# Which Bureau of Energy Efficiency Muzaffarnagar paper mill report saves most electricity: a bigger boiler fan, a bigger feed water pump or the process pumps?

Canonical: https://senseible.earth/answers/muzaffarnagar-paper-mill-fan-and-pump-reports-compared

In five Bureau of Energy Efficiency (BEE) Muzaffarnagar reports, the larger boiler fan saves less than the smaller one, 35.61 against 36.83 kilowatts, because it already runs at 42 percent efficiency, not 35. The larger feed water pump saves more, 84 against 50, because it draws more power. Size does not decide the saving.

## The five reports side by side

- Boiler fan, 5 cubic metres a second: cost rupees (Rs) 8.18 lakh, efficiency 35 up to 78 percent, 66.81 down to 29.98 kilowatts (kW), saving 36.83 kW, 294,649 kilowatt hours (kWh) a year, Rs 11.52 lakh, payback 0.71 years.
- Boiler fan, 7 cubic metres a second: Rs 8.18 lakh, 42 up to 82 percent, 73 down to 37.39 kW, saving 35.61 kW, 284,878 kWh, Rs 11.14 lakh, 0.73 years.
- Boiler feed water pump, 40 cubic metres an hour: Rs 19.85 lakh, 44 up to 68 percent, 142 down to 91.88 kW, saving about 50 kW, 400,941 kWh, Rs 15.68 lakh, 1.27 years.
- Boiler feed water pump, 60 cubic metres an hour: Rs 23.70 lakh, 46 up to 68 percent, 261 down to 176.56 kW, saving about 84 kW, 675,529 kWh, Rs 26.41 lakh, 0.90 years.
- Process pumps, five pumps together: Rs 6.74 lakh, saving 24.95, 20.60, 9.86, 8.83 and 11.30 kW, 75.54 kW in all, 604,310 kWh, Rs 23.63 lakh, 0.29 years. The five run at 18.76, 59.13, 60.31, 47.20 and 19.76 percent efficiency and would move to 77.07, 83.46, 77.23, 76.61 and 60.
- All use 8,000 hours a year and Rs 3.91 a kWh.

## Why size does not decide

Each saving is the present power times one minus present efficiency over new efficiency. Fan 1: 66.81 x (1 minus 35/78) = 36.83 kW. Fan 2: 73 x (1 minus 42/82) = 35.61 kW. The bigger fan is already better, so it has less to gain, and both fans cost the same. For the pumps, 142 x (1 minus 44/68) = 50.1 kW and 261 x (1 minus 46/68) = 84.4 kW. The 60 cubic metre pump draws 1.8 times the power of the 40, so it saves 1.7 times as much.

Each efficiency comes from one audit measurement of flow, pressure and power, and the new efficiency is the maker's quotation. Your own machine's reading decides the saving, not the size on the name plate.

## Where the reports slip

- The 7 cubic metre fan's operating table prints its flow of 6.34 in cubic metres an hour. It can only be cubic metres a second, as in the 5 cubic metre report, whose measured flow is 4.71.
- The process pump annexure labels 6.74 as the total monetary saving and 23.63 as the total investment. The cost table and payback show it the other way round, 6.74 invested for 23.63 saved a year.
- The process pump audit table and the saving table print slightly different present efficiencies, for example 18.76 and 18.83 percent for the first pump and 59.13 and 59.33 for the second. The saving table is the one the totals use.
- The two feed pumps were measured below their rating, 35 against 40 and 44.9 against 60 cubic metres an hour. The reports do not say how the new pumps are sized for those flows, so check that with the supplier.

## Seeing it on the bill

A single fan or pump is a small part of a mill's electricity. The bill shows the whole site, so a saving of 36 kW is hard to pick out of it. Log the kW of that machine before and after with a clamp meter or a sub-meter if a lender or buyer asks for proof.

## The 5 cubic metre fan, rebuilt from the report

- Present: 66.81 kW at 35 percent efficiency. New: 66.81 x 35 / 78 = 29.98 kW
- Saving: 66.81 minus 29.98 = 36.83 kW. Over 8,000 hours: 36.83 x 8,000 = 294,640 kWh (printed 294,649)
- Money: 294,649 x Rs 3.91 = Rs 11.52 lakh. Payback: 8.18 / 11.52 = 0.71 years

All inputs are the report's own figures. Any difference in the last digits is rounding of the kW.

## What Senseible does here

Senseible reads fuel invoices and electricity bills into monthly records, so a year of site electricity before a change can be compared once uploaded. Bills show site electricity, not one machine's, so the fan or pump saving needs its own meter reading.

- [Muzaffarnagar paper mills: steam and power per tonne](https://senseible.earth/answers/muzaffarnagar-paper-mills-steam-power-benchmark)
- [Kraft paper mill boiler fuel in Muzaffarnagar](https://senseible.earth/answers/muzaffarnagar-kraft-paper-mill-boiler-fuel)
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- [Free calculators](https://senseible.earth/calculators)

Sources: [BEE, Detailed project report: energy efficient boiler fan 5 cubic metres a second, Muzaffarnagar paper cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Muzaffernagar_paper_cluster/Energy_efficient_boiler_fan_5M3per_sec_Muzaffarnagar.pdf), [BEE, Detailed project report: energy efficient boiler fan 7 cubic metres a second, Muzaffarnagar paper cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Muzaffernagar_paper_cluster/Energy_efficient_boiler_fan_7M3per_sec_Muzaffarnagar.pdf), [BEE, Detailed project report: boiler feed water pump 40 cubic metres an hour, Muzaffarnagar paper cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Muzaffernagar_paper_cluster/EE_boiler_feed_water_pump_40M3per_hr_Muzaffarnagar.pdf), [BEE, Detailed project report: boiler feed water pump 60 cubic metres an hour, Muzaffarnagar paper cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Muzaffernagar_paper_cluster/E_e_boiler_feed_water_pump_60M3per_hr_Muzaffarnagar.pdf), [BEE, Detailed project report: energy efficient process pumps, Muzaffarnagar paper cluster (SAMEEEKSHA)](https://sameeeksha.org/pdf/dpr/Muzaffernagar_paper_cluster/Energy_efficient_process_pumps_Muzaffarnagar.pdf)

Last reviewed 2026-11-05. Report figures are from BEE's Small and Medium Enterprises (SME) programme project reports, at the report year's tariff of Rs 3.91 a kWh. Check your tariff, your own measured kW and a current quote before you rely on the payback.