A renowned PTA manufacturer was impressed by confirmation of a INR 75 lakhs in energy savings with the help of our state-of-the-art service AIRScan, which demonstrated the benefits of overhauling in terms of energy efficiency and monetary realization.
Project overview
It was mutually agreed with the client (a PTA manufacturer with a strong sustainability mindset) that AIRScan would be the first step. Pre and post measurement results showed how much saving in the operating Specific Power Consumption could be realized. Overhauling was performed with all genuine spares. The results were impressive.
The customer
Renowned PTA (Purified Terephthalic Acid) manufacturer
Location
West Bengal
The challenge
The PTA manufacturer has a strong sustainability mindset and eagerness to reduce wastage and establish an efficient utility system. They have always been looking to identify opportunities to reduce the energy cost of utilities. Compressed air being the major contributor of energy consumption, it has always on high on the list of areas to work upon.
Assessment
The client’s installation consisted of three 2000 CFM capacity compressors more than 15+ years. When the Atlas Copco Optimization team visited and explained about the first step of Optimization, which is measurement of the existing system first, it was a mutual agreement that AIRScan would be performed first.
Solutions and recommendations
So first, Atlas Copco’s specialized Audit team performed compressor operating efficiency measurements for all three compressors and the results were really insightful, which was also backed by the service visits of the compressor OEM: that attention to the overhauling is necessary in order to achieve machine uptime as well as energy efficiency.
Pre and post measurement results showed how much saving in the operating Specific Power Consumption could be realized..
Direct savings of 35 kW could be seen in machine power while an increase in 421 CFM could be seen in output delivery. But considering the plant’s additional requirement, the compressor would be running with almost 100% loading to cater to the increased plant demand. So, comparing the existing condition to the previous, approximately 133 kW in power saving is established.
Power savings with compressor overhaul: 133 kW
Energy savings with compressor overhaul: 133*8000 kWh/Annum = 10,64,000 kWh/Annum
Monetary savings with compressor overhaul: 1064000*7 INR/Annum= INR 74,48,000/Annum
Implementation & outcome
Overhauling was performed with all genuine spares and through the compressor OEM. After the overhauling (element replacement, gearbox overhauling, cooler cleaning, etc.) same more compressor operating efficiency measurements were taken. The results were really impressive and consequential proof of improvement in compressor performance was also seen, like reduction in motor current from breaker panel. Below are the meter readings that show evidence of improvements:
Mr. Basudeb Saha, AIRScan Engineer: The recommendation which we have given for improvement were proved in terms of savings which is the ultimate reward for an engineer.
Mr. Shibashish Chakraborty, Energy Consultant: The end result of this job is encouraging and inspiration for the future.
Summing up
AIRScan being a fantastic assessment tool; it helps in understanding the potential but also gives an opportunity to quantify the savings in a proper manner. In Atlas Copco, we do not compromise on the measurement pre-requisites and we follow a stringent protocol set by the specialized tool manufacturer, so the result what is being produced via AIRScan is best in class.
