ENERGY CONSERVATION IN COMPRESSED AIR SYSTEMS

Transcription

1 ENERGY CONSERVATION IN COMPRESSED AIR SYSTEMS BEE KNOWLEDGE EXCHANGE PLATFORM TEXTILE SECTOR 28 th November, 2015 Raymond Thane

2 ATLAS COPCO INDIA Established in the year Total employee strength : 2500 Annual Sales : ~ 27 BINR 4 Manufacturing plants Global Engineering Competence Centers at Pune & Bangalore - Provide mechanical engineering and project engineering support Annual Indian production 10,000 Screw compressors & 70 Centrifugal compressors

3 WHY IS ENERGY IMPORTANT IN COMPRESSED AIR SYSTEMS? 34% of energy is consumed in spinning, 23% in weaving, 38% in chemical processing and another 5% for miscellaneous purposes 5 to 20% of total plant electrical consumption in Compressed Air System (CAS) Energy is up to 80% of a compressor s lifecycle cost and 99% of its carbon footprint 80% Energy Maintenance Investment installation 3

4 ENERGY SAVINGS - AGENDA Blower Technology Energy Recovery CAS Audit Energy Savings Optimization Core Technology Efficient Air Treatment Drive Technology

5 INNOVATE TO GROW 8 Bar 20% Saving in Energy Consumption Oil-Injected system 6 Bar To Plant

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8 ENERGY SAVING DRYERS MD DRYERS (Patented Technology) 8 Working principal Heat of compression is used for drying No external energy or purge is required No filtration is required (no loose desiccant) Very low pressure drops Energy savings up to 25 % are possible!

9 Life Cycle Cost 10 Year 15-18% Purge loss 2% Purge loss + Blower & Heater ENERGY SAVING DRYERS Dryer Life Cycle Cost Comparison Initial price Delta compressor price Energy cost Maintenance cost ~ 500,000 Savings (INR 35,000,000/-) Heatless purge Heat regenerated (Blower) (I)MD Dryer type 9 Based upon 1700 l/s (3600 CFM) of air, 8000 hrs per year, 0.07/kWh (INR 5/- kwh)

10 THE ENERGY RECOVERY SYSTEM All energy used to compress air is transformed into heat, usually lost from the system. Laws of thermodynamics the compression elements the oil cooler the intercooler and the aftercooler The unique built-in energy recovery system of the Atlas Copco Z Screw compressor circulates water through all these components to maximize the potential heat recovery and yields hot water at up to 90 C. Recovers Energy up to 90% 10

11 THE ENERGY RECOVERY SYSTEM 11

12 LOW PRESSURE OIL-FREE SCREW BLOWERS

13 SCREW BLOWER PRODUCT EFFICIENCY COMPARISON to 40 % more energy efficient

14 WHO SAVED HOW MUCH NSL Textiles (AP) Segment: Textile Application: Biological Aeration of ETP (Dyeing Unit) Requirement: bar Existing installation : Lobe Blower EL 95 Equipment Offered: ZS 55 G 700 VSD X 2 Nos. 14

15 WHO SAVED HOW MUCH NSL Textiles (AP) Product placement which realized huge savings. Many more ZS references from Erode,TN Savings: ~ INR 3,500, per year & ROI is 1 year 15

16 MAXIMUM SAVINGS POSSIBLE Compressed Air usually represents 5-20% of a typical Textile industry s electricity consumption Energy Savings possible for a 20,000 cfm compressed air requirement plant (example): Installing Combination compressors : Centrifugal/Oil-Free Screw + Oil-Free Screw VSD HOC MD Rotary Drum-type Dryers Energy Recovery from Oil Free Screw compressors Central Controllers for optimum pressure generation Equivalent to 1.7 Lakh Trees growing for 1 year Screw Blowers Total Savings : 5,400,000 KWH per Year Equivalent to 3,000 Tons of CO2 16

17 INCENTIVE SCHEMES FOR ENERGY EFFICIENCY Example : USA

18 BEE PAT / INCENTIVE SCHEME : Proposals : Incentives on Energy Conservation & Efficiency to be extended to all major industries Incentives upon using following features : Air Audit and Leakage reduction Oil Free Screw Compressors with Integrated Variable Speed Drive For high air capacity requirements (above 5000 cfm) : Centrifugal/OFScrew + Oil Free Screw VSD Combination Integrated ZERO-Purge Heat-of-Compression Desiccant Dryer along with Oil Free Screw & Turbo compressors Central Compressor Controllers suitable for combination of Screw & Centrifugal compressors Screw Blowers for Low Pressure Conveying and Waster Water Treatment applications Being the Number 1 in the world (including India), we have been consulted by the Energy Ministries of various countries like USA, France, etc.

19 CONTACTS Atlas Copco, North Zone : Abhishek Dubey, Zonal Manager : abhishek.dubey@in.atlascopco.com Mob : Atlas Copco, West Zone : Mahesh Thakar, Zonal Manager : mahesh.thakar@in.atlascopco.com Mob : Atlas Copco, East Zone : Sourav Chaudhury, Zonal Manager : sourav.chaudhury@in.atlascopco.com Mob : Atlas Copco, South Zone : KVS Nagendra, Zonal Manager : nagendra@in.atlascopco.com Mob : Atlas Copco HO Pune : Arnab Maitra, Key Account Manager-India : arnab.maitra@in.atlascopco.com Mob :

20 COMMITTED TO SUSTAINABLE PRODUCTIVITY.

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