Modernization of the blower on the evaporators in the metallurgical plant
The modernization of the process blower enabled the reduction of pressure losses and energy consumption in the metallurgical plant. Thanks to the new blower station and improved air regulation, the client achieved annual energy savings of 7.82 GWh.
The challenge
Process installations in the metallurgical plant operated based on electrolyte evaporators powered by gas.
At the time of the audit, supplying the evaporators with air was done using old blowers without regulation capabilities, which resulted in high energy consumption. Air was transported to the evaporators over long distances through the process blower pipeline.
The nominal air demand for 7 operating evaporators was around 16,660 m3/h (an average of 2,380 m3/h per evaporator) at a minimum pressure of 0.07 MPa.
Our approach
The DB Energy team carried out:
- detailed calculations of the cost of producing compressed air and blower operation,
- measurements of air flow and pressure in the process blower pipeline,
- assessment of the possibility to install a new blower station closer to the evaporator to reduce pressure losses and increase system efficiency.
Based on this, a modernization plan was developed, considering device capacity and regulation capabilities, minimizing the need for additional compressed air.
Solution
The modernization included:
- installation of a new blower station directly at the operating evaporators,
- selection of device capacity to eliminate the need for additional compressed air,
- implementation of modern blowers with higher efficiency and improved regulation properties,
- shortening of air pipelines, reducing pressure and energy losses.
The total investment cost amounted to 1.1 million PLN.
Results
The modernization of the evaporator blower resulted in:
- reduction of energy consumption: 7.82 GWh per year,
- financial savings: 1.9 million PLN per year,
- reduction of pressure losses in the pipelines and improved efficiency of air transported to the evaporators,
- improved regulation and system stability,
- shorter response time to changes in air demand by the evaporators.
Conclusions
The modernization of the process blower shows that locating the blower station closer to process equipment and using modern regulation devices can significantly reduce energy costs and increase system efficiency.
Investment in the modernization of the compressed air system is quickly recoverable and brings measurable savings for the industrial plant.
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