Executive Summary
A leading glass manufacturer in India faced high energy costs due to inefficient compressed air systems. Energeia’s audit identified several inefficiencies and recommended various energy-saving measures, including addressing high delta pressure, optimizing ambient air intake, and recommending regular maintenance of suction filters. Implementation of these measures saved ₹26.8 lakh annually and reduced energy consumption by 3,35,000 kWh.
Key Stats
Monetary Savings Annually
Energy Savings Annually
CO₂ Emission Reduction
Customer Overview
The company is a leading integrated glass solutions company in India, catering to the automotive, building & construction, and consumer segments. The company operates across several locations, with a comprehensive product line ranging from automotive windshields to architectural glass and consumer products like microwave oven glass. The facility in Rewari, Haryana, relies heavily on compressed air systems for its manufacturing processes.
Challenges
The company faced multiple challenges with its compressed air system:
- High Pressure Drop: High pressure drop across the compressor plant in both low and high-pressure compressors led to increased energy consumption.
- Inadequate Ambient Air Intake: Suboptimal ambient conditions raised air intake temperatures, increasing compressor energy use.
- Suction Filter Inefficiencies: Lack of regular maintenance for suction filters caused increased energy consumption.
- Air Leakages: Although air leakage was low (under 5%), maintaining this standard through periodic audits remained a priority.
- Aging Compressors: Older compressors operated at low efficiency, leading to high maintenance costs and unreliable performance.
Energeia’s Solution: E-Air Optimization
Energeia conducted a detailed compressed air audit at the facility, identifying several energy conservation measures:
- Compressor Upgrade: Advised replacing older compressors (0.20 kW/CFM) with energy-efficient models to ensure optimal performance on the Low Pressure Side
- VFD installation: As average demand was much lower on the high pressure side than the compressor capacity, it was recommended to retrofit the compressor with a VFD.
- Delta Pressure Optimization: Recommended reducing delta pressure across compressors to enhance energy efficiency.
- Ambient Air Intake Improvements: Recommended relocating compressors to cooler environments to lower air intake temperatures by 6°C, leading to reduced energy consumption.
- Suction Filter Maintenance: Suggested regular maintenance of suction filters to ensure efficient airflow, reducing energy losses.
- Air Leakage Monitoring: Proposed periodic leak detection to maintain less than 5% air loss.
