ENERGY SAVING IN

COMPRESSED AIR SOLUTIONS

BEE KEP - ALUMINIUM SECTOR

Mr. Sumeet Das Adhikari

16th Dec, 2016

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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

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WHY IS ENERGY IMPORTANT IN COMPRESSED AIR SYSTEMS ?

Energy is up to 80% of a compressor’s lifecycle cost and 99% of its carbon footprint

Investment

Maintenance

installation

80%

Energy

From operating cost point of view : compressor room is one of the largest

electricity user therefore is priority equipment

5 to 40% of total plant electrical consumption in Compressed Air System (CAS)

For a plant capacity of 2.3 MTPA, Even by 1% reduction in Power Consumption Savings will be INR 2.3 Cr every year

SUSTAINABILITY

ENERGY SAVINGS - AGENDA

Core Technology

Drive Technology

Efficient Air Treatment

CAS Audit

Energy Savings

Optimization

Energy Recovery

Blower Technology

Understanding the entire compressed air system dynamics is the first

step towards an efficient air & energy usage

This should cover all parts of the compressed air Network: Supply, Distribution

and Demand

Logging critical parameters from the network it is the only valid

approach to show the current energy performance of the installation

For example: voltage, power, current, flow and pressure

Identifying the areas for improvement is done by analysis and

simulation by custom design software of the collected data

A comprehensive report is then generated including recommendations

to improve the AIRNet system

System improvements could involve all or part of:

Upgrades, leak repairs, energy recovery kits,new vessels, AIRNet

improvements, use of central controllers, service contracts, replacement

or new more efficient technologies (VSD)…

AIRScan

AIRSCAN ENERGY AUDIT

LEAKAGE DIAMETER ANNUAL COST

1 mm INR 36,800

3 mm INR 305,000

5 mm INR 850,000

MEDIUM PRESSURE COMPRESSED AIR SOLUTIONS

INEFFICIENT COMPRESSED AIR SYSTEM

Improvement areas :

Unwanted Blow-offs in centrifugal machines

Variable frequency drive in Screw Compressor

Energy Recovery

Twin Tower Adsorption dryers

Central control system

Low Pressure Blowers

Typical installation of compressed air system production

Turbo

Turbo

Turbo

Pre-filter

Pre-filter

Pre-filter

Fine filter

Fine filter

Fine filter

Adsorption dryer

Adsorption dryer

Adsorption dryer

Pressure Drop of 1.5 Bar

SER is to the tune of 0.192 KW / m3/hr

Main innovative solutions: Hybrid technology

Oil-free screw variable speed drive for variable Load

Fixed speed centrifugal for the base load

Heat-of-compression Dryers with 0% losses

Energy Saving Central control system

Remote Monitoring

Energy Recovery system

ENERGY EFFICIENT INNOVATIVE SOLUTION

Total energy savings up to 20%, SER can be reduced to 0.154 KW per m3/hr

0% losses adsorption dryer

0% losses adsorption dryer

0% losses adsorption dryer Oil-free screw VSD

Turbo

Turbo

Energy

Recovery

Central controller

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SUPERIOR HYBRID TECHNOLOGY – BEST SOLUTION

Combination of CENTRIFUGAL + Fixed Speed SCREW + VSD SCREW compressor

Centrifugal Compressor

( ATLAS COPCO ) Oil Free Screw

( ATLAS COPCO ) Oil Free Screw with VFD

( ATLAS COPCO )

Central Controller

( ATLAS COPCO )

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12

CASE STUDY – ALUMINIUM PLANT

DRIVE TECHNOLOGY – OPTIMUM HYBRID SOLUTION

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Combination of CENTRIFUGAL + VSD SCREW compressors

No blow-off in all operating conditions

24 hours of operation

4 8 12 16 20 24

0

4,000

5,000

6,000

7,000

8,000

9,000

10,000

Flo

w (

m3

/hr)

1,000

2,000

3,000 No Wasted Energy

Unbeatable Combination

Up to 25% savings in Power consumption

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Heat of compression is used for regeneration with -20 Deg C PDP

Extremely low pressure drops. No Filters needed.

Rotary Drum-type for virtually energy free drying

Another version with small regeneration heater for - 40 Deg C PDP

ZERO Purge

ENERGY SAVING IN HOC DRYERS

Heat Of Compression (HOC) Dryers – Negligible Power ( 120 Watt) Consuming Energy efficient air drying

0

100000

200000

300000

400000

500000

600000

700000

800000

900000

Heatless purge Heat regenerated Twin Tower HOC Rotary Drum HOC

10 y

ear l

ife c

ycle

cos

t (€)

Initial price Total energy cost Maintenance cost

Calculation basis:

Flow of 8,500 Nm3/hr – Pressure 7 bar (g) – Dew point requirement -40°C

Conditions:

8000 running hours per year – Electricity rate INR 5/kWh

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- 1

8%

Pu

rge

loss

ENERGY SAVING ACCESSORIES Dryer Life Cycle Cost Comparison (per year)

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~ INR 3.5 Crore Savings

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ENERGY RECOVERY (ER)

Energy Recovery – Save up to 80% of Input Power

Consider total 4000 kW Installed KW and an energy recovery of 3200 kW (80%)

Heat equivalent per second = 3200 kJ/s

Boiler uses heating oil (HO) with calorific value = 38,000 kJ/lit

Boiler efficiency = 80%, Heat exchanger efficiency = 90%

Heat generated per hour = 3800 kJ/s x 3600

Fuel saved = 0.8 x 3200 x 3600 / (38,000 x 0.9) = 270 lit/hr

Cost of fuel = Rs.40/lit x 270 lit/h = 10,800 Rs./hr

Yearly savings = 10800 Rs./hr x 1 year = INR 9,46,08,000 per year

Typically the Complete investment for New Compressor with Energy Recovery has a payback of less than 1 year Typically the Extra investment for Retrofit Energy Recovery unit has a payback of less than 5 months

LOW PRESSURE COMPRESSED AIR SOLUTIONS

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35% SAVINGS

SCREW BLOWER

Save up to 35% on existing installations / new Projects

RETURN ON INVESTMENT

8.5 MONTHS

INCENTIVE SCHEMES FOR ENERGY EFFICIENCY

Example : USA

Example : USA

BEE – PAT / INCENTIVE SCHEME :

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 + Oil Free Screw VSD Hybrid combination

– Integrated ‘ZERO-Power’ 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, we have been consulted by the Energy Ministries of various countries like

USA, France, etc.

Proposals :

COMMITTED TO

SUSTAINABLE PRODUCTIVITY.