Quick Links: Capital Investment | Operating Costs | Lifecycle Costs | Performance Comparison | Carbon Footprint | Get Guidance
Capital Investment: The Upfront Reality 💰
| System | Equipment / Integration | Installation / Commissioning | Total CAPEX |
|---|---|---|---|
| 500 TR Electric Centrifugal Chiller | Equipment: ₹3.5 - 4.2 cr Cooling tower & auxiliaries: ₹1.3 - 1.7 cr |
₹0.7 - 0.9 cr | ₹5.5 - 6.8 cr |
| 500 TR BROAD Steam VAM Chiller | VAM equipment: ₹3.2 - 3.8 cr Steam integration & auxiliaries: ₹2.2 - 2.7 cr |
₹1.0 - 1.3 cr | ₹6.4 - 7.8 cr |
CAPEX Verdict: Electric chillers cost 15-20% less upfront, but this is only the first chapter of the cost story.
Operating Costs: Where True Economics Emerge 🔥❄️
- Electricity: 1.92 - 2.22 million kWh @ ₹9 / kWh = ₹1.73 - 2.0 cr
- Demand Charges: 950 - 1,050 kVA = ₹45.6 - 50.4 lakhs
- Maintenance: Routine ₹8 - 10 lakhs + Compressor rebuild ₹4 - 6 lakhs
- Total Annual Cost: ₹2.30-2.66 crores
- Steam / Fuel: Waste steam → ₹0; dedicated steam → ₹70 - 90 lakhs
- Auxiliary Electricity: Pumps & controls ₹6 - 8 lakhs
- Maintenance: ₹6 - 8 lakhs
- Total Annual Cost: ₹12-106 lakhs (depending on steam source)
Operating Cost Advantage: VAM saves ₹1.60-2.54 crores annually.
Payback with Waste Heat ♻️
When BROAD VAM chillers utilize waste heat from DG set exhaust, process cooling, boiler economizers, or furnace exhaust, fuel cost approaches zero.Incremental CAPEX: ₹1.0 - 1.5 cr, Annual savings: ₹2.2 - 2.5 cr → Payback: 5 - 8 months ⏱️
20 - Year Lifecycle Cost Comparison 📊
| System | Initial CAPEX | 20 - year OPEX(discounted) | Major Overhauls | Total Lifecycle Cost |
|---|---|---|---|---|
| Electric Centrifugal Chiller | ₹6.0 cr | ₹31.5 cr | ₹2.0 cr(Year 12 rebuild) | ₹39.5 cr |
| BROAD Steam VAM(Waste Heat) | ₹7.0 cr | ₹4.2 cr | ₹1.5 cr | ₹12.7 cr |
Lifecycle Savings: ₹26.8 crores over 20 years ✅
Performance Comparison Beyond Cost ⚡
| Factor | Electric Chiller | BROAD VAM |
|---|---|---|
| COP | 5.0-6.5 | 0.7 - 1.3(thermal) |
| Primary Energy | Electricity | Heat(low - grade) |
| Electricity Use | 0.60-0.65 kW/TR | 0.01-0.02 kW/TR |
| Grid Dependency | 100% | Minimal |
| Refrigerant | HFCs (GWP 675-1,430) | Water(GWP 0) |
| Noise Level | 80-90 dB | 60 - 70 dB |
| Compressor Rebuilds | Every 10-15 yrs | None |
| Uptime | 95-97% | 98 - 99.5 % |
| Operational Life | 15-20 yrs | 20 - 30 yrs |
Carbon Footprint Analysis 🌱
- 500 TR Electric Chiller: 1.92-2.1 million kWh, 1,722 tons CO₂/year
- 500 TR BROAD VAM(Waste Heat): 45,000 kWh auxiliary, 37 tons CO₂/year
- Carbon Reduction: 98% reduction (~1,685 tons CO₂ annually)
Real - World Applications ✅
- Pharma Plant, Gujarat: 600 TR exhaust-fired VAM, ₹2.35 cr savings, payback 1.8 yrs
- Textile Mill, Tirupur: 500 TR hot water VAM, ₹1.82 cr savings, payback 2.1 yrs
- Data Center, Bangalore: 800 TR steam VAM, PUE 1.68→1.38, ₹3.1 cr savings
Discover how BROAD VAM can transform waste heat into cooling, cut costs, and reduce carbon footprint.
