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Bosch Energy and Building Solutions India
Driving energy efficiency in automotive industry
Case Study

Driving Energy Efficiency in Automotive Industry

Our customized energy efficiency solutions has helped automotive facilities in realizing cost savings and enabling better resource utilization. Learn more about how we supported Renault-Nissan India in bringing down their energy consumption and carbon footprint

Automotive

One unit of energy saved is equivalent to two units of energy generated – this is the golden rule to achieving energy security. To drive sustainability in a manufacturing facility, the primary focus has to be on how the per unit cost of production can be brought down. Energy efficiency provides a significant opportunity for cost reduction, especially in the automotive industry.

man selling car

Passenger vehicle sales has always served as a tell-tale sign of the rise in disposable income in fast growing economies like India. This is clearly visible from the fact that the automotive industry contributes to over 7% to the GDP of India. The automotive industry in India produced close to 2.5 million passenger vehicles in FY2017. While capacity utilization in most automotive manufacturing facilities are at an all-time high, the operating costs are also continuously increasing, especially energy costs. This is where Bosch Energy and Building Solutions comes in and provides clear commercial benefits to automotive manufacturing facilities, without affecting the production goals.

10%

of the operating costs in automotive industry is attributed to only energy costs.

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The Renault-Nissan Automotive India Pvt. Ltd. plant at Orgadam, Chennai.

With the capacity to produce over 400,000 units per year, the Renault-Nissan Alliance is one of the leading producers of passenger cars in India. The largest Alliance production facility in the world, the Renault-Nissan plant located at Orgadam, Chennai commenced its production in 2010. In 2016, it crossed the significant production milestone of producing its 1 millionth car. The plant produces cars for both domestic and international markets and has emerged as India's second largest car exporter, with exports to over 106 countries. The Renault-Nissan plant is among the top three in India when it comes to efficient manufacturing process in terms of power usage.

Heat pump operating principle

At the Chennai plant, which is known for its world-class powertrain manufacturing facility and tooling, component washing serves as one of the preparatory processes before the Powertrain assembly. The component washing process involves removing oil and muck from the components completely before tempering, using a chemical bath maintained at a constant temperature of close to 55 °C. This bath was operated using thermostatically controlled electric heating system of 4.5kW rating, immersed in tanks of capacity varying from 300 to 650 litres capacity.

The solution proposed by Bosch Energy and Building Solutions substituted the usage of less efficient electrical heaters by implementing an integrated solution. The Integrated Heating and Cooling solution combines energy efficient heat pumps with a custom-designed heat exchanger coil. Heat pumps operate with a higher efficiency compared to conventional electrical heaters, as it operates on the principle of refrigeration cycle. A heat pump can produce over 2 units of thermal output with 1 unit of electricity.

57%

energy cost savings were realized in the component washing process at Renault-Nissan, with the help of the Integrated Heating and Cooling solution from Bosch.

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The core of the solution lies in how the heat exchanger coil is designed. Special care was taken to design the heat exchanger to ensure optimum performance and hassle-free maintenance. The application of heat pumps in the component washing process resulted in the dual benefit of constantly maintaining the chemical bath temperature at the required levels as well as cooling the surroundings. After the implementation of the solution, the actual savings recorded were highly impressive. Owing to the reduction in electricity consumption, the solution helped Renault-Nissan Automotive India in lowering CO2 emissions by 50% and reducing greenhouse gas emissions as well.

“Bosch Energy and Building Solutions has not just met but exceeded the committed energy efficiency standards initially agreed with us for the solution. For this, we deeply appreciate the hard work and commitment put in by the entire Bosch Energy team throughout the project which made this possible.”

Jeyasinghraj I., Vice President Powertrain Renault-Nissan India
Integrated heating and cooling solution can be customized to several automotive processes

Over and above providing substantial energy savings, the solution is also instrumental in freeing up capacity of thermal utilities by bringing down the load factor. Freed up capacity enables better resource planning and brings down the need for fresh investment in utilities in case of plant expansion. The Integrated Heating and Cooling solution can be implemented for several thermal process applications in the automotive industry like paint shop and LPG vaporizers. Renault-Nissan is presently looking at extending the solution to other sections of the plant, and also other areas for realizing substantial energy savings.

Bosch customizes the design of the solution based on a detailed understanding of the processes and the production goals of the automotive facility. The design of the solution is verified and vetted with the help of detailed simulations taken up by the expert design and engineering team at Bosch. Moreover, the solution implementation is planned and executed without interrupting the regular operations of the facility. With this systematic approach, Bosch Energy and Building Solutions partners with the automotive industry to derive true commercial value and drive sustainability.

CII award energy efficiency circle
The Bosch Energy Efficiency team receiving the winners’ trophy at the Confederation of Indian Industry’s National Energy Efficiency Circle Competition 2017

Bosch Energy and Building Solutions was awarded the winner's trophy at the prestigious National Energy Efficiency Circle Competition 2017 (organized by the Confederation of Indian Industry) for the innovative solution implemented at Renault-Nissan India. The award is a special recognition of the uniqueness and savings potential of the Integrated Heating and Cooling solution, owing to the detailed design and implementation methodology.

Customized solutions for automotive industry

There is immense potential in the automotive industry to achieve substantial energy savings with the help of customized energy efficiency solutions. These solutions are designed to meet the technical needs of facilities while lowering operating costs - resulting in attractive payback periods.