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METI / ECCJ / ACE Training Program MTPEC06 (2007.01)

Manufacturing of precision machinery
Ex.5 Improvement in Compressor Ope. Management
1. Existing problems
     A considerable amount of energy is being wasted. (The discharge pressure of the factory’s compressors is too high. The factory has no system for controlling the number of compressors brought into operation according to load conditions. There is no receiver tank. Air is leaking from piping.)

Ex.5 Improvement in Compressor Ope. Management (Manufacturing of precision machinery)
2. Improvements in the management of compressor operation
(1) Reduction in discharge pressure
     The actual discharge pressure (0.68MPa) should be lowered to 0.58MPa.
(required range is 0.45 to 0.5MPa ).
[Pressure reduction △0.1MPa is corresponding to △8% of fuel consumption.]
(2) Control of the number of compressors brought into operation & installation of receiver tank
  Currently, 6 compressors are turned on and off separately at their pressure settings. The number of compressors brought into operation should be controlled in accordance with load conditions. This will reduce power consumption, and cut down the maintenance cost.
[The receiver tank will reduce the pressure fluctuation caused by load change.]
(3) Prevention of air leakage
  The main stop valve of each unused air pipe is closed, as is the air valve of each non-operating machine.
[Generally, the air leakage is more than 10%, sometimes it reaches to 20% in factory. Total air leakage should be reduced less than 5% by proper maintenance.]

3. Preconditions for estimation
     Compressors spec. and operation time: 37kW×1unit×400h/month
37kW×2units×300h/month
22kW×1unit×180h/month
75kW×1unit×250h/month
75kW×1unit×00h/month
Discharge pressure:
Reduction of electricity consumption:
Compressor load factor:
Electricity price:
0.58MPa(Down of 0.1MPa from .68MPa)
15%
80%
¥16/kWh
4. Estimated effect:
     Electric power saving = (37kW×400h/month + 37kW×2units×300h/month
+ 22kW×180h/month + 75kW×250h/month
+ 75kW×400h/month) ×0.8×12months/y ×0.15
= 129,180kWh/y
5. Effect:
     Reduction in crude oil equivalent
= 129.2MWh/y ×9.76GJ/MWh / 38.76GJ/kL = 32.5kL/y
CO2 reduction = 129.2MWh/y×0.555tCO2/kWh = 71.7t/y
Cost saving = 129,180kWh/y×\16/kWh = k\2,067/y
(= US$17,970/y)

Thank you
More Information
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ECCJ’s Internet Home Page at:
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