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ENERGY EFFICIENCY IN
COMPRESSED AIR SYSTEMS
BEE KNOWLEDGE EXCHANGE PLATFORM
FERTILIZER SEGMENT
16th February 2016
Indo Gulf Fertiliser, Jagdishpur (UP)
2
Established in 1873 in Sweden and in India since 1960
Listed in Stockholm and New York stock exchanges
World’s largest Compressed Air System manufacturer, only company with complete product and services
basket
Present in more than 150 countries with about 40,000 employees
First Oil Free Screw & Centrifugal compressors to be certified ISO Class “0” Air Quality
Fortune 100 Most Sustainable Global Companies in the World
Included in United Nations Global Compact 100 stock index
Among the Global 100 list presented at the World Economic Forum in Davos as one of the world’s most
sustainable companies
ATLAS COPCO – THE LEADER IN COMPRESSED AIR SYSTEMS
2014
Overall
Energy
Efficiency
Excellence
Over a century of innovation in energy saving features
ATLAS COPCO INDIA
Established in the year 1960.
Total employee strength : 2500
Annual Sales : ~ 28 Bn INR
4 Manufacturing plants
Global Engineering Competence Centers at Pune & Bangalore
- Provide mechanical engineering and project engineering support
Annual Indian production 10,000 Screw & Centrifugal compressors
WHY IS ENERGY IMPORTANT IN COMPRESSED AIR SYSTEMS ?
4
Major requirement is Instrument Air
Energy is up to 80% of a compressor’s lifecycle cost and 99% of its carbon footprint
Investment
Maintenance
Installation
80%
Energy
5 to 10% of total plant electrical consumption in Compressed Air System
ENERGY SAVINGS - AGENDA
Core Technology
Drive Technology
Efficient Air Treatment
CAS Audit
Energy Savings
Optimization
Energy Recovery
Blower Technology
INNOVATE TO GROW
6
To Plant
8 Bar
6 Bar
Oil-Injected system 20% Saving in Energy Consumption
Compressed air Consumption is primarily for Instrument Air and Plant Air
7
8
9
Energy savings up to 25 % are possible !
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 SAVING DRYERS – MD DRYERS (Patented Technology)
Working principal
10
0
100000
200000
300000
400000
500000
600000
700000
800000
900000
Heatless purge Heat regenerated (Blower) (I)MD
Life
Cyc
le C
ost
€ 1
0 Y
ear
Dryer type
Maintenance cost
Energy cost
Delta compressor price
Initial price
~ € 500,000 Savings (INR 35,000,000/-)
ENERGY SAVING DRYERS Dryer Life Cycle Cost Comparison
Based upon 1700 l/s (3600 CFM) of air, 8000 hrs per year, € 0.07/kWh (INR 5/- kWh)
15
- 1
8%
Pu
rge
loss
2%
Pu
rge
loss
+
Blo
we
r &
He
ate
r
11
THE ENERGY RECOVERY SYSTEM
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.
All energy used to compress air is transformed into heat, usually lost from the system. Laws of thermodynamics
Recovers Energy up to 90%
12
THE ENERGY RECOVERY SYSTEM
LOW PRESSURE OIL-FREE SCREW BLOWERS
14
SCREW BLOWER PRODUCT EFFICIENCY COMPARISON
30 to 40 % more energy
efficient
15
Product placement which realized huge savings.
More than 120 units ZS Screw Blowers references
Savings: ~ INR 3,500,000.00 per year & ROI is 1 year
SAVINGS ON REPLACING OLD LOBE BLOWERS
MAXIMUM SAVINGS POSSIBLE
Compressed Air usually represents 5-10% of a typical Fertilizer industry’s electricity consumption
Energy Savings possible for a 5,000 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
– Screw Blowers
Total Savings : 1,350,000 KWH per Year
Equivalent to 750 Tons of CO2 16
Equivalent to 45,000 Trees growing for 1 year
COMMITTED TO SUSTAINABLE PRODUCTIVITY
CONTACTS
Atlas Copco, North Zone :
– Abhishek Dubey, Zonal Manager : [email protected] Mob : 9643009775
Atlas Copco, West Zone :
– Mahesh Thakar, Zonal Manager : [email protected] Mob : 9327687540
Atlas Copco, East Zone :
– Sourav Chaudhury, Zonal Manager : [email protected] Mob : 9331888237
Atlas Copco, South Zone :
– KVS Nagendra, Zonal Manager : [email protected] Mob : 9380572236
Atlas Copco HO Pune :
– Arnab Maitra, Key Account Manager-India : [email protected] Mob : 9730756783
