Replacement of air compressors and implementation of a supervisory control system
Replacing old air compressors and implementing a supervisory control system in a metallurgical plant reduced electricity consumption by approx. 800 MWh per year. The modernization improved installation efficiency and lowered compressed air production costs.
The challenge
In a metallurgical enterprise, there were 7 fixed-speed screw compressors commissioned in the late 1990s. These devices operated under harsh conditions, and their energy efficiency had significantly decreased. The lack of central control caused suboptimal use of compressor capacity, generating excessive costs for compressed air production and increased electricity consumption.
Our approach
Analyzing the plant's needs, measurements of energy consumption and compressed air production in the existing installation were carried out.
The energy intensity ratio (energy consumption relative to production volume) was determined, and compressors that had lost the most efficiency were identified.
A comprehensive modernization was designed, including the replacement of selected units and the implementation of a supervisory control system to optimize the operation of the entire compressed air system.
Solution
The compressors were replaced with modern units of higher efficiency, and a supervisory control system was installed to automatically regulate the operation of all compressors according to the current plant demand. Central control allows individual units to be turned off or their load reduced during periods of lower demand while ensuring full capacity during peak demand.
The investment costs, including the purchase of compressors and the control system as well as installation work, amounted to approx. 700,000 PLN.
Results
The implemented investment resulted in:
- Electricity savings: 800 MWh/year
- Investment costs: approx. 700,000 PLN
- Quick payback period: less than 1 year
- Improved energy efficiency of the entire compressed air system
- Optimization of compressor operation through central control
Conclusions
The implemented modernization delivered annual electricity savings of approx. 800 MWh, significantly reducing compressed air production costs and improving the plant's energy efficiency.
Central control also enables better monitoring and real-time management of energy consumption, with a payback period estimated at less than 1 year.
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