services [3]. The combination of technical expertise, systematic analysis, and strategic implementation planning creates a roadmap for sustainable energy management and long-term cost optimization.
Ready to optimize your industrial energy efficiency? Contact SARK Engineers & Consultants for comprehensive energy audit services that deliver measurable results. Our proven methodology and expert team can help identify substantial energy savings opportunities in your facility.
FAQs: Magnum Ventures Ltd. Energy Audit
Q1: What was the main objective of the energy audit at Magnum Ventures Ltd.?
A: The audit aimed to identify and quantify energy-saving opportunities in the 6.6 MW cogeneration thermal captive power plant, focusing on reducing auxiliary power, optimizing fuel consumption, and improving operational efficiency.
Q2: Who conducted the energy audit?
A: The audit was conducted by SARK Engineers & Consultants (formerly Ansh Energy Solutions Pvt. Ltd.), a leading energy efficiency consultancy.
Q3: What were the key findings of the audit?
A: Major findings included a boiler efficiency of 80.91% (below the design target), significant energy consumption by water pumping systems (59% of auxiliary power), and opportunities to improve cooling tower and electrical system performance.
Q4: What energy-saving measures were recommended?
A: Recommendations included superheater modifications, improved insulation, flash steam recovery, pump and motor replacements, cooling tower upgrades, and installation of power factor correction capacitors.
Q5: What is the expected financial impact of implementing the recommendations?
A: The proposed measures could save approximately ₹2.90 crores annually, with a total investment of ₹50.25 lakhs and a payback period of just over 2 months.
Q6: How will these improvements benefit Magnum Ventures Ltd.?
A: Benefits include reduced energy costs (29% savings), improved plant efficiency, lower carbon footprint, and enhanced equipment reliability.
Q7: Why should industries consider a professional energy audit?
A: Professional audits provide actionable insights, uncover hidden inefficiencies, and offer a clear roadmap for sustainable energy management and cost savings.
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