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 Atmospheric Air To Process 85% Loss 10 o C Pr. in Heat Dew Point Air Refrigerant Process air After Cooler Compressor Dryer receiver ∞ 95-120 o C 7 bar Only 85% Compressed Air / CW Air fed to Air/CW Timer based Dryer regeneration To Desiccant Instrument Comp AIR has only 15% Energy of Air receiver Desiccant input Power ~15% Dry Comp Air Lost to Atmosphere for regeneration
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 To BFW/PROCESS CHW return CW Hot water BFW CHW to VAM 80% Heat recovery 60’C by-pass if CHW Supply 6’C process CHW supply atm is cooler 10 o C Pr. 80 o C Water than 10’C Plate-Type HE 90 o C Dew Pt Lubricated Heat Air After Receiver Tank Process Air CHW based Air Pre- Receiver Recovery Cooler Compressor Cooler dryer 7 bar CW make up To ETP Desiccant Dew Point based switching Desiccant Spent Air from Regenerating Tower CW Instrument Discharge HP Air Receiver Inlet LP Suction
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 40 O C TO SAY 20 O C ≈ 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 Certified Energy Manager Certified Measurement & Awarded Legend in Energy at Receiving the Prestigious International (CEMI), AEE, USA Verification Professional Washington DC, by Ex-US Energy Engineer of the Year (CMVP), EVO, USA President, Mr. Bill Clinton . 2015, at WEEC, Orlando, FL, USA. Best Performance National Awards – SEEM-2015- Both as a “Certified Energy Auditor” Best Performance National Award – AEE Young Professional of the Year 2016 – & “ Academy (ACE) as a Energy Auditor at SNEMA/SEEM-2017 WEEC, Washington DC, USA firm” SyGu Guru ru Innova vators ors Pvt Ltd. 11 15 ISO 9001 01:2 :2015
You our r Partn tners ers in n ENER ERGY GY CON ONSERVATIO ERVATION N – ENER ERGY GY AUDIT S, M&V, , TRAININ INING G & IMPLEM EMENT ENTATIO ATION N • Corporate Connect: Sy SyGuru uru In Innovators ators Pv Pvt Ltd . RM . - PAT T ACC CCREDITE REDITED D FI FIRM A CADE DEMY FOR C ONSE RVATION OF E NERGY NSERVAT RGY – 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: info@syguruace.com – Facebook: www.facebook.com/aceenergyexperts SYNERGY WITH ENERGY 12
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