INNOVATIVE SCHEMES for ENERGY SAVING in COMPRESSED AIR GENERATION - - PowerPoint PPT Presentation

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

Only 85% Compressed Air fed to Dryer

Air Compressor

7 bar

After Cooler

Air / CW

∞

Refrigerant Dryer Process air receiver Desiccant To Instrument Air receiver

Timer based regeneration ~15% Dry Comp Air Lost to Atmosphere for regeneration 85% Loss in Heat 95-120oC 10oC Pr. Dew Point

Desiccant To Process Air/CW Atmospheric Air Comp AIR has only 15% Energy of input Power

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

Lubricated Air Compressor 7 bar

Heat Recovery

Receiver Tank Process Air Receiver Desiccant

Instrument Air Receiver

Dew Point based switching 80% Heat recovery

10oC Pr. Dew Pt

Air Pre- Cooler

After Cooler

Plate-Type HE

CHW based dryer

CW

Spent Air from Regenerating Tower

HP Inlet LP Suction Discharge

CHW supply 80oC Water

Hot water VAM

CHW Supply 6’C

CW

CW make up

90oC

BFW 60’C

Desiccant To BFW/PROCESS

CHW to process

by-pass if atm is cooler than 10’C

To ETP

CHW return

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 40OC TO SAY 20OC ≈ 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

SyGu Guru ru Innova vators

• rs Pvt Ltd.

ISO 9001 01:2 :2015 15

11 Awarded Legend in Energy at Washington DC, by Ex-US President, Mr. Bill Clinton. Receiving the Prestigious Energy Engineer of the Year 2015, at WEEC, Orlando, FL, USA. Certified Measurement & Verification Professional (CMVP), EVO, USA Certified Energy Manager International (CEMI), AEE, USA

Best Performance National Awards – SEEM-2015- Both as a “Certified Energy Auditor” & “ Academy (ACE) as a firm” Best Performance National Award – Energy Auditor at SNEMA/SEEM-2017 AEE Young Professional of the Year 2016 – WEEC, Washington DC, USA

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