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Compressed Air Solutions

Innoprudent > Energy Saving Solutions In Compressed Air Network (Godrej)

Energy Saving Solutions In Compressed Air Network (Godrej)

Godrej & Boyce is a 123-year-old flagship company of the Godrej Group with a turnover of over 6 billion USD and spread over 3200 acres in Mumbai. Our family of almost 28,000 Employees works together to realize a brighter and more sustainable future for our country and communities.

  • As one of 14 businesses of Godrej & Boyce company, Godrej Electricals & Electronics is as old as the company.
  • Our businesses strive to contribute to the vision of the group by delivering Sustainable Technology Solutions.
  • Compressed Air Solutions is one of the important business verticals of Godrej Electricals & Electronics

GODREJ CONTROL AIR SOLUTIONS

Energy Conservation Is The Foundation Of Energy Independence

Years

Years

Years

Our Solutions Are Helping The Industry To Save Energy Everyday …..

CAS - Sustainable Energy Saving Solutions

Compressed Air Audits

  • +1000 Air Audits
  • Team of Experienced Auditors
  • Experience in All Manufacturing Sectors
  • Total Solution Provider with Guaranteed Energy Savings

ControlAiR™ IFC & ICC

  • Supply & Demand Side Management Solution
  • 4 to 25 % Energy Saving in Air Compressors with supply & demand side optimization
  • Constant Plant Pressure within +/- 1 psig
  • +4500 Systems Installed in India, South East Asia & Netherlands

ES Solutions

  • Design, Installation of zero leak, energy saving Al Piping
  • Heat Recovery systems in compressors
  • Centralized Monitoring of complete compressed air system for continuous improvements

ControlAiR IFC’s Achievements & Credentials

Why Penumatic Energy Is The Most Inefficient Source Of Energy?

Basic Compressed Air System

Basic Compressed Air System

  • Air Compressors
  • Heat Exchanger
  • Wet Air Receivers Tanks & Condensate Drains
  • Air Treatment Equipment: Air Dryers & Filters with Condensate Drains
  • Dry Air Receiver Tanks & Condensate Drains

Demand Side: Air Consumption in Factory

  • Piping Distribution
  • Pneumatic equipment: Machines & Tools
  • Cleaning
  • Drying
  • Conveying

Fig : Sankey Diagram For Compressed Air System

Compressed Air: Most Expensive Form of Energy!

Compressed Air Utilisation In Conventional System

Even with VSD Compressor/Centrifugal Compressor, Pressure May Be Stable At Compressor, But Not At The End Use (Demand Side)

End Use Requirement Real Pressure

Just because of the plant 4 required the pressure of 7 bar, all other plants receive air at 7 bar pressure. This is artificial demand.

Problems With Fluctuating Air Pressure:

  • Higher Energy Consumption.
  • Inconsistent equipment performance.
  • Variable product quality.
  • Increased maintenance costs.
  • Premature equipment failure.
  • Higher operating costs.
  • Interruptions in production schedules.

Godrej ControlAiR Intelligent Flow Control (IFC) System Demand Side Management System

Compressed Air System – With IFC and Useful Storage Concept

The IFC creates useful storage – it helps to run the system more efficiently by providing a normal pr. Band at the comps and primary receivers, and by maintaining a stable reduced system pressure

Compressed Air System with IFC

IFC Reduces Load Time

IFC Reduces loading time of the Compressor ……..Gives Energy Savings

IFC Reducing Loading time & Increasing Unloading time of the Compressor ……..Gives Energy Savings

Energy Savings with Fixed Speed Compressor

IFC Reducing Loading time & Increasing Unloading time of the Compressor ……..Gives Energy Savings

Energy Savings with Variable Speed Compressor

  • Works with All Brands & Types of Air Compressors
  • Reduces Artificial Demand & Save Energy, 4 ~ 25 %
  • Provides Constant Pressure at the End Use, within +/- 1 psig
  • Fail To Open System with Autobypass facility
  • Improves control performance of VSD Compressors
  • 99 Pressure scheduling & remote PC Visualization software can be done

HMI Touch Screen

Pressure Graphs: With IFC System

Increased Efficiency Using Godrej Control Systems

ControlAiR™ IFC Product Range

IFC Models

10-Bar(g) Downstream Control

10-Bar(g) Upstream Control

ControlAiR™ IFC Case Studies

ControlAiR™ IFC Case Study in 7 barg Network @ Textile Industry

Benefits: Productivity Improvement and Energy Saving

  • Reduction in Artificial demand leading to energy saving in air compressors
  • Constant plant pressure within +/- 0.5 psig
  • Recued Yarn breakages by 17% leading to higher production due to less downtime

Simple Payback Period with Energy Saving @ 8%: 09 months

ControlAiR™ IFC Case Study in 40 bar PET Application @ Beverage Industry

Benefits: Quality Improvement and Energy Saving

  • Very Stable air pressure : 5 barg fluctuations reduced to just within 0.2 barg
  • Reduction in Artificial Demand è Energy saving ~15% in Compressed Air!
  • Simple Payback Period with Energy Saving @ 15%: <6 months

Simple Payback Period with Energy Saving @ 16%: 2 months

ControlAiR™ IFC Case Study in Nitrogen Application @ Auto Ancillary Company

Benefits: Productivity Improvement and Energy Saving

  • Very Stable N2 Pressure – Production interruptions completely eliminated
  • Equivalent reduction in Artificial Demand è 2X Saving in Nitrogen than in Compressed Air!
  • N2 Generator Capacity Reduction by 27%

Simple Payback Period with Energy Saving @ 16%: 2 months

Industries We Serve & Our Esteemed Clients

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Godrej & Boyce Mfg Co Ltd