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28 Jul, 2022
Posted by Anand
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Compressed Air Systems

Compressed air systems are a major utility area in the process industry and consume up to 20-30% of energy in the plant. In the current Situation, the compressed air cost is around Rs 1-3 CFM which is pricey.

80% of Industries use screw compressors. Screw compressors due to their unloading consumption patterns cause a loss of electrical energy of up to 60%. Also as these compressors start getting old their specific power benchmark consumption value which should be around 0.16 kW/cfm goes on increasing up to 0.24-0.25 kW/cfm.

So we have taken up compressed air systems at the center of our energy conservation scope and have completed assessments of compressed air systems in rubber / plastic molding / dairy / pharma industries.

Here’s how a Milk Dairy industry in Pune has used Powerbot to do just that:

Case Study I- Compressed air system

Industry: Tools Manufacturer Compressor: ELGI (E15-7.5)Operations: Pneumatic valve control, CNC machines and cleaning operationsMonthly energy consumption: 4353;
Compress UnitsEnergy-saving due to VFD installation & air leakage rectifications: 2633 Units per monthMonetary saving: Rs. 26,325 per month

The ideal value of actual air volume delivered by the compressor w.r.t. of energy consumption should be 0.16 kW/CFM, but it comes as close to 0.22 to 0.24 kW/CFM. It clearly shows energy-saving opportunities, as high as 40%. During the unloading condition of a compressor, the air is not compressed but the motor consumes the power, resulting in a loss of energy. We helped them reduce 60% of their electrical energy consumption by eliminating unloading conditions.

At Powerbot, we focus on only one thing – minimizing electricity costs for industries. Today, we are working with 300+ industries in Maharashtra and have so far helped them realize savings of Rs. 10 Cr. Our clients include Thermax, Kalyani Group, Tata Group, Advik, Bajaj, Aditya Birla Group, Poonawalla Group, American Axle and Many more.