AIRScan report reveals savings for cement manufacturer
A leading producer of cement and ready-mixed concrete wanted to reduce their carbon emission so they could reach their Science Based Targets Initiative goals by 2030.
The Challenge
The installation consists of two separate air net systems, including 31 compressors, 18 of which run at full load.
The customer experienced difficulties managing the energy efficiency of this complex installation. Additionally, their ventilation system was inadequate to cope with the generated heat. In search for help in addressing these issues, the customer reached out to Atlas Copco.
The Solution
A full compressed air audit was carried out by the Atlas Copco team to identify optimization opportunities. All measurement results and an action plan were compiled into a detailed AIRScan Report.
Based on the report, a proposal was made to gradually optimize the compressed air network with the following activities:
- Leakage repair
- Upgrade blowers and compressors
- Installation of Optimizer 4.0 central controller
- Upgrade pipelines
The client's utility team prioritized leak repair as a quick win that required no investment. Thanks to the AIRScan Report, the customer knew they could achieve energy savings of 162 000 kWh/year and a CO2 reduction of 11 400 tons/year with leak repair alone.
In addition, ventilation was improved by adding hot air discharge fans.
The Outcome
The leak repair achieved energy savings of 2 553 kWh/week (120 300 kWh and USD 10 700 / ₹900 000 annually) and a CO2 reduction of 21.5 tons/year. This also provided a reduction in the taxed hours of the machines. These savings were confirmed through installed energy meters and counters for compressor operation.
The proposal for the other activities, such as upgrading the pipelines, blowers and compressors, and installing an Optimizer 4.0 central controller, is currently being validated by the customer.
Other updates, besides leak repair, will provide additional savings, allowing them to save up to 2 690 000 kWh per year.
