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Alexander Pavlov IETC, New Orleans, 20-21/05/10 Energy Efficiency in Compressed Air Systems.

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Presentation on theme: "Alexander Pavlov IETC, New Orleans, 20-21/05/10 Energy Efficiency in Compressed Air Systems."— Presentation transcript:

1 Alexander Pavlov IETC, New Orleans, 20-21/05/10 Energy Efficiency in Compressed Air Systems

2 2 Atlas Copco in a Snapshot  A world-leading provider of industrial productivity solutions.  Products and services range from compressed air and gas equipment, generators, construction and mining equipment, industrial tools and assembly systems, to related aftermarket and rental.  In close cooperation with customers and business partners, Atlas Copco delivers sustainable solutions for increased productivity through innovative products and services.  Headquartered in Sweden, the Group’s global reach spans more than 170 markets.  In 2009 Atlas Copco had 30 000 employees and annual revenues of approximately BSEK 64 (BEUR 6.0).

3 3 The Atlas Copco Organization Executive Group Management and Corporate Functions Oil-free Air Industrial Air Portable Air Specialty Rental Gas and Process Compressor Technique Service Airtec Compressor Technique Construction and Mining Technique Industrial Technique Underground Rock Excavation Surface Drilling Equipment Drilling Solutions Secoroc Construction Tools Road Construction Equipment Geotechnical Drilling and Exploration Rocktec Atlas Copco Tools and Assembly Systems Motor Vehicle Industry Atlas Copco Tools and Assembly Systems General Industry Chicago Pneumatic Tooltec Customer Centers and Service Providers President and CEO Board of Directors

4 4 Worldwide Presence Production sites

5 5 Value of Energy in Compressed Air Systems  70% to 80% of life cycle costs is energy  In EU compressed air accounts for 10% of the energy consumed by industry  1 bar lower in pressure, reduces energy by 7%  Typically, after 5 years leakages can take 20% of the total air consumption Some useful facts and figures Investment 12% Installation 3% Maintenance 15% Energy consumption 70% Energy Savings

6 6 CO2 emissions – the big picture  Design of product  Logistics  Energy use  Re-use  Design of product  Less electricity consumption Atlas Copco focus (95% +)

7 7 Why Atlas Copco Saving energy is our way of life A century of innovation in energy saving features Over 400 patents

8 8 EU electricity consumption in compressed air Real consumption in CAS TWh Share of electricity In EU the compressed air accounts for 10% of the energy consumed by industry, 80 TWh/year Source: Compressed air systems in the European Union, 2001, study by Fraunhofer Institute, ADEME, ECE, University of L’Aquila

9 9 Potential contribution to energy savings System installation or renewal% applicability (1) % gains (2) Potential contribution (3) Improvement of drives (high efficiency motors, HEM)25 %2 %0.5 % Improvement of drives (adjustable speed drives, ASD)25 %15 %3.8 % Upgrading of compressor30 %7 %2.1 % Use of sophisticated control systems20 %12 %2.4 % Recovering waste heat for use in other functions20 % 4.0 % Improving cooling, drying and filtering10 %5 %0.5 % Overall system design, including multi-pressure systems50 %9 %4.5 % Reducing frictional pressure losses50 %3 %1.5 % Optimising certain end use devices5 %40 %2.0 % System operation and maintenance Reducing air leaks80 %20 %16.0 % More frequent filter replacement40 %2 %0.8 % TOTAL32.9 % Table legend:(1) % of CAS where this measure is applicable and cost effective (2) % reduction in annual energy consumption (3) Potential contribution = applicability * reduction Source: Compressed air systems in the European Union, 2001, study by Fraunhofer Institute, ADEME, ECE, University of L’Aquila 32.9 % = 30.5 TWh/yr = 0.7 million tonnes of CO²/yr

10 10 Superior solutions Total energy saving concept From products to solutions The unique approach Customer needs core technology drive technology energy saving accessories energy recovery demand assessment optimization of the room

11 11 The Energy Circle Superior solutionsCustomer needs core technology drive technology energy saving accessories energy recovery demand assessment optimization of the room

12 12 Demand assessment  System audit: –Flow measurement –Pressure measurement –Power measurement  Report: –Simulation of optimal compressor installation –Simulation of central control system –Potential energy savings Overall system design

13 13 Leak detection  Ultrasound leak detection  Report –Location –Leak flow –Equivalent energy loss

14 14 System assessment AirScan - Tools Hot tapping Temperature Leak detection Flow Dewpoint measurement Power/logging device VIP sens Measurement box Flow measurement output

15 15 The Energy Circle Superior solutionsCustomer needs core technology drive technology energy saving accessories energy recovery demand assessment optimization of the room

16 16 Oil-free screw compressors 55-900 kW Oil-injected screw compressors 5-500 kW Turbo compressors 500-2500 kW Matching air treatment equipment Dryers,filters,drains,separators,etc ES – energy saving central controllers Optimization, monitoring, control Oil-free scroll compressors 1-15 kW Oil-free tooth compressors 15-45 kW Best compression and treatment technologies under one roof Products

17 17 Atlas Copco has all the technologies available Specific energy J/l (Hp/cfm) centrifugal screw tooth Power (flow) scroll Appropriate selection can save a lot of energy 18 kW55 kW750 kW Energy Savings

18 18 Before 19902008 Specific Energy (J/l, Hp/cfm) 110 (21.2)100 (212)1000 (2,120) FAD l/s (cfm) 1995 - 20032000 - 2006 System design : innovations in screw elements 3-5%3% 11kW22kW30kW55kW90kW132kW200kW300kW 5- 6%

19 19 The Energy Circle Superior solutionsCustomer needs core technology drive technology energy saving accessories energy recovery demand assessment optimization of the room

20 20 Monday Tuesday Wednesday Thursday Friday Saturday Sunday l/s hour 50 100 150 200 250 Typical air demand pattern Measurement and simulation tools are available to calculate precise energy savings in a real environment Energy Savings Average use 50%

21 21 time Theory Loaded pressure Unloaded system pressure Energy savings with VSD T T- time for complete system venting Actual Excess energy Power consumption during transition from load to no load with traditional regulation

22 seconds kW 0 10 20 30 40 50 0 20406080 100120140160180200220240260 Power consumption GA45 L-NL at 50% Energy savings with VSD ~80% Power consumption during transition from load to no load with traditional regulation vs. VSD VSD

23 23 VSD technology can save up to 35% of energy centrifugal screw tooth Flow m 3 / min scroll 18 Kw55 Kw750 Kw $/M3 Specific energy J/L or $/M3 Energy cost per m3 of air at 7 bar(e) (100 psig) VSD – Variable speed drives

24 24 0 250 500 750 1000 kW Company A Company B Company E Others : mainly promoting free-standing Company C Company D Atlas Copco Widest integrated VSD range (from 7.5 to 900 KW) Our commitment to VSD technology

25 25 The Energy Circle Superior solutionsCustomer needs core technology drive technology energy saving accessories energy recovery demand assessment optimization of the room

26 26 MD and XD dryers – energy-less air drying  Heat of compression is used for drying  No external energy or purge is required  Very low pressure drops Energy savings between 5 and 20% are possible ! Efficiency – Air quality

27 27 Dryer energy consumption (-20 o C, -4°F PDP) Type of dryer % of compressor power

28 28 The Energy Circle Superior solutionsCustomer needs core technology drive technology energy saving accessories energy recovery demand assessment optimization of the room

29 29 PRESSURE BAND CASCADE com- pressor 1 com- pressor 2 com- pressor 3 com- pressor 4 Net pressure Time LOCAL CONTROL CENTRAL CONTROL Average pressure Required minimum pressure HIGH COSTSLOW COSTS Energy savings through optimization  ES controls the net pressure –Net pressure is guaranteed while compressors run at lowest required pressure  Lower pressure by 1 bar reduces energy by 7%

30 30 Automatic selection of “Best Size” compressor  Net pressure drops fast  Net pressure drops slowly Pressure Time Pressure Time Big compressor Small compressor

31 31 Efficient? Optimization of VSD compressors VSD 2: ~ 70% Local control Flow Time VSD 2: 50% VSD 2: ~50% ES optimization Flow Time VSD 1: 30% SER (J/l) Flow (l/s) VSD 1VSD 2 SER (J/l) Flow (l/s) VSD 1VSD 2

32 32 Optimization of Turbo’s and VSD Efficient? Local control SER (J/l) Turbo 2 Turbo 1 SER (J/l) Flow (l/s) VSD SER (J/l) Flow (l/s) VSD Blow-off SER (J/l) Turbo 1 Blow-off Turbo 2 Flow Time Turbo 2: 50% (blow-off ~20%) Turbo 1: 100% (blow-off 0%) VSD 2: 90% ES optimization Flow Time Turbo 2: 80% (blow-off 0%) Turbo 1: 100% (blow-off 0%) VSD 2: 50% …..

33 33 Carbon Zero The unique approach core technology drive technology efficient air treatment optimization of the room demand assessment ‘Carbon Zero’ “net zero energy” The new milestone Recovery

34 34 Measured parameters TÜV test

35 35 Type test of ZR 55-750 range with built-in energy recovery systems Comparison of the electrical energy consumption with heat energy recovered Certified results  “100% of the electrical energy consumed could be recovered”  “ net power (energy) consumption of the ZR compressor with built-in energy recovery at specific design conditions is zero” Certified results  “100% of the electrical energy consumed could be recovered”  “ net power (energy) consumption of the ZR compressor with built-in energy recovery at specific design conditions is zero”

36 36 Introducing Carbon Zero Electrical energy input converted to heat 10% losses in radiation, etc. Direct energy recovery 90% Energy in atmospheric air (latent heat) Atmospheric energy 12% 102 Result – Net Zero energy consumption Released due to condensation in coolers 100% 15%

37 37 Carbon Zero principal build-up ZR Energy recovery ZR Energy recovery Oil cooler HP element LP element Aftercooler Intercooler Thermostatic valve ER control unit Water circuit 42% 37% 9% 12% Recovered energy at 10 bar(e) (145 psig) 20-40°C (68-104°F) 70-90°C (158-194°F)

38 38 Components of the energy recovery systems HH H H T T TI PI HH HH Control unit scope is within the dashed line. Outside is customer’s scope. H Heat consumer ZR Secondary cooling water system

39 39 What makes ZR compressor unique  Compared to oil-injected screws –ZR compressors have much higher temperatures due to which they can recover 100% of the electrical energy as heat, under design conditions. Watercooled OIS can recover +/- 70%  Compared to turbos –Lower temperatures in turbos restrict energy recovery severely –Interstage energy recovery can create instability –At reasonable temperatures energy recovery is 30-35%  Compared to other oil-free screws –Others are not recovering energy from oil coolers and jackets, thus losing 20-25%. So energy recovery with competitors OFS could be at best 80%

40 40 Applications Space heating Showers Boiler feed

41 41 Some high level steam applications

42 42 Example of savings with Carbon Zero  Consider a ZR132 kW compressor and an energy recovery of 135 kW  Heat equivalent per second = 135 kJ/s  When using heating oil (HO)  Calorific value = 41,200 kJ/l  Boiler efficiency = 70% without recovery and 90% with recovery  Heat generated per hour = 135 kJ/s x 3600  Fuel saved = 135 x 3600 / (41,200 x 0.9) = 13 l/h = 3.4 gal/h  Cost of fuel = 0.5€/l x 13 l/h = 6.50 €/h = 8 $/h  Yearly savings = 6.5€ x 8000 h/y = 52,000 € per year = $ 64,000 per year * Calculation based on full load running for 8000 hours – full potential

43 43 Carbon Zero ZR range 270 m³/h 7,470 m³/h 4 bar(e) 58 psig 10.4 bar(e) 151 psig ZR 55 – ZR 750 ZR 75 VSD – ZR 700 VSD 159 cfm 4,387 cfm

44 44 Conclusions: Energy Efficiency in CAS  Reducing air leaks –Ultrasonic leak detection  Overall system design –System audits and simulation –Optimal compression technologies –Control and ancillary systems  Use of adjustable speed drives (ASD) –Variable Speed Drives  Recovery of waste heat –Carbon Zero compressors recover up to 100% Atlas Copco approach

45 45 Committed to sustainable productivity.

46 46


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