Energeia’s Air Compressor Optimization Saves a Paper Manufacturer ₹2.1 Crore Annually

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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Energeia optimized a leading paper manufacturer’s compressed air system by replacing two outdated compressors with an energy-efficient centrifugal compressor featuring turbo, screw technologies, and VFD.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

0.1 Crore

Monetary Savings Annually

0,15,000 kWh

Energy Savings Annually

0,882 Tonnes

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:

  1. Aging Compressors: Models dating from 2005 to 2009 showed declining performance.
  2. Inefficient Compressors: Two compressors exhibited high specific energy consumption (CF1: 0.274 kW/CFM, CF3: 0.465 kW/CFM).
  3. Frequent Wastage: Excessive purging and air wastage during low-load conditions.
  4. Maintenance Issues: Persistent challenges due to outdated equipment.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.

Results

  • Energy Savings: Reduced energy consumption by 35,15,000 kWh annually, cutting operating costs by ₹2.1 Crore.
  • CO₂ Emission Reduction: Lowered emissions by 2,883 tonnes annually, aligning with sustainability goals.
  • Enhanced Performance: Improved system reliability and reduced maintenance downtime.

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