Compressed air optimization in glass factories Menno Verbeek - - PowerPoint PPT Presentation

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Compressed air optimization in glass factories Menno Verbeek - - PowerPoint PPT Presentation

Jul 05, 2023 128 likes •408 views

Compressed air optimization in glass factories Menno Verbeek VPInstruments 1 Example project: Food Added Value: Leakage management Maintenance management Compressed air: Cost allocation Measures ~ 4..5 % of global electricity

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Compressed air

  • ptimization in

glass factories

Menno Verbeek VPInstruments

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Example project: Food

Added Value:

  • Leakage management
  • Maintenance management
  • Cost allocation

Measures

  • VPVision with 20 flowmeters
  • Supply and demand side
  • Combined with existing energy

management system ROI: 1 year

Compressed air:

~ 4..5 % of global electricity consumption One of the largest industrial energy savings opportunities

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Why save compressed air

  • 8 to 10 times the cost of Electricity
  • Compressed air is 10% - 30 % of the

electricity bill of an average industrial company

  • Relatively easy to save money ”low

hanging fruit”

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Why is compressed air important

In the glass industry

  • Up to 30% of the electricity bill
  • In container glass crucial for high quality glass

In the US electricity use for forming is glass is estimated to be 105 kWh/t, of which largest part is for compressed air

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Examples of compressed air use

In Glass Industry

  • Production process
  • Forming of containers and specialty glass
  • Lifting of plate glass
  • Cutting, blowing, moving
  • Packaging
  • Conveyors
  • Pneumatic tools
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Compressed air: Where does it all go?

Electricity

Heat 85%

$$$

Leaks Artificial demand Inappropriate use Production

50% wasted 50% Air 15%

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Fact: Compressed Air Energy Costs

Equipment Maintenance Energy More than 75% of the compressor total cost of ownership over 10 years: energy costs.

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Artificial demand Inappropriate use Leaks Production

30% 10% 10% 50%

Compressed air Savings potential

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How to save?

Recovering waste heat Adjustable speed drives Optimize control Overall system design Optimize buffer size Reduce the pressure Reduce air leaks Eliminate pressure loss

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Glass container industry

Savings opportunities

  • Compressor control/ configuration
  • Reducing leakages
  • Pressure reduction/ stabilization
  • Drier /condensate issues
  • Drying low- and high-pressure air
  • Filter management/ maintenance
  • Alternative energy source
  • Other
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Glass container industry

Challenges with any project:

  • Different stakeholders
  • Capex/ Opex budget separated
  • Changing behavior
  • Internal Politics
  • Capacity (maintenance crew)
  • Budget / ROI
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Drain management

  • The low hanging fruit
  • A form of leakage and a quality issue
  • Often neglected or dealt with in a wrong

way

  • ROI 3…6 months when properly

implemented

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Filter management

  • Inlet filters of Centrifugal machines
  • Decrease of inlet pressure: decrease
  • f output flow & decrease of

efficiency for same discharge pressure.

  • Beware out environment: dusty

roads, trucks etc: Intake location & conditions.

  • Downstream filters
  • Proper sizing
  • Preventive maintenance
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Replace compressed air

  • Alternatives for cooling of molds
  • Blowers
  • Nozzles
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Glass container industry

  • High- and low-pressure compressors

1.5 to >2 Megawatt in total

  • Multiple compressor rooms in one plant
  • Blowers for furnace and for cooling

purposes

  • Vacuum pumps
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Measure to Discover and Save

Why measure & monitor?

  • Predictive maintenance (condition monitoring, leakage)
  • Make founded investment decisions based on consumption

data & costs

  • Monitoring efficiency of compressors and production

equipment

  • Know your baseline
  • ISO 50001 compliance
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Measure to Discover and Save

Power

  • Correlation with electricity bill

4-in-1 flow meters: flow, pressure, temperature, total flow

  • Flow consumption
  • Pressure and temperature level
  • Total flow

Dew point sensors:

  • Safeguard your equipment and production process

Monitoring systems

  • Combine all data in one system with alarms and reports
  • Permanent monitoring is key to energy savings
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Where to start?

Efficiency monitoring Air audits/ Leakage management Cost allocation

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Where to start?

Point of use measurement Auditing Pressure loss

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Permanent monitoring vs audits

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Dutch glass factory ~ 2007

Solution

  • Monitoring system with 20 flow meters
  • Supply and demand side
  • Combined with existing energy management system

Savings:

  • Leakage in machines
  • Optimization of oven cooling
  • Compressor inlet filter maintenance

ROI:

  • 1 year
  • Total > 200,000 Euro / year

‘Thanks to individual efficiency monitoring on each turbo compressor, we can optimize our maintenance schedule’.

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Dutch glass factory

Supply side optimization project

  • Control system optimization
  • Lay out
  • New Master Controller
  • Flow meters as input for optimized

control

  • Total savings > 300 K/ year
  • ROI < 12 months
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Step-by-step

Step-by-Step € € € € € € € € € € € € € € €

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Conclusions

  • Compressed air savings is your low hanging fruit
  • Compressed air savings increases competitiveness
  • Measurements leads to the right optimization decision
  • Measurements provides proof of realized savings
  • Step-by-step approach
  • Permanent monitoring is key to optimum energy savings
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