Executive Summary
Energeia optimized a leading paper manufacturer’s compressed air system by replacing two outdated compressors with an energy-efficient centrifugal compressor featuring turbo, screw technologies, and VFD. This eliminated inefficiencies, saving ₹2.1 Crore annually, reducing energy usage by 35.15 Lakh kWh, and cutting CO₂ emissions by 2,882 tonnes while improving reliability and sustainability.
Key Stats
Monetary Savings Annually
Energy Savings Annually
CO₂ Emission Reduction
Customer Overview
The client, a prominent paper manufacturer in India, relies heavily on compressed air systems essential to its production processes.
Challenges
FAD (Free Air Delivery) Audit
Energeia conducted a detailed FAD (Free Air Delivery) audit using advanced diagnostic tools and IoT-enabled real-time monitoring.
Comprehensive Performance Evaluation:
- Measured FAD at pressures of 4.8, 5.2, and 5.5 bar.
- Analyzed specific power consumption for each compressor.
Detailed Analysis:
The audit identified several inefficiencies, including:
- Aging Compressors: Models dating from 2005 to 2009 showed declining performance.
- Inefficient Compressors: Two compressors exhibited high specific energy consumption (CF1: 0.274 kW/CFM, CF3: 0.465 kW/CFM).
- Frequent Wastage: Excessive purging and air wastage during low-load conditions.
- Maintenance Issues: Persistent challenges due to outdated equipment.
Energeia’s Solution: Air Compressor Optimization
Energeia replaced two inefficient air compressors with a single energy-efficient centrifugal compressor that delivers industry-leading performance. The new compressor combined turbo and screw technologies with a Variable Frequency Drive (VFD). This optimized setup eliminated air blow-offs and ensured the system operated at maximum efficiency.