Project Description: 50.4 kWthermal SWHS with 72 m2 flat plate collectors and 5000 litre water storage tank for space heating purposes at a refrigerator manufacturing unit of Godrej & Boyce, Mohali, Punjab
General Information on the company using solar thermal energy
Description of the company
Godrej & Boyce Mfg. Co. Ltd., is the holding company of the Godrej Group, started with the manufacture of high quality locks in 1897. Presently, they have 15 diverse business divisions offering consumer, office, and industrial products and services of the highest quality to every corner of India and across the globe. This plant is situated in Mohali and is manufacturing refrigerators of different capacities.
Type of Industry
Metal Manufacturing Unit
Location of the company and the solar plant
The solar system is installed at the location of:
M/s Godrej & Boyce Manufacturing Company Ltd
Plot No. A-40, Phase 8A
Industrial Area, Mohali
Heat demanding processes
The heat demand required for the plant on an average is for 8 hours. The heat generated by the solar system is used for performing certain quality assurance tests like Pull down test, Ice Making test, Compressor overload test and Voltage stability test at 440°C.
Conventional heat supply
12 Infrared Light bulbs each of 250 watts were used for maintaining the ambient temperature of Quality Assurance room at 440 C. The system is used for heating 4 such rooms.
Conventional fuel used
No Fuel; Electricity was used for generating the required heat.
Motivation to use solar thermal energy
To decrease the cost in manufacturing process.
Description of the solar thermal system
Type of solar plant
It’s an FPC based Industrial Solar Water Heating System with a storage tank of capacity 5000 litre. The system is generating the hot water which is used for generating heat for performing Quality tests on the manufactured products.
Year of installation
The SWHS was commissioned in January 2014.
Solar collector field
The SWH System has 36 FPC collectors with a total collector area of 72 m2 (@ 2 m2 per collector).
Collector arrays are connected to a water storage tanks with a volume of 5000 litre.
The system is a closed loop system with a radiator.
Operation of the system
Water from the storage tank of 5000 litre capacity is recirculated using pump of 0.5 horse power (HP) capacity into the Flat Plate collectors where it gets heated and attains a temperature of 650 C. This water is then allowed to pass through a radiator with a fan attached to it which supplies hot air into the room. The required temperature in the room is 440 C. At this temperature several load tests are performed on the manufactured product (refrigerator).
Supplier/ manufacturer of the solar system
The solar system was designed, delivered and commissioned by:
M/s Akson Solar
42/1, Sahajanand Society
Gandhi Bhawan, Kothrud
The plant is not maintaining any log books/ data.
Energy balance and economy
The heat requirement in one room is on an average of 24 kWh per day (250 Watt X 12 X 8 hours) and 8760 kWh per year (considering 365 days of plant operation per year). Since there are 4 such rooms the total heat requirement is 96kWh per day and 35 MWh annually.
Solar radiation-on site
The site receives an average annual solar insolation of 5.44 kWh/m2/day which means 1985 kWh/m2/year on horizontal surface. On collectors with an inclination of 30° the irradiation is about 1.13 * 1985 kWh/(m2*year) = 2,243 kWh/(m2*year).
Location: Longitude: 76.69 E & Latitude: 30.78 N
Source: NASA Surface meteorology and Meteonorm
Useful solar energy delivery
The solar radiation on the collector surface is
72 m2 * 2243 kWh/(m2*year) = 160 MWh/year.
Assuming a system efficiency of about 20%, the useful solar energy is about 160 MWh/year * 0.2 = 32 MWh/year, which corresponds to 88 kWh/day.
The useful solar energy delivered by the SWHS per m2 of collector is: 1.22 kWh/m2/day.
Electricity saved by solar energy
The unit is saving around 88 units of power per day after implementation of this project. Assuming per unit of power is costing Rs 6 and the plant is running for 365 days, the net savings of the unit is Rs 192,720 per year.
Around 31.36 tonne of CO2 are saved over a year period.
(Considering 32MWh of grid electricity substituted and taking Grid emission factor of 0.98 t CO2/MWh for India, refer here)
The project is commissioned with an overall investment of Rs.11 lakhs, corresponding to Rs 15,277 per m2 of collector area.
No subsidy is taken from Government or MNRE.
Economics of the solar system
The simple payback period is around 5.5 years without MNRE grant.
Operation of the system is good.
Statement of the owner
Owner is satisfied about the operation and savings due to implementation of Solar Water Heating System.
Statement of the supplier/manufacturer
Supplier expressed his satisfaction about the operation of the system.