Improve efficiency of your compressed air systems
Godrej decides to reduce the Air Compressors’ energy consumption by reducing the company’s artificial air demand, optimise the flow and stabilise compressed air pressure with the help of Godrej Compressed Air Solutions (CAS) team.
Godrej Compressed Air Solutions improved the efficiency of compressed air systems in one of largest textile manufacturing company based in Gujarat, Western India –leading to energy savings of more than 991 kWh/day @ 3%
Foreword:
Compressed air which is industry’s 4th utility is the most expensive utility, consuming approximately 15% to 20% of the total energy consumption of the entire factory in Textile industry sector.
This case study offers insights on how our compressed air solutions have helped one of the textile plants achieve energy savings through their compressed air network.
Overview:
One of the largest Textile manufacturers based out of Ahmedabad.
This manufacturing facility in Ahmedabad has a manufacturing capacity of 110 MMTPA. Complete manufacturing process takes place through various shops like power plant, spinning mills and 138 looms. Each shop is highly dependent on compressed air for its processes which is fulfilled by a centralised compressed air network.
A major problem faced by the Textile manufacturer was very high energy consumption of air compressorsi.e.32,500 kWh/day, high artificial demand, pressure fluctuations & inconsistent pneumatic operation and product quality due to that.
So, the client decided to reduce their Air Compressors’ energy consumption by reducing their artificial air demand, optimize the flow and stabilize compressed air pressure with the help of Godrej Compressed Air Solutions (CAS) team.
Step 1- Feasibility study visit:
Godrej CAS team conducted a feasibility study using data logging instruments in the existing compressed air network to understand the operation patterns of Compressors, variations in plant air demand and to work out a suitable solution along-with an estimation of envisaged energy savings.
The Textile manufacturer has been using the following air compressors to fulfill their compressed air requirements in various shops viz. Spinning mills, looms and Power plant.
Godrej CAS team installed instruments to simultaneously carry out real time data logging as a part of the feasibility study in the Textile products manufacturer’s compressed air system and analysed the gathered data to estimate the real air demand and artificial demand, the potential of Energy Saving in Air Compressors.
Data logging instruments were installed at multiple locations viz:
- Generation – Before dryer
- Air treatment System After dryer
- Application – In each shop viz. Spinning Mills, Weaving (138Looms) and power plant
Pressure drop was checked in compressor house as well as in application points
Step 2- Observations & findings:
- During the feasibility study, pressure fluctuation in Application was found to be
- 86 psig (5.9 barg) to 92 psig (6.3 barg) which resulted in high artificial demand leading to increased energy consumption of air compressors.
- Compressor’s energy consumption was around 32,500 kWh/day
The status before: Pressure Variation in Compressed Air System from 86 psig to 92 psig
Step 3- Problems identified& solutions offered:
After analyzing the measured data, Godrej CAS team worked out a suitable solution and submitted an energy saving proposal.
It was recommended to install Control AiR IFC-Demand Side Management Systems for every shop to reduce the Artificial Demand by optimizing flow & pressure supplied to each shop leading to huge energy savings and constant compressed air pressure in each shop could be achieved.
With installation of Demand Side Management Control Systems it was envisaged to provide
- Energy saving in Compressed Air System = 650 kWh/day @ 2% and
- Constant pressure to the plant = within +/- 1 psig (0.07 barg).
Step 4- Implementation & results
As per the recommendations, the manufacturer installed ControlAiR IFC systems for individual applications as below,
By implementing the recommendations of the Godrej Compressed Air Systems, the Textile manufacturer was able to realise huge benefits such as constant air pressure in plant, reduced artificial demand and ultimately energy saving in Air Compressors.
Benefits
- Actual Energy Saving achieved = 3% @991 kWh/day
- Constant Air Pressure with ControlAiR™ IFCs = ±0.1 psig
- Reduction in CO2 Emissions = 285T/year
- Simple Payback Period = Less than 1.5 year
Other benefits
With installation of Godrej ControlAiR™ IFC Systems the pressure in application was observed to be constantwithin +/- 0.1 psig. Constant pressure in the plant helps in
- Improves pneumatic equipment performance
- Improves product quality
- Reduction in Compressed Air Leakages
Real time pressure trends with Godrej ControlAiR IFCs in each application
With Godrej ControlAiR IFCs installed in each shop exact demand in terms of flow & pressure is matched and very stable pressure within +/- 0.1 psig is provided to applications.
Set Pressure: 78 psig (within +/- 0.1 psig)
Air compressors performance with & without IFC
The Textile manufacturer had Centrifugal type compressors to fulfill the compressed air demand.
Normally, it is said that energy saving on centrifugal compressors cannot be achieved. But Godrej CAS team with its extensive experience, recommended a solution which directly impacted on working pattern of compressors leading to reduced artificial demand and good energy saving.
