ENERGY SAVING COMPRESSED AIR SOLUTIONS THERMAL POWER PLANTS 28 th October, 2015
ATLAS COPCO INDIA Established in the year 1960. Total employee strength : 1600 Annual Sales : ~ 22 BINR 4 Manufacturing plants Global Engineering Competence Centers at Pune & Bangalore - Provide mechanical engineering, CAE, CFD, FEA and project engineering support Annual Indian production 10,000 Screw compressors & 70 Centrifugal compressors
PRODUCT PORTFOLIO Oil Free & HP Lubricated Piston Oil Free Oil Free Oil Injected Screw Turbo Screw Air Nitrogen Energy Control & MP Treatment Generation Recovery Monitoring Oil Free Screw Oil Free Turbo LP Compression Treatment Generation Energy Saving 3
A CENTURY OF INNOVATION IN COMPRESSORS XD energyless First full First UR oil-free screw MD energyless First oil-free VSD Star insert coolers in dryers feature Process turbo symetric profile dryers Z machines range First water First Elektronikon Scroll oil-free cooled two control ZB high speed compressors Z integration Double tooth stage piston Screw drives introduction Blowers 1952 1964 1970 1980 1996 2001 2003 1973 1986 1993 1995 2004 2005 2010 1994 1904 1954 1966 1979 1980 1987 1995 1997 2002 1973 2003 2005 2006 High pressure First VSD AirScan Z screw gets ISO First OIS First silenced Plant air 40 bar(e) introduced compressors compressors 8573 Class 0 turbo range machines First Z oil-free Z full feature with AirOptimizer First packaged and First oil- Z tooth High pressure screw IMD introduced silenced turbo free compressors machines asymmetric compressors piston ….Over 400 patents profile Innovating the compressor business for more than 100 years
CORE TECHNOLOGY Extensive product portfolio PISTON : Oil-free / Oil Injected Piston Compressors 0.5 - 10 kW SCROLL: Oil-free scroll compressors 1 - 15 kW TOOTH: Oil-free tooth compressors 15 - 50 kW OIL-FREE SCREW: Oil-free screw compressors & Blowers, fixed and variable speed 55 - 900 kW OIL-INJECTED SCREW: Oil-injected screw compressors, fixed and variable speed 2 - 500 kW CENTRIFUGAL: Standard Oil-free turbo compressors 350 – 3000 kW
CARING FOR ENERGY A rational mix of multiple technologies scroll tooth screw SPECIFIC ENERGY J/l centrifugal FLOW L/Sec
INDUSTRIAL COMPRESSORS Compressor Technique
QUALITY AIR SOLUTIONS™ Heat of Heatless compression Heated purge blower purge Refrigerating Heat of compression Twin tower …….all types of dryers manufactured in -house
WHY IS ENERGY IMPORTANT IN COMPRESSED AIR SYSTEMS ? From operating cost point of view : compressor room is one of the largest electricity user therefore is priority equipment 15 to 20% of total Power Plant electrical consumption in Compressed Air System (CAS) Energy is up to 80% of a compressor’s lifecycle cost and 99% of its carbon footprint Maintenance 80% Energy Investment installation For a power plant of 800MW X 3, by reducing 5% in CAS Power Consumption Savings can be 500,000 KWH every year 9
Typical Thermal Power Plant Service Air Flue gas desulphurization 8 bar (real demand 5~6 Low pressure bar) Oil Free Air; No Air Dryer 100% Variable demand Stable demand of Air required Coal handling Oil Free Air plants Dust suppression systems Instrument Air Pneumatic Conveying Air 8 bar (real demand 6~7 bar) Low presure 50% stable demand ; 50% Variable Oil Free Air; No Air Dryer Oil Free Air ; - 40C ADP Stable demand of Ar required 10
ENERGY SAVINGS - AGENDA Blower Technology Energy Recovery CAS Audit Energy Savings Optimization Core Efficient Air Technology Treatment Drive Technology
INEFFICIENT COMPRESSED AIR SYSTEM Pressure Drop of 1.5 Bar Typical installation of compressed air system production Adsorption dryer Turbo/Fixed Speed Main Improvement areas : Pre-filter Fine filter Unwanted Blow-offs in centrifugal machines Turbo Variable frequency drive in Screw Compressor Adsorption dryer Fine filter Pre-filter Energy Recovery Twin Tower Adsorption dryers Central control system Turbo Adsorption dryer Pre-filter Fine filter Low Pressure Blowers SER is to the tune of 0.192 KW / m3/hr
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15 ENERGY SAVING DRYERS – MD DRYERS (Patented Technology) Working principal 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 savings up to 25 % are possible !
ENERGY SAVING DRYERS Dryer Life Cycle Cost Comparison Initial price Energy cost Delta compressor price Maintenance cost 900000 800000 700000 Life Cycle Cost € 10 Year 600000 15 - 18% Purge loss 500000 Blower & Heater 2% Purge loss + ~ € 500,000 Savings 400000 (INR 35,000,000/-) 300000 200000 100000 0 Heatless purge Heat regenerated (I)MD Dryer type Based upon 1700 l/s (3600 CFM) of air, 8000 hrs per year, € 0.07/kWh (INR 5/- kWh) 16
THE ENERGY RECOVERY SYSTEM All energy used to compress air is transformed into heat, usually lost from the system. Laws of thermodynamics the compression elements the oil cooler the intercooler and the aftercooler The unique built-in energy recovery system of the Atlas Copco Z compressor circulates water through all these components to maximize the potential heat recovery and yields hot water at up to 90°C. Recovers Energy up to 90% 17
THE ENERGY RECOVERY SYSTEM 18
ADVANCEMENT IN MULTIPLE COMP. CONTROL - ES Multiple compressor installations are best controlled through a central controller This controller not only sequences the compressors and lowers the pressure band but has a possibility of starting and stopping different capacity machines to get the most efficient compressed air system 19
ENERGY EFFICIENT INNOVATIVE SOLUTION Central controller Main innovative solutions: Oil-free Screw FS 0% losses adsorption dryer Hybrid Screw technology Oil-free Screw Fixed speed for the base load Oil-free Screw Variable speed for variable Load Heat-of-compression Dryers with 0 power & 0% losses Oil-free Screw FS 0% losses adsorption dryer Energy Saving Central control system Remote Monitoring through Smartlink Energy Recovery system Energy 0% losses adsorption dryer Oil-free Screw FS Oil-free screw VSD Recovery
MAXIMUM SAVINGS POSSIBLE Compressed Air usually represents 15% of a typical Thermal Power Plant’s electricity consumption Energy Savings possible for a 800MW X 3 plant every year : – Installing Hybrid Screw compressors : Oil Free Screw FS + Oil Free Screw VSD : 10,87,500 KWH – Energy Recovery from Oil Free Screw compressors : 83,52,000 KWH – Central Controllers for optimum pressure generation : 3,88,000 KWH – Screw Blowers for ETP/WTP : 1,41,000 KWH – Air Leakage fixing : To be Assessed Total Savings : 99,68,500 KWH per Year 21
COMMITTED TO SUSTAINABLE PRODUCTIVITY.
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