best practices in energy efficiency in textile sector€¦ · the unique built-in energy recovery...
TRANSCRIPT
BEST PRACTICES IN ENERGY
EFFICIENCY IN TEXTILE SECTOR
BEE KNOWLEDGE EXCHANGE PLATFORM
COMPRESSED AIR SYSTEM
28th June’ 2016
Ahmedabad
ATLAS COPCO INDIA
Established in the year 1960
Total employee strength : 2500
Annual Sales : ~ 30 BINR
4 Manufacturing plants
Global Engineering Competence Centers at Pune & Bangalore
- Provide mechanical engineering and project engineering support
Annual Indian production 10,000 Screw compressors & 100 Centrifugal compressors
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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
34% of energy is consumed in spinning, 23% in weaving, 38% in chemical processing and another 5% for
miscellaneous purposes
5 to 20% of total plant electrical consumption in Compressed Air System (CAS)
WHY COMPRESSED AIR SYSTEM OPTIMIZATION?
ROOM FOR IMPROVEMENT
Air is Free but Compressed air is NOT
MAXIMIZE ENERGY EFFICIENCY
Air quality
Reliability
Efficiency
ENERGY SAVINGS - AGENDA
Core Technology
Drive Technology
Efficient Air Treatment
CAS Audit
Energy Savings
Optimization
Energy Recovery
Blower Technology
SP
EC
IFIC
EN
ER
GY
J/l
centrifugal
screw
tooth
FLOW L/Sec
A rational mix of multiple technologies
CARING FOR ENERGY
scroll
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AIR QUALITY
INNOVATE TO GROW – HYBRID TECHNOLOGY
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To Plant
8 Bar
6 Bar
Oil-Injected system 20% Saving in Energy Consumption
1 bar increase in pressure = 7% energy consumption
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EXCELLENCE IN CENTRIFUGAL TECHNIQUE 12
Horizontally split design
– Easy preventive maintenance access
Compact, lightweight, yet robust design
– Optimized for production
– Optimized on cost
Backward leaning impeller design
6% more efficient than earlier design with
optimization of flow paths & improved dedign
of impellers
Computational Fluid Dynamics (CFD)
optimization on +100 design parameters
Energy saving up to 8-10 % is achieved !
PIONEERS IN VARIABLE SPEED DRIVE COMPRESSORS
Rotor design Coating principle on elements
Cooling jackets around the elements Pressure drops are minimized
In the air inlet system In the coolers In the waterseparators In the connecting piping In the check valve
Energy-saving control features
Delay Second Stop function Dual pressure band Timer based start/stop
Use of high efficiency motors (IE3) Narrow pressure band
Frequent loading & unloading is possible with Z
Clever design Air seal design for minimum leakage Cooler design for lowest approach temperature Zero-loss water drains
Energy saving up to 35 % is possible !
MARKET LEADERS IN OIL FREE SCREW COMPRESSORS
Skid mounted unit – Complete scope integrated
– No foundation required
Canopied versions – Truly engineered canopies
– Reduced noise levels
– Protects the units
– Appealing aesthetics
Footprint – Lowest footprint
– Reduced installation space requirement
– Intergrated HOC drum dryers [MD]
– Layout of maintainance points
GA VSD+ DESIGN: THE HEART OF THE VSD+
Permanent Magnet motor
Pressure-tight IP66 motor
Direct Drive:
– No belts, gears or seals
– Negligible energy losses
Vertical set-up
Oil-cooled drive train
(one oil circuit for motor, element, bearings)
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Small heart, huge performance
Best efficiency: IE 4
Silent
Reliable, maintenance-free (IP66)
Optimal cooling at all speeds
Motor: SER -4% Transmission: SER -2% Element: SER -1%
We challenged ourselves and achieved the above savings against our own previous designs
which had already set a performance benchmark in the industry !!!
Sentinel: SER -1%.
GA 7-75 VSD+ MOTOR EFFICIENCY
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IE 2
IE 1
IE 3
IE 4
Efficiency of Atlas Copco’s GA 7-75 VSD + Range
Motor: SER -4%
96,0% 96,3% 96,5%
IE 2
IE 1
IE 3
IE 4
96,7% 96,8%
IE 2
IE 1
IE 3
IE 4
IE 2
IE 1
IE 3
IE 4
IE 2
IE 1
IE 3
IE 4
Heatless
purge
Heat of
compression Heated
blower purge
Heat of compression
Twin tower
Refrigerating
QUALITY AIR SOLUTIONS™
…….all types of dryers manufactured in-house
Energy less
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Energy saving up to 25 % is possible !
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 SAVING DRYERS – MD DRYERS (Patented Technology)
Working principal
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SUMMING UP –MD DRYERS
Purge
Pre Filtration
After Filtration
Un wanted pressure drops
Switching towers/ valves, actuators
External heating source-wastage of energy
Frequent replacement of desiccants
Extra piping costs
Loud noise
Say No to
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0
100000
200000
300000
400000
500000
600000
700000
800000
900000
Heatless purge Heat regenerated (Blower) (I)MD
Life
Cyc
le C
ost
€ 1
0 Y
ear
Dryer type
Maintenance cost
Energy cost
Delta compressor price
Initial price
~ € 500,000 Savings (INR 35,000,000/-)
ENERGY SAVING DRYERS Dryer Life Cycle Cost Comparison
Based upon 1700 l/s (3600 CFM) of air, 8000 hrs per year, € 0.07/kWh (INR 5/- kWh)
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- 1
8%
Pu
rge
loss
2%
Pu
rge
loss
+
Blo
we
r &
He
ate
r
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THE ENERGY RECOVERY SYSTEM
the compression elements the oil cooler the intercooler and the aftercooler
The unique built-in energy recovery system of the Atlas Copco Z Screw compressor circulates water through all these components to maximize the potential heat recovery and yields hot water at up to 90°C.
All energy used to compress air is transformed into heat, usually lost from the system. Laws of thermodynamics
Recovers Energy up to 90%
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THE ENERGY RECOVERY SYSTEM
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SCREW BLOWER PRODUCT EFFICIENCY COMPARISON
30 - 40 % more energy efficient
CASE STUDY 1 – SSM FINE YARNS
MAXIMUM SAVINGS POSSIBLE
Compressed Air usually represents 5-20% of a typical Textile industry’s electricity consumption
Energy Savings possible for a 20,000 cfm compressed air requirement plant (example):
– Installing Combination compressors : Centrifugal/Oil-Free Screw + Oil-Free Screw VSD
– HOC MD Rotary Drum-type Dryers
– Energy Recovery from Oil Free Screw compressors
– Central Controllers for optimum pressure generation
– Screw Blowers
Total Savings : 5,400,000 KWH per Year
Equivalent to 3,000 Tons of CO2 25
Equivalent to 1.7 Lakh Trees growing for 1 year
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/O. F. Screw + Oil Free Screw VSD Combination
– Integrated ‘ZERO-Purge’ 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 (including India), we have been consulted by the Energy Ministries of
various countries like USA, France, etc.
Proposals :
CONTACTS
Atlas Copco, North Zone :
– Aneek Roy, Zonal Manager : [email protected] Mob : 9643009775
Atlas Copco, West Zone :
– Sunil Natekar, Zonal Manager : [email protected] Mob : 9819788493
Atlas Copco, East Zone :
– Sourav Chaudhury, Zonal Manager : [email protected] Mob : 9331888237
Atlas Copco, South Zone :
– KVS Nagendra, Zonal Manager : [email protected] Mob : 9380572236
Atlas Copco Central Zone :
– Lokesh Jatapathi, Zonal Manager : [email protected] Mob : 9379105946
Atlas Copco H.O. Pune :
– Arnab Maitra, Key Acct. Manager- India : [email protected] Mob : 9730756783
COMMITTED TO
SUSTAINABLE PRODUCTIVITY.
