INNOVATIVE SCHEMES for ENERGY SAVING in COMPRESSED AIR GENERATION Som Derashri Managing Director, SyGuru Innovators Pvt. Ltd. (PAT ACCREDITED FIRM BEE) ISO9001:2015 Alkapuri, Baroda 390007 info@syguruace.com, 09824079910
CONVENTIONAL COMPRESSED AIR SYSTEMS Atmospheric Air Air Compressor 7 bar 95-120 o C 85% Loss in Heat After Cooler Air/CW Air / CW Comp AIR has only 15% Energy of input Power Refrigerant Dryer Timer based regeneration Desiccant Desiccant 10 o C Pr. Dew Point To Process Process air receiver Only 85% Compressed Air fed to Dryer To Instrument Air receiver ~15% Dry Comp Air Lost to Atmosphere for regeneration
COMPRESSED AIR LIFE CYCLE COST
COMPESSOR SELECTION- CHECK RETROFIT POSSIBILITY While its only gear train change in Atlas Capco costing a few thousands, The kaeser insists on changing the complete screw end & costs more.
IMPACT OF INLET AIR TEMPERATURE REDUCTION ON AIR DENSITY THE POWER SAVING IS PROPORTIONAL TO DENSITY INCREASE AS COMPRESSORS ARE VOLUMETRIC COMPRESSON MACHINES. MORE DENSITY...MORE MASS FOR SAME VOLUME PER UNIT TIME. Intake Cool Air & Exhaust low grade Hot Air from Enclosure (Motor cooling & Radiation heat) Outside
Question Why -40 C Dew Point is needed? Establish Optimum Dew Point Understand Pressure & Atmospheric Dew Point: +10 C at 7 bar (Pr. Dew pt.) is almost equal to -20 C Dew Pt. @ Atmospheric Pressure
Sankey Diagram - ENERGY BALANCE Item 3 & 5 (72+13 =85%) is high grade heat that can be usefully Exploited! * VAM (Hot Water 90/80 C) to give 7/12 chilled water * BFW/PROCESS HOT WATER (Heating from 30 to 60 C) to preheat make up water
0 LOSS ENERGY N COMPRESSED AIR SYSTEM Receiver Tank Plate-Type HE by-pass if atm is cooler than 10 C Air Pre- Cooler CW CHW return CW make up 80% Heat recovery CHW supply Lubricated Air Compressor 7 bar Hot water VAM 90 o C Heat Recovery To ETP 80 o C Water CW After Cooler BFW 60 C To BFW/PROCESS CHW Supply 6 C Spent Air from Regenerating Tower CHW based dryer CHW to process 10 o C Pr. Dew Pt Process Air Receiver Desiccant Dew Point based switching Desiccant HP Inlet Discharge Instrument Air Receiver LP Suction
HEAT RECOVERY VAM & ZERO LOSS DRYERS COST ECONOMICS EFFICIENCY IMPROVEMENTS PRE COOL SUCTION AIR ~ 7% AIR DRYER USING VAM-CHW! 1% RECYCLING SPENT DRY AIR TO RECEIVER ~ 15% CHILLED CONDENSATE HEAT RECOVERY ~0.1 % NON CONTAMINATED CONDENSATE TO COOLING TOWER ~ 0.1% PLC CONTROL - INLET AIR TEMP & DEW Pt. BASED REGENERATION ~ 0.1-5% OPERATING MODE : UNLOAD to START/STOP ~ 0.1-5% FILTER dp OPTIMISATION 0.1-1% PAYBACK PERIOD = 10 to 18 MONTHS
SUMMARY OF ENERGY SAVING SCHEMES SELECT OPTIMUM PRESSURE RATING OF COMPRESSOR - NEEDED (NOT DESIRED) RETROFIT POSSIBLE PRE-COOLING AIR FROM 40 O C TO SAY 20 O C 6.7% ENERGY SAVING: Heat Recovery 85% POSSIBLE: GENERATE HOT WATER (90/80 C) FOR HEATING BFW/PROCESS HOT WATER 30-90 C HAVE COMBO OF HOT WATER ( 90/80 C) FOR VAM (6/12 C CHW) + HOT WATER (30-60 C) FOR BFW/PROCESS/CANTEEN. USE CHW (VAM) - COOLING INPUT AIR, REFRIGERATION DRYER, PROCESS COOLING RECYCLE REGENERATION BED WET AIR BACK TO AIR RECEIVER- ZERO LOSS DRYING OPTIMISE DEW POINT WHY -40 C? (DEW POINT SENSED REGENERATION). GRADED COOLING : CW-->CHW-->DESICCANT COLD CONDENSATES TO PRE COOL AIR STREAMS & REDUCE CHILLED WATER USE. Drain out oil contaminated moisture condensed. RECYCLE CONDENSATE FROM SUCTION AIR COOLER & DRY AIR RECEIVER AS MAKE UP TO CT. CHOOSE START/STOP MODE & NOT NO LOAD RUNNING - RUN MOTOR COOLER - PRECOOLED AIR Change from Dual/Quarta to Dynamic mode Ensure low motor winding temp exhaust hot air & pre cool (Evaporative cooling of cooling air) USE ENERGY EFFICIENT FLAT BELT AND PRESSURE SENSED CLOSE LOOP VFD TO IMPROVE SPC - 5%. ENSURE LOW DP ACROSS FILTERS & CLEAN/CHANGE AT OPTIMISED DP POINT.
ACHIEVEMENTS Awarded Legend in Energy at Washington DC, by Ex-US President, Mr. Bill Clinton. Certified Energy Manager International (CEMI), AEE, USA Certified Measurement & Verification Professional (CMVP), EVO, USA Receiving the Prestigious Energy Engineer of the Year 2015, at WEEC, Orlando, FL, USA. AEE Young Professional of the Year 2016 WEEC, Washington DC, USA Best Performance National Award Energy Auditor at SNEMA/SEEM-2017 Best Performance National Awards SEEM-2015- Both as a Certified Energy Auditor & Academy (ACE) as a firm SyGuru Innovators Pvt Ltd. ISO 9001:2015 11
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