CONSERVATION OF

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

2013-14

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 resources.

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..!