A study of compressed air system for an automotive components manufacturing unit was undertaken to reduce the overall compressed air requirement and energy saving with very low investment. System mapping, data measurement & analysis, understanding functional requirement and various tests and assessments were carried out i.e. free air delivery, leakage test, specific energy consumption etc.
SAVING MEASURES
1,92,616 kWh
Energy saving per year
- Compressor pressure setting optimization considering the functional requirement of compressed air at every point of use
- Cut-in and cut-out pressure setting of all four compressors such that unloading time of compressors will be reduced
- Distribution line size study and suggestion for header pipeline modifications to reduce the pressure drop
- Compressed air leakage quantification, identifying the causes of leakages, rectification procedure & root cause analysis, monitoring schedule for leakage correction and verification
- Reduction in compressed air requirement of shot blasting machine by bifurcating the functional use of compressed air system i.e. sand lifting and shot blasting. Sand lifting system was mechanised so compressed air requirement was drastically reduced
32%
Energy saving in current compressor consumption
BUSINESS OUTCOME
15.4 Lakh INR
Saving in cost
There were four compressors running to cater the compressed air demand of the plant. By implementing the energy saving measures, the plant could operate with only two compressors. This lead to 32% reduction in energy consumption of compressors having 1.5 Million INR savings.