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Webinar - Energiebesparing bij industriële compressoren - praktijkcase
The webinar discusses energy savings in industrial compressors, focusing on a case study involving compressed air systems in the glass industry. Implementation of control system improvements and new technology has resulted in significant energy savings of approximately €280,000 annually, alongside reductions in CO2 emissions. Key strategies included installing flow meters, a booster compressor, and a master controller to optimize system performance.
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Webinar - Energiebesparing bij industriële compressoren - praktijkcase
- 1. Plaatje leaflet hier invoegen Wijstarten om 12.00 uur. U kunt tijdens het webinar vragen stellen via de Q&A knop in het zoom-menu. Tijdens het webinar staan alle bezoekers op ‘mute’. Welkom bij het Webinar ENERGIEBESPARING BIJ INDUSTRIËLE COMPRESSOREN
- 2. PRAKTIJKCASE - ENERGIEBESPARING BIJINDUSTRIËLE COMPRESSOREN
- 3. 3 December 2, 2020Page 3 INTRODUCTION DICK VAN MAANEN DICK VAN MAANEN Product Specialist compressed air systems. Stork Specialist Services • 30 years experience on compressed air systems. • Specialized in centrifugal air compressors and complete air systems demand site. • Controls specialist centrifugal air compressors. We have delivered master control systems at these customers in the Netherlands • Owens Illinois • Mars • NXP Semiconductors • Cargill • Alvance Aluminium
- 4. 4 December 2, 2020Page 4 COMPRESSED AIR IN GLASS INDUSTRY Adjustable speed drives 10% 26% 42% 12% 10% All other measures Overall system design Recovering waste heat reducing air leaks & optimize supply MAJOR ENERGY SAVING MEASURES Critical utility for production Up to 30% of electricity costs Savings potential up to 50% Pressure band width is critical: • Quality of glass • Continued production
- 5. 5 December 2, 2020Page 5 COMPRESSED AIR SYSTEM LAY OUT Low pressure @ 340 kPa av. consumption 15.500 Nm3/hr High pressure @ 580 kPA av. consumption 22.000 Nm3/hr
- 6. 6 December 2, 2020Page 6 COMPRESSOR ROOM LAY-OUT - BEFORE 2 x Centrifugal Full load Each 7.200 - 5.400 Nm3/hr 700-540kW 8 x Screw Load/unload/stop Each 2.100 Nm3/hr 250kW Centrifugal 13.000 -10.000 Nm3/hr 930-700kW- Centrifugal 9.400 -6.400 Nm3/hr 730-540kW LP Pressure 340kPa +/- 15.500 Nm3/hr HP Pressure 580kPa +/- 22.000 Nm3/hr Regulator emergency valve 580 to 340 kPa Max. Capacity 22.400 Nm3/hr. Min. Capacity 16.400 Nm3/hr. (900 Nm3/hr. blow-off = Energy waist!!!) Max. Capacity 31.200 Nm3/hr. Min. Capacity 10.800 Nm3/hr.
- 7. 7 December 2, 2020Page 7 BEFORE IMPLEMENTATION HIGH PRESSURE SYSTEM • Both centrifugal air compressors always running full load. • Screw compressors started @ 580 kPa: resulting in pressure fluctuations: 560..585 kPa. • Unloaded hours on screw compressors. • Emergency regulator: only activated when pressure drops in LP system to 320 kPa • Flow meters installed in 2013 + only for indication: observe flow/kWh consumption.
- 8. 8 December 2, 2020Page 8 BEFORE IMPLEMENTATION LOW PRESSURE SYSTEM • LP compressor: maintaining 340 kPa in main header. • Compressors running without communications but on same system pressure transmitter. • No load sharing. • Occasional blow off.
- 9. 9 December 2, 2020Page 9 HOW WE ADD VALUE Install & connect flow meters Install booster compressor Modify regulator valve Install Master controller Energy savings !
- 10. 10 December 2, 2020Page 10 COMPRESSOR ROOM LAY OUT IMPROVEMENTS Booster Compressor 340 to 580 kPa 4.000 Nm3/hr 130kW
- 11. 11 December 2, 2020Page 11 REQUIREMENT FROM CUSTOMER • Low Pressure system is most critical. Pressure 340 kPa. Dev. +/- 5 kPa • Energy savings @ maximum when booster compressor is running full load. • Energy savings @ maximum when screw compressors are only running full load (implemented at phase 2) • When one of the low pressure units trips actions: – Booster should unload and stopped. – Screw compressors starts up depending on the needed flow. – Emergency regulator valve should open to maintain the low pressure.
- 12. 12 December 2, 2020Page 12 1ST PHASE IMPLEMENTATION RESULTS • Installation centrifugal booster: capacity 4.000 Nm3/hr. – Booster feeds the HP system: 3 screw compressors are not needed • Rebuild LP compressors to a new control system including load sharing. • Rebuild HP compressors to a new control system including load sharing. • Rebuild existing control from emergency regulator to Stork controller.
- 13. 13 December 2, 2020Page 13 ENERGY SAVINGS Energy savings : 294 kW/hr. € 140.150,00 Just the beginning….
- 14. 14 December 2, 2020Page 14 IMPROVEMENT STEP 2 HIGH PRESSURE SYSTEM • High pressure compressors: rebuilt with Stork control panel (Siemens S7-1200) • Connect to new master controller • 8 screw compressors and centrifugal compressors will be controlled by the master controller.
- 15. 15 December 2, 2020Page 15 IMPROVEMENT STEP 2 RESULT • System pressure can be safely set to a lower value from 580 kPa to 520 kPa. • 2 Centrifugal air compressors control the pressure using inlet guide vane modulation. • Centrifugal control range ~ 1 screw compressor! • Flow signal control system: Calculate if a screw compressor should be started or shut down and loaded into the system. • Also this solution will provide the same energy savings ~ 140 K Euro/ year.
- 16. 16 December 2, 2020Page 16 CONTROL LOGIC STACKING COMPRESSORS 2100 2100 5400-7200 5400-7200 2100 2100 2100 2100 2100 2100 4000 Booster
- 17. 17 December 2, 2020Page 17 CONTROL LOGIC … CENTRIFUGAL IGV 2100 2100 5400-7200 5400-7200 2100 2100 2100 2100 2100 2100 4000 Booster
- 18. 18 December 2, 2020Page 18 CONTROL LOGIC … CENTRIFUGAL IGV 2100 2100 5400-7200 5400-7200 2100 2100 2100 2100 2100 2100 4000 Booster Flow in Nm3/hr.
- 19. 19 December 2, 2020Page 19 OPTIMALISATION WITH NEWEST TECHNOLOGIE ON CENTRIFUGAL AIR COMPRESSORS
- 20. 20 December 2, 2020Page 20 CONCLUSIONS • Without major changes of basic hardware: estimated savings: € 280K. • Implementation possible on every compressor. • Signicant CO2 reduction. • Delivered mastercontroller software is not a black box. Program can be updated when the process changes on customer side. • A master controller is a must have for any production plant with multiple compressors.
- 21. December 2, 2020Page 21 Questions Via Q&A Sustainable Performance Improvement Or get in touch with our Subject Matter Expert: Dick van Maanen Dick.vanMaanen@stork.com +31 6 22 79 44 97 WEBINAR ENERGY SAVINGS @ INDUSTRIAL COMPRESSORS
- 22. STORK IS HERETO HELP YOU Contact us: AMT@stork.com 9 December Innovation & Asset management @ Tank Terminals 16 December Impact of Gatekeeping @ Maintenance Processes Sign in @ www.stork.com/wednesday-webinars Next webinars:
- 23. THANK YOU FOR YOURATTENTION
Editor's Notes
- #22 Vragen: Wat zijn de criteria voor het inzetten van een High Performance Team? Hoe ga je om met de cultuur verschillen? Je noemde in de definitie van High Performance Team dat ‘er druk aanwezig is’. Hoe ervaart het team deze druk? Hoe gaat het team hiermee om? In welke cases is dit toegepast? Wat waren de effecten? Welke eisen stelt dit aan het eigen bedrijf? Is dit iets wat STORK alleen kan doen? De referentie database, wat zit daar in? Is dit een standaard?
- #23 Slide voor donderdag