Analysis and Optimization of Mechanical Utility System
- 1. Analysis and Optimization of Mechanical Utility System Presented by: Kolambkar Deeptej Govind Nandu Pooja Kishor Sinkar Kiran Kashinath Sohal Simran Avtarsingh
- 2. Project Objectives • To Carry out a detailed analysis of the mechanical utility system. • Identification of a system which might require improvement and optimization. • Increasing system efficiency by finding a feasible alternative to the currently employed compression system. • Prediction and documentation of the monetary, power and maintenance savings after replacement.
- 3. Compression System • Chemical plant operation requires pure nitrogen, obtained by adsorption process. • Ambient air is compressed to a pressure of 7.7 Kg/cm2 in a 2 stage reciprocating air compressor. • The compressed air passes through a Carbon Molecular Sieve (CMS) • Oxygen and other gases are adsorbed on the CMS surface & only nitrogen is passed to the storage cylinder. • The required mass flow rate of nitrogen for chemical processes is 100 m3/ hr.
- 4. Utility System Floor Layout
- 5. Component Overview • First bullet point here • Second bullet point here • Third bullet point here Sr. No. Component Name Operating Parameters Power Rating Application 1. Reciprocating air compressor Pressure Ratio= 7.454 Flow rate = 257.407cfm 45 kW/ 60 hp To supply compressed air to nitrogen filter. 2. Reciprocating air compressor Pressure Ratio = 6.5 23 kW/ 30 hp Used for operation of various pneumatic valves in MUS. 3. Reciprocating air compressor (20 TR) Flow rate = 163.8 cfm 55 kW/ 75 hp To supply compressed ammonia to brine chiller for cooling purpose. 4. Reciprocating air compressor (30 TR) Flow rate = 245.74 cfm 70 kW/ 95 hp To supply compressed ammonia to brine chiller for cooling purpose. 5. Nitrogen separator Pressure = 5 kg/cm2 Flow rate = 61.72 cfm - Required for chemical processes.
- 7. Maintenance • First bullet point here • Second bullet point here • Third bullet point here Component Life Cost per unit (Rs.) Maintenance time per unit Total cost per year (Rs.) V-belt 3 months 1600 30 minutes 25,600 Piston Rings 6 months 2800 3 to 4 hrs. 11,200 Piston 2 to 3 years 12000 4 hrs 8,000* Discharge Valves 4 months 3925 4 hrs 23,550 Suction valves 4 months 4250 4 hrs 25,500 Page 37 -39
- 8. Component Breakdown Frequency 0 1 2 3 4 5 6 Category 1 Category 2 Category 3 Category 4 Series 1 Series 2 Series 3 3 6 24 4 4 3 6 0 5 10 15 20 25 30 V-Belt Piston Ring Piston Discharge Valves Suction Valves Lubricant Oil Air Filters Time(inmonths) Frequency Page 40
- 9. Maintenance Down Time 0 1 2 3 4 5 6 Category 1 Category 2 Category 3 Category 4 Series 1 Series 2 Series 3 30 240 240 240 240 5 15 120 480 160 720 720 20 30 0 100 200 300 400 500 600 700 800 V-Belts Piston Ring Piston Discharge Valves Suction Valves Lubricant Oil Air Filter Time(inminutes) Down Time per Unit Down time per year per unit Page 40
- 10. Total Maintenance Cost 27% 12% 8%24% 27% 0.2% 2% V-Belt : Rs.25600 Piston Rings : Rs.11200 Piston : Rs. 8000 Discharge Valves : Rs. 23550 Suction Valves : Rs. 25500 Lubricant Oil : Rs. 400 Air Filters : Rs. 1900 Total cost : Rs. 96150 Page 42
- 11. Maintenance Time & Cost Saving • First bullet point here • Second bullet point here • Third bullet point here Component Time saved per Annum V-belts 120 minutes. Piston rings 480 minutes. Piston 160 minutes. Total time saved 760 minutes = 12 hours 40 minutes. Component Cost saved / Annum V-belts Rs. 25,600. Piston rings Rs. 11,200. Piston Rs. 8,000. Total maintenance cost minimized Rs. 44,800. Page 43; 44
- 12. Power Consumption & Savings 20 41 14 27 0 5 10 15 20 25 30 35 40 45 No load Full load POWER(KW) LOAD CONDITION Operating Power Comparison Reciprocating Compressor Screw Compressor Page 50
- 13. Load Cost Per Day 1131.9 700.7 4419.8 2910.6 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Reciprocating Compressor Screw Compressor Costperday(inRs.) No Load Full Load Page 50;51;52
- 14. Savings Related to Pumping Motor Power (kW) 1.74 Electricity Cost Saving (Rs.) For a Day 321.55 For a Month 9,646.56 For a Year 1,15,758.72 The table shows saving in pumping cost if reciprocating compressor is replaced by screw compressor since latter does not require intercooler as it is single stage compression process. Page 53
- 15. Saving in Compression Cost Full Load No Load Motor Power (kW) 14 8 Electricity Cost Saving (Rs.) For a Day 1,509.2 431.2 For a Month 45,276 12,936 For a Year 5,43,312 1,55,232 The table shows saving in motor power and electricity cost in compression process for full load and no load conditions if screw compression is used. Page 52
- 16. Need for Efficiency Optimisation
- 17. Productive Demands LeaksInnappropriate Uses Artificial Demands System Losses Typically, only 50% of compressed air is used for productive demands
- 18. Over 10 years, the energy cost will be 10 to 30 times the initial capital cost Capital Installation Maintenance Energy
- 19. Efficiency Improvement RECIPROCATING COMPRESSOR SCREW COMPRESSOR Ideal work 27.829 kW 27.829kW Motor Power 45 30 Efficiency=ideal/motor 61.84 % 92.76 % Page 62 - 64
- 20. Floor Space Saving 213 130 Dimensions are in cm.
- 21. Total Financial Savings Contents Annual Savings Pumping Cost 115758 Compression Cost 543312 (full load) 155232 (no load) Maintenance Cost 96150 Total Cost 9,10,452
- 22. THANK YOU