ENERGY IN

AUTOMOBILE
INDUSTRY

SUBMITTED BY:
KESHAV GARG
08814804911

INTRODUCTION
In this Presentation, well get familiar with the ways to improve the existing
technologies with the help of proposed technologies for conservation of energy.
We will assume the existing systems to be similar for the most of the Indian
Automobile Industries.

AUTOMOBILE PRODUCTION TRENDS WITH NUMBER OF VEHICLES:

CATEGORY

2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

201314

SPECIFIC ENERGY CONSUMPTION

AUTOMOBILE CHASIS
THERMAL ENERGY
CASTING & FORGE
TONNAGE
PAINT SHOP
OTHER EQUIPMENTS LIKE :
- PUMPS
- MOTORS
- COMPRESSORS
- COOLING TOWERS

SCOPE OF SAVINGS

Reducing idling of drive motors by installing TIMERS,

INTERLOCKING, etc on the machines.

Using lower wattage energy efficient lamps for lighting in the plant.
Improving loading of Transformers thereby reduction of losses.
Modify & Improving furnaces for efficient heat utilization in Forge.
Covering more shop areas for natural day-lighting by installing
translucent roof-sheets.
Saving in compressed air energy by regular audits & correction
leakages from 15%-29%.
Ensuring scheduled running of Aqua thermic fluid boilers in paint
shop.
Efficient heat utilization in energy intensive furnaces & equipment by
use of various measures like improving insulation, right-sizing of
chambers, using temperature controllers, etc.

IMPROVE ENERGY EFFICIENCY

1) ENERGY EFFICIENT EQUIPMENT/LIGHTING
ENERGY EFFICIENT MOTORS.
T-5 (CODE OF FLUORESCENT LAMP) LIGHTING FOR OFFICE.
INLET AIR COOLING.
2) EQUIPMENT COMMONIZATION
AIR WASHER PUMP COMMONIZATION
ELIMINATION OF TRANSFORMERS.
3) USE OF ALTERNATE SOURCES OF ENERGY
USE OF SOLAR ENERGY
WATER HEATING
STREET LIGHTS
TRAFFIC LIGHTS

 USE OF WIND ENERGY

WATER HEATING
STREET LIGHTS
TRAFFIC LIGHTS
USE OF NATURAL LIGHTING
OPEN ROOF TOP
OPEN SIDE WALLS
STEAM TURBINE DRIVEN AIR COMPRESSOR FOR BASE LOAD OPERATION.

MAJOR INITIATIVE TOWARDS

REDUCING WATER CONSUMPTION
Controlling of water supply from overhead tanks based on
demand.
Provision of water tanks over toilets.
Replacement of old, choked leaking main header pipes.
Introduction of self-closing taps for wash up taps.
Introduction of timer controlled solenoid valve for quarters
water supply.
Recycling and reusing of water at a rate of 12 lakhs litre per
day.

 REDUCING COMPRESSED AIR CONSUMPTION

Replaced the defective and leaking wheel
valves by ball valves.
Attending of air leaks based on petrol
inspection.
Replaced the dia cleaning point nozzles by
3/16 dia nozzle.
Introduced Air Blow Guns for cleaning points.
Introduction of Screw Compressors with Soft
Starter instead of conventional reciprocating
compressors.

WASTE HEAT RECOVERY

(FOR RUNNING AIR COMPRESSOR)

CONSERVATION OF ENERGY IN VARIOUS

SECTIONS

IGV (INLET GUIDE VANES) FOR CENTRIFUGAL COMPRESSOR

PRESSURE
OPTIMIZATION BY

AIR TEMPERATURE
OPTIMIZATION

AIR PRESSURE
OPTIMIZER

REMOTE CONTROL & MONITORING

OPTIMIZATION OF AIR PRESSURE

THROUGH PRV

AUTO GROUP OPERATION OF

COMPRESSORS

LOCALISED PRESSURE BOOSTERS

LEAKAGE IDENTIFICATION & ELIMINATION

USE OF PROGRAMMABLE VALVES

CFM AIR COMPRESSOR-AUTOMATIC TRANSFER SWITCH (ATS) PANEL

REPLACED WITH SOFT STARTER PANEL

INSTALLATION OF POWER FACTOR CONTROLLERS AT USER &

DISTRIBUTION END IN PLANT

INSTALLATION OF SOFT STARTERS

ON MOTORS OF 5HP & ABOVE

USE OF SPECIAL REFLECTORS IN R&D

METHODOLOGIES
1. FUEL SUBMISSION WITH THERMIC FLUID HEATING
Instead of Liquefied petroleum gas (LPG), Heavy Petroleum Stock (HPS) is to be used
with help of thermic fluid heating in all water/paint drier of all the Paint Shops
EXISTING SYSTEM

2.

PROPOSED SYSTEM

PUMP PERFORMANCES

EXISTING SYSTEM

PROPOSED SYSTEM

3. COOLING TOWERS
EXISTING SYSTEM

PROPOSED SYSTEM

3. OUTSIDE LIGHTING FIXTURE REPLACEMENT

EXISTING SYSTEM

PROPOSED SYSTEM

SAVING AT A GLANCE

By Studying the Proposed System, Capital Investment will be needed in early

setup stages but it will pay back in the mean time. It will also decrease labour
pressure and will add to energy conservation and less exploitation of

CONCLUSION
IN ORDER TO ACHIEVE SUSTAINABLE DEVELOPMENT, IMPROVEMENTS
SHOULD NECESSARILY BE BROUGHT IN CONTEXT TO AUTOMOBILE
INDUSTRIES.
ENERGY CONSERVATION SEEMS TO BE EASY TO SPELL BUT HARD TO ACHIEVE
PRACTICALLY MAYBE NOT TODAY THEN TOMORROW, BUT CHANGES HAS TO
BE BROUGHT.

REFERENCES
NATIONAL PRODUCTIVITY COUNCIL, NEW DELHI
PETROLEUM CONSERVATION RESEARCH ASSOCIATION
ENERGY CONSERVATION INITIATIVES, MARUTI SUZUKI
PASSENGER CAR BUSINESS UNIT, TATA MOTORS
ASHOK LEYLAND
ENERGY AUDITS, MAHINDRA & MAHINDRA LTD. NASHIK PLANT
BEST PRACTICES & SUCCESS STORIES, HERO HONDA MOTORS LTD.
TVS TYRES
SOLTRON INDIA PVT. LTD.
RESOURCE CONSERVATION DEPTT., SONA KOYO STEERING SYSTEMS LTD.

THANK YOU..!