INNOVATIVE SCHEMES

for
ENERGY SAVING
in
COMPRESSED AIR GENERATION
Som Derashri
Managing Director,
SyGuru Innovators Pvt. Ltd.
(PAT ACCREDITED FIRM BEE)
ISO9001:2015
Alkapuri, Baroda 390007
info@syguruace.com, 09824079910
CONVENTIONAL COMPRESSED AIR SYSTEMS
Atmospheric Air To Process
85% Loss
in Heat 10oCPr.
Dew Point
Air Refrigerant Process air
Compressor After Cooler
Dryer receiver
7 bar 95-120oC ∞ Only 85%
Compressed
Air / CW
Air/CW Air fed to
Timer based Dryer
regeneration
To
Desiccant Instrument
Comp AIR has only 15% Energy of Air receiver
input Power Desiccant

~15% Dry Comp Air Lost to

Atmosphere for
regeneration
COMPRESSED AIR LIFE CYCLE COST
 COMPESSOR SELECTION-
CHECK RETROFIT POSSIBILITY

While its only gear train change in Atlas Capco costing a few thousands,
The kaeser insists on changing the complete screw end & costs more.
 IMPACT OF INLET AIR TEMPERATURE REDUCTION ON AIR DENSITY
THE POWER SAVING IS PROPORTIONAL TO DENSITY
INCREASE AS COMPRESSORS ARE VOLUMETRIC
COMPRESSON MACHINES…. MORE DENSITY...MORE MASS
FOR SAME VOLUME PER UNIT TIME.
Intake Cool Air & Exhaust low grade Hot Air from Enclosure (Motor cooling & Radiation heat) Outside
 Question
Why -40’C Dew Point is needed ?
Establish Optimum Dew Point

Understand Pressure &

Atmospheric Dew Point:
+10 ‘C at 7 bar (Pr. Dew pt.)
is almost equal to
-20’C Dew Pt. @
Atmospheric Pressure
 Sankey Diagram -
ENERGY BALANCE
Item 3 & 5
(72+13 =85%)
is high grade heat that
can be usefully
Exploited
!
* VAM (Hot Water 90/80’C) to
give 7/12 chilled water
* BFW/PROCESS HOT WATER
(Heating from 30 to 60’C)
to preheat make up water
 ‘0’ LOSS ENERGY N COMPRESSED AIR SYSTEM
CHW return To BFW/PROCESS
Hot water CW BFW
80% Heat recovery VAM 60’C CHW to
by-pass if CHW Supply 6’C
atm is cooler CHW supply process
than 10’C 80oC Water 10oC Pr.
90oC

Plate-Type HE
Lubricated Dew Pt
Air Heat After Process Air

Receiver Tank
Pre- Air CHW based
Recovery Receiver
Cooler Compressor Cooler dryer
7 bar
CW make up
To ETP Desiccant
Dew Point
based switching
Spent Air from Desiccant
Regenerating Tower
CW

Instrument
Discharge
HP Air Receiver
Inlet

LP Suction
 HEAT RECOVERY VAM & ZERO LOSS DRYERS
COST ECONOMICS
EFFICIENCY IMPROVEMENTS
• PRE COOL SUCTION AIR ~ 7%
• AIR DRYER USING VAM-CHW ! 1%
• RECYCLING SPENT DRY AIR TO RECEIVER ~ 15%
• CHILLED CONDENSATE HEAT RECOVERY ~0.1 %
• NON CONTAMINATED CONDENSATE TO COOLING TOWER ~ 0.1%
• PLC CONTROL - INLET AIR TEMP & DEW Pt. BASED REGENERATION ~ 0.1-5%
• OPERATING MODE : UNLOAD to START/STOP ~ 0.1-5%
• FILTER dP OPTIMISATION – 0.1-1%

PAYBACK PERIOD = 10 to 18 MONTHS

 SUMMARY OF ENERGY SAVING SCHEMES
• SELECT OPTIMUM PRESSURE RATING OF COMPRESSOR - NEEDED (NOT DESIRED) – RETROFIT POSSIBLE
• PRE-COOLING AIR FROM 40OC TO SAY 20OC ≈ 6.7% ENERGY SAVING:

• Heat Recovery 85% POSSIBLE: GENERATE HOT WATER (90/80’C) FOR HEATING BFW/PROCESS HOT WATER 30-90 ‘C
• HAVE COMBO OF HOT WATER ( 90/80’C) FOR VAM (6/12’C CHW) + HOT WATER (30-60’C) FOR BFW/PROCESS/CANTEEN.
• USE CHW (VAM) - COOLING INPUT AIR, REFRIGERATION DRYER, PROCESS COOLING
• RECYCLE REGENERATION BED WET AIR BACK TO AIR RECEIVER- ZERO LOSS DRYING
• OPTIMISE DEW POINT – WHY -40’C ? (DEW POINT SENSED REGENERATION).
• GRADED COOLING : CW-->CHW-->DESICCANT
• COLD CONDENSATES TO PRE COOL AIR STREAMS & REDUCE CHILLED WATER USE.
• Drain out oil contaminated moisture condensed.
• RECYCLE CONDENSATE FROM SUCTION AIR COOLER & DRY AIR RECEIVER AS MAKE UP TO CT.
• CHOOSE START/STOP MODE & NOT NO LOAD RUNNING - RUN MOTOR COOLER - PRECOOLED AIR
– Change from Dual/Quarta to Dynamic mode – Ensure low motor winding temp – exhaust hot
air & pre cool (Evaporative cooling of cooling air)

• USE ENERGY EFFICIENT FLAT BELT AND PRESSURE SENSED CLOSE LOOP VFD TO IMPROVE SPC - 5%.

• ENSURE LOW DP ACROSS FILTERS & CLEAN/CHANGE AT OPTIMISED DP POINT.

 ACHIEVEMENTS

Certified Energy Manager Certified Measurement &

Awarded Legend in Energy at Receiving the Prestigious
International (CEMI), AEE, USA Verification Professional
Washington DC, by Ex-US Energy Engineer of the Year
President, Mr. Bill Clinton. (CMVP), EVO, USA
2015, at WEEC,
Orlando, FL, USA.

Best Performance
National Awards –
SEEM-2015- Both as a
Best Performance National Award – “Certified Energy Auditor”
AEE Young Professional of the Year 2016 – & “ Academy (ACE) as a
WEEC, Washington DC, USA Energy Auditor at SNEMA/SEEM-2017
firm”

SyGuru Innovators Pvt Ltd. 11

ISO 9001:2015
 Your Partners in ENERGY CONSERVATION –
ENERGY AUDIT S, M&V, TRAINING & IMPLEMENTATION
• Corporate Connect:

SyGuru Innovators Pvt Ltd . - PAT ACCREDITED FIRM

ACADEMY FOR CONSERVATION OF ENERGY
– 820, Siddharth Complex, R.C. Dutt Road, Alkapuri, Baroda – 390 007, Gujarat, India
Ph: +91-265-2325024 Tele/Fax: +91-265-2325034
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SYNERGY WITH ENERGY 12