BATTERY ENERGY STORAGE SYSTEM (BESS) RACKS AND ENCLOSURES MANUFACTURING PLANT

BATTERY ENERGY STORAGE SYSTEM (BESS) RACKS AND ENCLOSURES MANUFACTURING PLANT

EIRI/EDPR/4858 J.C.3079

OVERVIEWENERGYSTORAGESEGMENT

Overviewofenergystoragetechnologies

Energy storage technologies can be broadly divided into four segments – mechanical, electromechanical, chemical,andthermalstorage.However,onlyafewtechnologiesareavailableonacommercialscaleworldwide. Technologiessuchaspumpedstorageproject(PSP),liquidelectrolytebasedlithiumion,andsodiumionbatteries are available commercially and are being used for different applications.

Considering the intermittent and unpredictable nature of RE technologies, such as solar and wind technologies, efficient and economicalgridoperation isincreasingly becoming oneof thecritical challenges forIndia’spower system. This challenge calls for solutions such as spinning reserves (extra generating capacity which can be activated on decision of the system operator), flexible generation, ancillary services, transmission system augmentation & frequency control, etc.

Pumped Storage Project

PSPisthe mostwidelyusedand commerciallyavailablemeansofenergystoragetechnology inIndia.However, thetotalinstalledcapacityofPSPisminuscule4.7GW(~4.6%oftheexploitablepotential)inthecountry.Asof May-2025, ~10 GW capacity of PSP is under construction and ~67 GW capacity is at various stages of development (DPR concurred by CEA, Under Examination, Under Survey and Investigation).

AspertheupdatedNDC,IndianowstandscommittedtoreduceemissionsintensityofitsGDPby45%by2030, from2005 leveland achieveabout50%cumulativeinstalled electricitycapacity from non-fossilfuel-based energy resources by 2030. This PSPs are likely to play a vital grid-scale storage solution in India for the next 5-7 years led by low cost, large scale, and no reliance on international supply chains.

 COST ESTIMATION

Plant Capacity                            10 Ton/Day 

Land & Building (1Acre)          Rs.2.15  Cr    

Plant & Machinery                       Rs. 2.93 Cr 

Working Capital for 2 Month    Rs. 4.15 Cr 

Total Capital Investment          Rs. 9.95 Cr 

Rate of Return                          17%

Break Even Point                     36%

CONTENTS

INTRODUCTION

OVERVIEWENERGYSTORAGESEGMENT

B.I.S. SPECIFICATION

INDUSTRY OVERVIEW

MANUFACTURING PROCESS

ALUMINIUM

STEEL

STAINLESS STEEL

KEYINDUSTRYREGULATIONSANDPOLICIES

DOCUMENTS REQUIRED FOR LICENSES

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

UTILITIES

M.S. /SS PIPE & TUBE /SHEET MANUFACTURER

MIG ELECTRODE WIRE

SHEET DRAWING MACHINE MANUFACTURER

POWDER COATING EQUIPMENTS MANUFACTURER

GALVANIZIG PLANT MANUFACTURER

SUPPLIERS OF PRECISION MEASURING TOOLS

SHEET BENDING MACHINE MANUFACTURERS

STEEL PRODUCTS MANUFACTURING PLANT & MACHINERY SUPPLIERS

GRINDING AND FINISHING MACHINE

PICKLING CHEMICALS

IR COMPRESSOR MANUFACTURERS

FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS

WEIGHING BREIDGE MANUFACTURER

WEIGHING MACHINES

LABORATORTY EQUIPMENTS MANUFACTURERS

D.G. SET MANUFACTURERS & SUPPLIERS

ELECRICAL GOOD & SWITCH MANUFACTURE

ETP MANUFACTURERES

LATHE MACHINE MANUFACTURERS

PLANT LAYOUT

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

ADDRESSES OF FINANCIAL INSTITUTIONS

ORGANIZATION CHART

IMPLEMENTATION SCHEDULE

PROPOSED IMPLEMENTATION SCHEDULE 12 MONTHS

STEEL PRODUCTS MANUFACTURING CONSULTANT

RAW MATERIAL PHOTOGRAPHS

FINAL PRODUCT PHOTOGRAPHS

PROCESS FLOW CHART

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)