System Optimization for Economic and Sustainable Production and Utilization of Compressed Air (A Case Study in Asbestos Sheet Manufacturing Plant)

Abstract

AbstractThis paper presents the findings of “performance optimization of a compressed air system—a case study in a large size asbestos sheet plant. The study was aimed at assessing the large compressed air network optimization, evaluating improvements, and suggests energy conservation measures (ECMs). Free air delivery (FAD) was evaluated to be 48–95% and specific energy consumption (SEC) as 0.08–0.12 kW/m3/min. The pneumatically controlled units were consuming electricity also at different loads. Total air consumed in the main machines, associated systems in sheet processing units (SPUs), receiver was estimated about 25% of 520 cfm generated (de-rated minimum) and equated to total FAD. The lines leakage was also estimated to be 20.3–65.1%. The study revealed that the strategic operation of compressors (include replacing or overhauling), ensuring merit-order-rating/ECMs and realize the saving of about 225 kWh/day (8–12 months payback). The housekeeping could plug the leakage in SPUs up to 10.3–55.1% (large part about 400 cfm leaked; allowable 10%) for energy saving of 30–700 kWh/day. Additional optimizing systems installations were also in progress. The sheet processing (kg asbestos per m3 compressed air or kWh) rate would be improved by 11–27 kg/m3 and 232–295 kg/kWh. Asbestos units throughout the world have been undergoing considerable pneumatic system modifications and technological advanced designs. The overall efforts on multiple factors provided a solution for the progressive capabilities, economic production, and utilization of compressed air, without which it could not be fully sustained with poor performing facilities and not maintaining its norms and processes of the upgraded systems.KeywordsSystem optimizationSustainable productionCompressed airAsbestos sheet