Compressed Air System Optimization: Case Study Food Industry in Indonesia

Abstract

Compressors and compressed air systems was one of the most important utilities in industries or factories. Approximately 10% of the cost of electricity in the industry was used to produce compressed air. Therefore the potential for energy savings in the compressors and compressed air systems had a big challenge. This field was conducted especially in Indonesia food industry or factory. Compressed air system optimization was a technique approach to determine the optimal conditions for the operation of compressors and compressed air systems that included evaluation of the energy needs, supply adjustment, eliminating or reconfiguring the use and operation of inefficient, changing and complementing some equipment and improving operating efficiencies. This technique gave the significant impact for energy saving and costs. The potential savings based on this study through measurement and optimization e.g. system that lowers the pressure of 7.5 barg to 6.8 barg would reduce energy consumption and running costs approximately 4.2%, switch off the compressor GA110 and GA75 was obtained annual savings of USD 52,947 ≈ 455 714 kWh, running GA75 light load or unloaded then obtained annual savings of USD 31,841≈ 270,685 kWh, install new compressor 2x132 kW and 1x 132 kW VSD obtained annual savings of USD 108,325≈ 928,500 kWh. Furthermore it was needed to conduct study of technical aspect of energy saving potential (Investment Grade Audit) and performed Cost Benefit Analysis. This study was one of best practice solutions how to save energy and improve energy performance in compressors and compressed air system.