ENERGY CONSERVATION IN COMPRESSED AIR SYSTEMS BEE KNOWLEDGE EXCHANGE PLATFORM PULP & PAPER SECTOR 21 st August, 2015 New Delhi
ATLAS COPCO THE LEADER IN COMPRESSED AIR SYSTEMS 2014 Overall Energy Efficiency Excellence 2 Over a century of innovation in energy saving features
3 ATLAS COPCO INDIA INDIA 2,500 Employees Atlas Copco (India) Ltd. - Incorporated in the year 1960. Manufacturing facilities at Pune and Nasik Sales and service offices spread all over the country. ISO 9001 and 14001 multisite approval Chandigarh Gurgaon Udaipur Ahmedabad Ranchi Baroda Kolkata Nashik Nagpur Mumbai Pune Hyderabad Bangalore Chennai April 17, 2014 Atlas Copco Group Presentation
WHY IS ENERGY IMPORTANT IN COMPRESSED AIR SYSTEMS? From operating cost point of view : compressor room is one of the largest electricity user therefore is priority equipment 5 to 15% 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 4 For a plant capacity of 800 TPD, by 10% reduction in Power Consumption Savings will be INR 1 Cr every year
SUSTAINABILITY It has been estimated that by 2020 paper mills will produce almost 500,000,000 tons of paper and paperboard per year, so great efforts are needed to ensure that the environment is protected We should all do our best Reduce Power Consumption in Compressed Air Systems by 20%
ENERGY SAVINGS - AGENDA Blower Technology Energy Recovery CAS Audit Energy Savings Optimization Core Technology Efficient Air Treatment Drive Technology
INEFFICIENT COMPRESSED AIR SYSTEM Typical installation of compressed air system production Main Improvement areas : Turbo/Fixed Speed Screw Pressure Drop of 1.5 Bar Adsorption dryer Pre-filter Fine filter Unwanted Blow-offs in centrifugal machines No VFDs in Screw Compressors No Energy Recovery Turbo/Fixed Speed Screw Pre-filter Adsorption dryer Fine filter Purge-type Twin Tower Adsorption dryers No Central control system Turbo/Fixed Speed Screw Adsorption dryer Roots-type Low Pressure Blowers Pre-filter Fine filter Specific Energy Requirement is to the tune of 0.192 KW / m3/hr
ENERGY EFFICIENT INNOVATIVE SOLUTION Central controller Main innovative solutions: Combination technology Oil-free Screw with Integrated Variable Speed Drive Fixed-Speed Centrifugal for the base load Turbo 0% losses adsorption dryer Heat-of-compression Dryers with ZERO purge losses Energy Saving Central control system Oil-free screw FS 0% losses adsorption dryer Remote Monitoring Energy Recovery system Energy Recovery Oil-free screw VSD 0% losses adsorption dryer Total energy savings upto 20%, SER can be reduced to 0.154 KW / m3/hr
LOW PRESSURE OIL-FREE SCREW BLOWERS
Screw blower product efficiency comparison 10 30 to 40 % more energy efficient
MAXIMUM SAVINGS POSSIBLE Compressed Air usually represents 5-15% of a typical Pulp & Paper industry s electricity consumption Energy Savings possible for a 800 TPD plant (example): Installing Combination compressors : Centrifugal/Oil-Free Screw + Oil-Free Screw VSD : 25,20,000 KWH HOC Rotary Drum-type Dryers : 20,00,000 KWH Energy Recovery from Oil Free Screw compressors : 33,60,000 KWH Central Controllers for optimum pressure generation : 8,82,000 KHW Equivalent to 2.35 Lakh Trees growing for 1 year Screw Blowers : 100,000 KWH Total Savings : 90,00,000 KWH per Year Equivalent to 4,700 Tons of CO2 11
INCENTIVE SCHEMES FOR ENERGY EFFICIENCY Example : USA
Example : USA
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.
CONTACTS Atlas Copco, North Zone : Abhishek Dubey, Zonal Manager : abhishek.dubey@in.atlascopco.com Mob : 9643009775 Atlas Copco, West Zone : Mahesh Thakar, Zonal Manager : mahesh.thakar@in.atlascopco.com Mob : 9327687540 Atlas Copco, East Zone : Sourav Chaudhury, Zonal Manager : sourav.chaudhury@in.atlascopco.com Mob : 9331888237 Atlas Copco, South Zone : KVS Nagendra, Zonal Manager : nagendra@in.atlascopco.com Mob : 9380572236 Atlas Copco HO Pune : Arnab Maitra, Key Account Manager-India : arnab.maitra@in.atlascopco.com Mob : 9730756783
COMMITTED TO SUSTAINABLE PRODUCTIVITY.