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ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

GODREJ-AIR CONTROL-SOLUTION
GODREJ CONTROL AIR SOLUTIONS

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

“Energy Conservation Is The Foundation Of Energy Independence”

energy-saving-each-year-innoprudent
number-of-ifc-installations-by-innoprudent
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Our Solutions Are Helping The Industry

To Save Energy

Everyday …..

CAS - Sustainable Energy Saving Solutions

CAS- Sustainable Energy Saving Solutions-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

Compressed Air Audits

 ControlAiR™ IFC & ICC

 ES Solutions

Godrej ControlAir Intelligent Flow Control (IFC) System-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

ControlAiR IFC’s Achievements & Credentials

ControlAiR IFC’s Achievements & Credentials- ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

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

Sankey Diagram For Compressed Air System- ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

Out of 100 % Electricity Input,

  • 5 % are mechanical losses
  • 80 % are heat losses
  • Finally, only 15 % is Actually Used

Compressed Air: Most Expensive Form of Energy!

compressed-air-energy-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

Compressed Air Utilisation In Conventional System

Compressed Air Utilisation In Conventional System-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)
Even with VSD Compressor/Centrifugal Compressor, Pressure May Be Stable At Compressor, But Not At The End Use (Demand Side)
VSD Compressor/Centrifugal Compressor, Pressure-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)
End Use Requirement Real Pressure
End Use Requirement Real Pressure-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

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
Godrej ControlAiR Intelligent Flow Control (IFC) System Demand Side Management System-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)
Compressed Air System – With IFC and Useful Storage Concept
compressed-system-with-(IFC)-and-useful-storage-concept-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

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

compressed-system-with-(IFC)-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)
IFC Reduces Load Time
IFC Reduces Load Time-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

IFC Reduces loading time of the Compressor

……..Gives Energy Savings

IFC Reducing Loading time & Increasing Unloading time of the Compressor Gives Energy Savings-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

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

Energy Savings with Fixed Speed Compressor

Energy Savings with Fixed Speed Compressor-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

Energy Savings with Variable Speed Compressor

Energy Savings with Variable Speed Compressor-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)
where-to-install-IFC-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)
  • 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

HMI Touch Screen- ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

Pressure Graphs: With IFC System

Pressure Graphs With IFC System-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

Increased Efficiency Using Godrej Control Systems

Increased Efficiency Using Godrej Control Systems-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

ControlAiR™ IFC Product Range

ControlAiR IFC Product Range-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

IFC Models

10-Bar(g) Downstream Control

10-Bar(g) Upstream Control

IFC Downstream & Upstream Control-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

ControlAiR™ IFC Case Studies

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

ControlAi--IFC-Case-Study-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

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

Controller-IFC Case Study on Nitrogen Application at Auto Ancillary Company-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

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

Controller-IFC-Case-Study-in-Nitrogen-Application-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

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

Industries We Serve & Our Esteemed Clients-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)
Industries We Serve & Our Esteemed Clients-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

Team Strength

Team Strength-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

Our Global Presence

Our Global Presence-ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)
Create Wealth from Thin Air!- ENERGY SAVING SOLUTIONS IN COMPRESSED AIR NETWORK (GODREJ)

Contact Us

Godrej & Boyce Mfg Co Ltd

Compressed Air Solutions

Godrej | Electrical & Electronics

Pirojshanagar, Vikhroli, Mumbai – 400079. India

Tel.: +91-22-67962251 to 2255

E-mail: casene@godrej.com; roshe@godrej.com; shrirame@godrej.com;

Web : www.godrejcas.com ; www.godrej-airsolutions.com