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
“Energy Conservation Is The Foundation Of Energy Independence”
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
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 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
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
Team Strength
Our Global Presence
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