Page 14 - Arebian

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7. Presently specific power consumption for compressor no.AC5 is 0.260 kW /cfm and for
compressor no.AC 7 is 0.252 kW /cfm It’s higher than normal operating conditions of

screw compressor.As per std.for screw compressor it varies in the range of 0.18 to 0.21
kw/cfm as per the actual output from the compressor. Following are some measures to
optimize the SEC.
a) By proper overhauling of screw elements, oil separator, suction filters, solenoid
valves and screw compressor unit internals,
b) Maintaining temperature around the compressor to as low as possible. Lower
temp. of suction air improves compressor efficiency and specific consumption.
c) Reduction in operational pressure.
8. Provision of isolation of high and low pressure machines and placement of air boosters,
blowers wherever required. Following are the Production m/c, segregated with respect

to working pressure required,

1) Compressed air of 6 bar pressure is required for,

a) Slitter m/c
b) Rewinding m/c
c) Beiling m/c
d) Core cutter m/c

2) Compressed air of 7 bar pressure is required for,

e) Printing m/c
f) Lamination m/c
g) Polish star m/c
h) Pouch m/c
i) Accordingly its recommended that, separate the above in two circuits with separate air
compressors of individual pressure settings as per the requirement of process. This gives
lot of savings in electrical units consumption.
j) Its observed that in plant, primarily compressed air is used for pneumatic operations.
Presently observed discharge pressure of 7.4 bar. As per the feedback from facility dept,
6.0 bar pressure is required for Slitter m/c, Rewinding m/c, Beiling m/c & Core cutter
m/c for critical operations at plant level. Hence it’s clear that, we can modulate
generated compressed air pressure in 6.5 to 6.8 bar inplace of 7.4 bar at generation

point .Reduction in generated pressure by 0.7 to 1.0 bar would definitely save energy a
lot. Any specific Machines which require higher pressure than 6.0 Bar can be identified
& air boosters can be installed for such machines.

6) Its recommended to replace Existing G.I piping Circuit with extruded aluminum piping
circuit. The internal bore of this piping is smooth and corrosion resistant which makes the