In veel industrieën zijn compressoren grootverbruikers van elektriciteit. Zeker wanneer er meerdere compressoren naast elkaar actief zijn met elk hun eigen aansturing blijkt dat veel meer vermogen wordt gevraagd dan feitelijk noodzakelijk is. Door het slim koppelen en aansturen van compressoren kunnen enorme besparing worden gerealiseerd in verbruik, en daarmee in kosten en CO2 uitstoot. In dit webinar neemt Dick van Maanen u mee in een praktijk case met verbluffende resultaten: De realisatie van een significante energiebesparing op de compressorinstallatie bij een Nederlandse glasfabrikant. Dick van Maanen is Subject Matter Expert Air compressors bij Stork.

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ENERGIEBESPARING BIJ INDUSTRIËLE COMPRESSOREN

2. PRAKTIJKCASE - ENERGIEBESPARING
BIJ INDUSTRIËLE COMPRESSOREN

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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

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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

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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

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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.

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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.

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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.

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HOW WE
ADD VALUE
 Install & connect flow meters
 Install booster compressor
 Modify regulator valve
 Install Master controller
Energy savings !

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COMPRESSOR ROOM LAY OUT
IMPROVEMENTS
Booster Compressor
340 to 580 kPa
4.000 Nm3/hr 130kW

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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.

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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.

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ENERGY
SAVINGS
Energy savings :
294 kW/hr.
€ 140.150,00
Just the
beginning….

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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.

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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.

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CONTROL LOGIC
STACKING COMPRESSORS
2100
2100
5400-7200
5400-7200
2100
2100
2100
2100
2100
2100
4000
Booster

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CONTROL LOGIC …
CENTRIFUGAL IGV
2100
2100
5400-7200
5400-7200
2100
2100
2100
2100
2100
2100
4000
Booster

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CONTROL LOGIC …
CENTRIFUGAL IGV
2100
2100
5400-7200
5400-7200
2100
2100
2100
2100
2100
2100
4000
Booster
Flow in Nm3/hr.

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OPTIMALISATION WITH NEWEST TECHNOLOGIE
ON CENTRIFUGAL AIR COMPRESSORS

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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.

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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

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