How many kilowatt hours of electricity per kilogram of product do the Bureau of Energy Efficiency Vapi reports give for a typical dye unit?

Question

Accepted Answer

The Bureau of Energy Efficiency (BEE) Vapi reports describe four different typical units that use 0.16 to 3.86 kilowatt hours (kWh) of electricity for each kilogram of product. Two reports print 0.94 and the gasifier reports 0.16 and 0.54. The 400 kilogram boiler report prints none; our division gives 3.86. Electricity per kilogram is your year of power in kilowatt hours divided by the kilograms you made. A kilowatt hour is what a one kilowatt heater uses in an hour. The number tells you how power-hungry each kilogram of dye is to make, so a big unit and a small one can be compared. Hot air generator and 600 kilogram boiler reports: 567,795 kWh, 505 tonnes of wood and 603,000 kilograms of product. 567,795 / 603,000 = 0.94 kWh a kilogram, printed as 0.94. Wood 0.83 kilograms a kilogram, as printed. 400 kilogram boiler report: 308,621 kWh, 135 tonnes of wood and 80,000 kilograms. The report prints no per-kilogram line. 308,621 / 80,000 = 3.86 kWh a kilogram (our division), and wood 1.68, as printed in the wood table. 4 lakh (400,000) kilocalorie gasifier report: 98,844 kWh and 31,500 kilograms of fuel. On its 600,000 kilograms of product that is 0.16 kWh and 0.05 kilograms, as printed. 5 lakh (500,000) kilocalorie gasifier report: 32,640 kWh and 28,290 kilograms on 60,000 kilograms. 32,640 / 60,000 = 0.54 kWh, and 0.47 kilograms, as printed. All five reports put energy at 8 to 10% of manufacturing cost. The hot air generator and boiler reports say heat is 42% of that energy cost and electricity the rest. The two gasifier reports say heat is 88%. Our reading: the units behind them run more oil-fired heat and less power, in line with their 0.16 and 0.54 kWh a kilogram, but the reports do not say. A 24-fold spread between the lowest printed figure and our own 3.86 may come from product mix, or from a slip in the 308,621 kWh. Compare with a unit making the same product. Your bills give the top of the sum. Product made in the same months gives the bottom. Use whole months, not a part of a month. General advice, not from the reports: if you are far above a similar unit, look at motors running unloaded, blowers and fans before you look at the meter.

How many kilowatt hours of electricity per kilogram of product do the Bureau of Energy Efficiency Vapi reports give for a typical dye unit?

What this number means, in plain words

The four typical units

Thermal share of the energy bill

What to take from it

An example unit (not from the reports)

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