This document discusses Omax's efforts to conserve energy and use renewable energy sources. It outlines Omax's facilities and capabilities, explains why conserving energy is important to reduce costs and protect the environment. It then details Omax's three phase energy conservation strategy, including implementing energy audits, recovering waste heat, installing fuel saver devices, and trading contracts. Omax has also installed rooftop solar power plants and wind turbines. Going forward, it plans to install more rooftop solar and pursue megawatt scale solar projects.

1. ENERGY
CONSERVATION &
RENEWABLE ENERGY
An OMAX case study

5. Overview
Amongst top three companies in Automotive Stamping and two
wheeler & Commercial vehicle Chassis manufacturing-
(Process 85k Tons Steel pa)
Largest Sprocket manufacturing capacity (11 Million pa) in
South East Asia.
Facilities
Largest Tri Nickel Chrome Plating facility (120 Million DM2)
Largest & full spectrum welding facility in India with robots &
800 MIG welding sets (100 Km welding capacity per day)
Largest consolidated Piston Rod manufacturing facility with
super finishing capability catering to Europe & United States.

6. ONE STOP SOLUTION:
Designing
Automotive Stampings
Two Wheel & Commercial Vehicle Chassis manufacturing
Process
Capability
Machined Parts – Sprockets/ Piston Rods/ Oil Pumps/
Transmission Shafts
Full spectrum welding process- Robotic MIG, spot and friction
Powder Coating & Liquid Painting
Zn Plating, Tri Nickel Chrome Painting & Hard Chrome Plating

7. Why conserve Energy?
– To protect Earth
– To reduce costs and be competitive
– To survive power and fuel unavailability and cost increase
HSD Price NG Price
50 35
30
40
25
30 9% 25% 20
17% 61%
20 15
10
10
5
0 0
FY 10-11 FY 11-12 FY 12-13 FY 10-11 FY 11-12 FY 12-13
Till Nov'12 Till Nov'12
Grid Power
7
6
5
13% 38%
4
3
2
1
0
FY 10-11 FY 11-12 FY 12-13…

8. Why conserve energy?
Power & Fuel Cost Power &
Fuel Cost
would be
almost
double!!
Actual
If unattended
FY 08-09 FY 09-10 FY 10-11 FY 11-12 FY 12-13…
Daily Average Power Cut Hours
14
12 ~ 6 hrs of power cut
10
everyday (25%)
8
6
Daily Average Power
4 Cut Hours
2
0
Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12

9. Energy Conservation Strategy
Energy Saving
Strategy
PHASE I PHASE II PHASE III
Move towards
Reduce Energy Reduce Energy
Renewable
Consumption Cost
Energy
Energy Audits and Reduction in
Contract Demand
Optimization Rooftop Solar
Power Trading
Waste Heat Recovery
Cheaper Alternate
Fuel Saver Devices Fuels
Monitoring and (Pet coke, Rice
husk, briquettes Future Plan
Management 1 MW Rooftop Solar for
etc.)
Captive Power

10. Power Factor
• P is the Active power (kW)
• S is the apparent power (kVA)
• Q is the reactive power
• Reactive power is necessary to generate the magnetic
field needed to run certain types of loads like lighting,
induction motors, electric furnaces
• But it also tends to increase the difference between P
and S.
If PF is not close to 1, we will be paying for more power than we actually use.
Dharuhera 0.99
Speedomax 0.98
Binola 0.99
Manesar 0.99

11. Conventional vs Waste Heat Recovery
Exhaust
HRU Steam generation
Air Conditioning
Exhaust
DG SET DG SET
FUEL FUEL
Jacket Water
Jacket Water Air
Conditioning
Cooling Tower

12. Waste Heat Recovery at OMAX
• Omax Dharuhera :
• 1.5 MW Gas Genset
• HRU installed
• Replaces Hot water generator at powder coating facility
• 400 SCM/day savings in PNG
• ~Rs. 2.5 Lac/month savings
• Omax Manesar:
• 1.5 MW Gas Genset
• HRU under planning
• Exhaust heat will be used to heat ovens at powder coating
• Jacket water heat will be used for Air conditioning using VAM
HAREDA provides subsidy for waste heat recovery projects.
Both the above projects have been selected

13. Fuel Saving Techniques
Catalytic Fuel Saver device
• Installed at the diesel line inlet of DG, burners
• Simple catalytic device
• Results in savings of about 6 - 9% in fuel consumption
Diesel Additive
• 250 ml of additive for every 1000 ltr of Diesel
• Improves the fuel properties
• Results in savings of 5 -10%

14. Technology Upgrade
• Modular type IGBT rectifier to replace old
technology rectifiers in Electroplating
• Approx 20% higher efficiency
• Easy to maintain and upgrade
Innovative Day-lighting system
• Innovative method to utilize Sun’s visible light indoors
• No heat addition
• project in process

15. WATERLESS URINAL
• Water and Energy are inter linked
• Saving water saves energy and reduces cost
• Savings by means of reduction in:
• Pumping power
• Treatment cost

16. Omax Renewable Energy
• 2 x 100 kWp rooftop solar power plants have been installed for captive
use
• 2 x 1.25 MW Grid Connected, Wind Turbine Generators have been
commissioned at Jaisalmer, Rajasthan in 2012.
• Further 1 MW Rooftop Solar has been planned in FY 13-14 for captive
use across our manufacturing units.

17. Omax Renewable Energy
2.5 MW
200 kWp

18. Mega Watt scale Solar Projects
• Omax is venturing into the Solar EPC sector
• Installation of MW scale rooftop Solar Power Plants for
Captive use
• Easy to adapt financial model
• Long term hedging against power cost increase
• Added benefits through Renewable Energy Certificates (REC).
CLEAN ENERGY GREEN ENERGY

19. Gallery
SOLAR 100 kWp SOLAR 100 kWp
LED
FUEL SAVER
HRU
LED

20. Gallery
Powerless exhaust
VFD on compressors
Timers
Servo Voltage
Stabilizer

21. NEED OF THE HOUR
ACTION!!
Thank you!!
Save Energy Save Earth