Case Study Detail
Chemical Processing Unit, Ankleshwar
1MW Pure Wind Turbine System
Ankleshwar, India • Chemical & Speciality Processing Industry
System Capacity 1MW Pure Wind
Monthly Bill Offset 60% Offset
Monthly Savings ~₹17.5 Lakhs / mo
Payback Period ~4.0 Years
Facility Overview
Operating in Ankleshwar, India — a prime chemical industrial hub — this facility produces specialty organic intermediates and specialty chemicals. Operating 24/7 continuous reactors, effluent treatment plants (ETP), and cooling chillers, the facility recorded an average baseline electricity utility bill of ₹29.2 Lakhs per month.
The Challenge
- Continuous Chemical Processing: Reaction vessels and cooling chillers require 24/7 unbroken power security to prevent runaway reactions.
- Sensitive to Voltage Fluctuations: Industrial grid trips caused control system resets and expensive batch spoilage.
- Corrosive Industrial Atmosphere: High chemical fumes prohibited rooftop solar mounting due to rapid panel degradation risks.
- High Outage Downtime Costs: Averaged 15 hours of grid outage downtime monthly, risking chemical batch spoilage.
The Solution
OnLoop Energy deployed a 1MW Pure Captive Wind Turbine System with anti-corrosion marine grade coatings, situated outside the plant's corrosive vapor zone.
- 24/7 Wind Power Generation: Direct-drive PMA turbines deliver continuous clean energy around the clock.
- Perimeter Installation: Placed away from plant chemical exhaust vents for maximum structural longevity.
- Grid Synchronized Stability: Advanced power electronics stabilize voltage frequency, protecting sensitive process chillers.
Before vs After Performance
Financial Breakdown & ROI
Turnkey System Investment ~₹8.0 Crores
Annual Tariff Savings ~₹2.10 Crores / year
Estimated Payback Period ~4.0 Years
20-Year Lifetime Savings ~₹42 Crores