We partnered with a major cement manufacturer in Karnataka to assess their compressed air management system, and to identify the savings potential though realistic and simple actions. They had two compressed air networks (mainly for conveying and instrument air), comprising of 31 compressors in total with different capacities and for varying applications.
Project overview
With initial discussion, our Energy Consultancy team conducted one complimentary walkthrough audit and identified the pathway for optimization. Both parties discussed the proposals and concluded that measurement was necessary before any action.
The AIRScan compressed air audit was conducted at customer premises vy our compressed air experts. Site information was compiled in a comprehensive AIRScan report for an action plan that would result in tangible savings.
The implementation of simple leak arresting with proper planning and strategy, helped the utility team observe savings of 1,20,356 kWh per year, resulting in utility cost savings amounting to INR 9 lakh.
The customer
The customer is India's foremost manufacturer of cement and ready mixed concrete with a countrywide network. In 2021, it became the first and only Indian cement company to sign the Net Zero pledge. Their carbon emission reduction targets for 2030 were validated by the Science Based Targets Initiative (SBTi).
Location
Wadi, Karnataka
The challenge
A broadly spread compressed air network and tough barrier for the team of auditors while performing the audit activities. However unstinting support from the the customer's utility team and a good understanding of compressed air system, helped us complete the activity within 20-30.
Assessment
Generation side
Out of the 31 total compressors, approx. 18 compressors are running with maximum loading. Key findings included like maintenance planning, overhauling of schedule, upgradation analysis, central controller feasibility, dryer uptime, room ventilation.
Distribution side
While 2 different networks, no major pressure drops were observed except in coal mill, kiln and fly ash purging header. Key findings included pipeline layout, choked pipe replacements.
Demand side
With multiple flow-pressure meters and different areas of consumption, non-productive usages were identified with key findings like requirement and artificial demand.
Solutions and recommendations
Recommendations were provided keeping practicality and feasibility in mind in relation to the outcome benefits. These were categorized in priorities for better action planning.
Implementation & outcome
The customer's utility team took the recommendations on very serious note and acted on the leak repair activity first as this was very easy to implement with the AIRScan report (coloured image/are-description) and the investment part it not required. With sincere efforts, within 30-45 days of time all the identified leakages were rectified. After the rectification activity, Atlas Copco team once again visited the site and captured the site running data in accordance with the production output for the validations.
Energy savings of 2553 kWh/week (120356 kWh & 9 lakh per year) were realized through the AIRScan recommendation implementation in Instrument air network and the same was verified though the installed energy meters and compressor running counters/utilization. Also, customer is in process of upgrading their conveying system to the Industrial highly efficient blower and expecting savings of 130000 kWh per year.
Ashish PJ, Audit Engineer: Handling such broad compressed air network project was really challenging but with the help of customer support and intention toward optimization scopes made the execution informative and engaging.
Yukesh Raj Deenan, Energy Consultant: Happy to contribute to the client’s net zero initiative and overwhelmed to be part of such result centric project.
Summing up
As there are many aspects to energy optimization in compressed air network, it is important to have holistic view of the existing condition and the client’s future needs. Even small, simple steps can contribute significantly. The saying “If you can’t measure, you can’t improve” really goes well with the compressed air system management.
