lateral thinking for energy saving in compressed air system presentation... · summary of energy...
TRANSCRIPT
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 [email protected], 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
Rec
eive
r Ta
nk Process Air
Receiver
Desiccant
Instrument Air Receiver
Dew Point based switching
80% Heat recovery
10oC Pr. Dew Pt
Air Pre-
Cooler
After Cooler
Pla
te-T
ype
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
SyGuru Innovators Pvt Ltd.
ISO 9001:2015
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
Your Partners in ENERGY CONSERVATION –
ENERGY AUDIT S, M&V, TRAINING & IMPLEMENTATION • Corporate Connect:
SyGuru Innovators Pvt Ltd. - PAT ACCREDITED FIRM
ACADEMY FOR CONSERVATION OF ENERGY
– 820, Siddharth Complex, R.C. Dutt Road, Alkapuri, Baroda – 390 007, Gujarat, India
Ph: +91-265-2325024 Tele/Fax: +91-265-2325034
• Web Connect:
– Our Website: www.syguruace.com
– Email us: [email protected]
– Facebook: www.facebook.com/aceenergyexperts
SYNERGY WITH ENERGY 12