Compressed air optimize circuit

Submitted to the Board

Of

Futehally Chemicals (2024)

Prepared by: Muhammad Hamza Majeed

Reviewed by: Syed Shahroz Ali

Approved by: Mustafa Ahmed

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 CONFIDENTIALITY

This report is prepared for the organization’s use and contains the confidential
technical information of Futehally Chemicals. This report is strictly private,
confidential, and personal to its recipients and should not be copied, distributed,
or reproduced in whole or in part, nor passed to any third party working in the
same domain of compressed air audit services. Futehally Chemicals will limit the
access of confidential information to only those employees in its relevant
departments that have a legitimate right of access, not below the Technical
Manager or General Manager of the organization. A soft copy of this report shall
be shared with the customer at the written request of the Authorized Person of
the organization.

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 PREFACE

This Detailed Audit Report encompasses a comprehensive evaluation of data,

procedures, and interviews conducted with technical, operation, and maintenance
team members. The assessment utilized Flow Meters, Leakage Detectors, and
Temperature/Humidity Sensors. The report is based on the prevailing electricity
rate of _________. It discusses corrective actions derived from our findings and
summarizes the auditor's activities, recommendations, and potential savings in
energy, capital, and recurring costs through these proposed measures.

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1.1.1 Table of Contents
1. Executive Summary 07
1.1 Context

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2 Executive Summary
1.1 Context

Under the air audit and compressed air structure evaluation plan, AirAudit Private Limited conducted
a compressed air audit of __________________ (Unit #) (2023) from 31st May to 8th June 2023.

1.2 Purpose of Air Audit

The purpose of the audit is to investigate and highlight;

 Inefficiencies in the existing compressed air network with recommendations
 Cost/energy saving options through eliminating wasted air energy
 Estimated energy saving potential in the existing compressed air installations

1.3 Audit Findings

The detailed compressed air audit was conducted in order to identify, evaluate and suggest
recommendations associated with the existing compressed air network. The analysis was based on the
detection, measuring, and examination of compressor room location and installations, distribution
piping network analysis, and losses in compressed air usage that govern the energy loss, in terms of
money. The criteria and methods used in the audit were based on energy saving at prevalent energy
prices.

1.4 Audit Methodology

The audit methodology included detection through electronic equipment, data analysis, visual
inspection of the compressed air system, and interviews with the client’s technical staff, related to the
compressed air utility, in conformity with audit guidelines laid out in European Standard ISO
11011:2013.

1.5 Opportunity

On the basis of the Air Audit findings, the estimated cost-saving opportunity in the compressed
air and major defects of the system are highlighted in this report.

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3 Compressed air main line consumption:

3.1 Artificial demand

4 Pneumatic convey Consumption

4.1 Pneumatic 1:
Flow (m³/min) Pressure (bar)
Max 9.1 Max 5.95
Avg 7.4 Avg 5.387167
Min 4.3 Min 4.78

Pneumatic 1
10.0 7.0
8.0 6.0
5.0
6.0 4.0
4.0 3.0
2.0
2.0 1.0
0.0 0.0
17:48:29
17:48:39
17:48:49
17:48:59
17:49:09
17:49:19
17:49:29
17:49:39
17:49:49
17:49:59
17:50:09
17:50:19
17:50:29
17:50:39
17:50:49
17:50:59
17:51:09
17:51:19
17:51:29
17:51:39
17:51:49
17:51:59
17:52:09
17:52:19
17:52:29
17:52:39
17:52:49
17:52:59
17:53:09
17:53:19

Pressure (bar) Flow (m³/min)

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 0.0
5.0
10.0
15.0
20.0
25.0
30.0
0.0
10.0
20.0
30.0
40.0
50.0
17:53:04 18:05:39
17:53:19 18:05:49
17:53:34 18:05:59
17:53:49 18:06:09

Avg
Min
Max
17:54:04
Avg
Min
Max

18:06:19
17:54:19 18:06:29
4.2 Pneumatic 2:

4.3 Pneumatic 3:
17:54:34 18:06:39
17:54:49

Flow (m³/min)
18:06:49
Flow (m³/min)

17:55:04 18:06:59
17:55:19 18:07:09
17:55:34 18:07:19
17:55:49

6.6
20.1
25.0
18:07:29
17:56:04
25.8
34.6
38.3

18:07:39

Pressure (bar)
17:56:19

Pressure (bar)
18:07:49
17:56:34
18:07:59
17:56:49
18:08:09
Pneumatic 2

17:57:04

Pneumatic # 3
18:08:19
17:57:19
18:08:29
17:57:34
18:08:39

Avg
Min
Max
Flow (m³/min)

17:57:49

Flow (m³/min)
18:08:49
Avg
Min

17:58:04
Max

18:08:59
17:58:19
18:09:09
17:58:34
18:09:19

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17:58:49
Pressure (bar)

18:09:29
Pressure (bar)

17:59:04
18:09:39
17:59:19
18:09:49
17:59:34
18:09:59

7
17:59:49
18:10:09
4.72
5.77

18:00:04
5.7

5.244706
4.75
5.166

0.0
1.0
2.0
3.0
4.0
5.0
6.0

0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0

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 4.4 When Pneumatic 1 and 2 running

Flow (m³/min) Pressure (bar)

Max 38.3 Max 5.7
Avg 35.1 Avg 5.085149
Min 25.8 Min 4.62

Pneumatic 1 and 2 running

45.0 6.0
40.0
5.0
35.0
30.0 4.0
25.0
3.0
20.0
15.0 2.0
10.0
1.0
5.0
0.0 0.0
18:01:49
18:02:04
18:02:19
18:02:34
18:02:49
18:03:04
18:03:19
18:03:34
18:03:49
18:04:04
18:04:19
18:04:34
18:04:49
18:05:04
18:05:19
18:05:34
18:05:49
18:06:04
18:06:19
18:06:34
18:06:49
18:07:04
18:07:19
18:07:34
18:07:49
18:08:04
18:08:19
18:08:34
18:08:49
18:09:04
18:09:19
18:09:34
18:09:49
18:10:04
Pressure (bar) Flow (m³/min)

4.5 When Pneumatic 1 and 3 running

Flow (m³/min) Pressure (bar)

Max 32.4 Max 5.77
Avg 27.1 Avg 5.244706
Min 7.2 Min 4.72

Pneumatic 1 and 3 running

35.0 7.0
30.0 6.0
25.0 5.0
20.0 4.0
15.0 3.0
10.0 2.0
5.0 1.0
0.0 0.0
17:53:04
17:53:19
17:53:34
17:53:49
17:54:04
17:54:19
17:54:34
17:54:49
17:55:04
17:55:19
17:55:34
17:55:49
17:56:04
17:56:19
17:56:34
17:56:49
17:57:04
17:57:19
17:57:34
17:57:49
17:58:04
17:58:19
17:58:34
17:58:49
17:59:04
17:59:19
17:59:34
17:59:49
18:00:04

Pressure (bar) Flow (m³/min)

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 4.6 When all Pneumatics are running

Flow (m³/min) Pressure (bar)

Max 59.3 Max 5.01
Avg 53.4 Avg 4.530588
Min 42.5 Min 4.1

When all Pneumatics are running

70.0 6.0
60.0 5.0
50.0
4.0
40.0
3.0
30.0
2.0
20.0
10.0 1.0
0.0 0.0
17:22:14
17:22:24
17:22:34
17:22:44
17:22:54
17:23:04
17:23:14
17:23:24
17:23:34
17:23:44
17:23:54
17:24:04
17:24:14
17:24:24
17:24:34
17:24:44
17:24:54
17:25:04
17:25:14
17:25:24
17:25:34
17:25:44
17:25:54
17:26:04
17:26:14
17:26:24
17:26:34
17:26:44
17:26:54
17:27:04
17:27:14
17:27:24
17:27:34
17:27:44
Pressure (bar) Flow (m³/min)

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5 EXISTING PNEUMETIC CONVEYING

4 bar
6.5 bar
FSD 200 32 m3/min 64 m3/min Machine need 60 m3/min
10,000 ltr
FSD 200 32 m3/min tank Pneumatic Pneumatic Pneumatic
1 2 3

5.5 bar
VSD 90 17.07 m3/min
5,000 Rest of the plant
FSD 90 16.71 m3/min ltr tank

5.1 2 hours Flow trend. (Pneumatic only)

Flow (m³/min) Pressure (bar)

Max 59.3 Max 6
Avg 18.2 Avg 5.2
Min 0.0 Min 2.9

Pneumatic Convey flow chart

1.2 0.007

1 0.006
0.005
0.8
0.004
0.6
0.003
0.4
0.002
0.2 0.001
0 0
16:58:04
17:00:49
17:03:34
17:06:19
17:09:04
17:11:49
17:14:34
17:17:19
17:20:04
17:22:49
17:25:34
17:28:19
17:31:04
17:33:49
17:36:34
17:39:19
17:42:04
17:44:49
17:47:34
17:50:19
17:53:04
17:55:49
17:58:34
18:01:19
18:04:04
18:06:49
18:09:34
18:12:19
18:15:04
18:17:49
18:20:34
18:23:19
18:26:04
18:28:49
18:31:34
18:34:19
18:37:04
18:39:49

Pressure (bar) Flow (m³n/sec)

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CALCULATION:

within 2 hrs of logging, compressors goes on off-load 4 times and as off

1.2
load consumes 30% of extra energy by implementing this recomendation
will reduse the off-load cycles.
1
Four times offloading
• compressor # 1 offload 4 times within 2 hours (which is 4 min)
• compressor # 2 offload 6 times within 2 hours 0.8
• 8760 hours in a year

For Compressor # 1 0.6

8760 X 2 = 17520 times/annum

= 17520 times off load for x 1 min 0.4

= 17520 x 17520
1 = min off load /annum
= 17520/60
= 292 hrs /annum
0.2

For 200Kw 4 times off loading

0
= 292 hrs /annum

0.706990741
= Compressors Kw X 30% X Off-loading time
= 200 X 0.30 X 292
= 17520 Kw/ Annum

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6 Proposed

6.1 Scenario 1

Centralized Compressor room.

Base Max
4 bar minimum
18.2 m3/min 59.2 m3/min Regulatate
pressure to
6.5 bar
optimum
Centeralized compressor 30,000 ltr Pneumatic 1 Pneumatic 2 Pneumatic 3
requirement
tank
room

200 FSD 32 m3/min

250 VSD 40 m3/min Near to dust collector
6.5 bar
30,000 ltr
tank

6.5 bar 6.5 bar

10,000 Rest of the plant 10,000
ltr tank ltr tank

Base Max
11.7 m3/min 25 m3/min

Pneumatic
1 Pneumatic 2 Pneumatic 3
MAX 9.1 38.3 25.0
regulator should be install on every single
FLOW

AVG 7.4 34.6 20.1

Min 4.3 25.8 6.6 machine to its minimum pressure setting
Pressure

MAX 6.0 5.7 5.8

AVG 5.4 5.2 5.2
Min 4.8 4.8 4.7

Savings:

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 6.2 Scenario 2.
Automation

remain 13 m3/min will be

given by tank Base Max
4 bar minimum
18.2 m3/min 59.2 m3/min
Regulatate pressure
to optimum
200 FSD 32 m3/min 47 m3/min 6.5 bar 60 m3/min requirement
60,000 ltr Pneumatic 1 Pneumatic 2 Pneumatic 3
90 VSD 15 m3/min
tank

Maintain 6.5 bar

valve
Maintain 5.9 bar controller Pneumatic control
Valve

90 VSD 15 m3/min Oriface if needed

90 FSD 15 m3/min
Rest of the plant

NRV
Base Max
11.7 m3/min 25 m3/min

Pneumatic 1 Pneumatic 2 Pneumatic 3

MAX 9.1 38.3 25.0
regulator should be install on every
FLOW

AVG 7.4 34.6 20.1 single machine to its minimum pressure

Min 4.3 25.8 6.6
setting
Pressure

MAX 6.0 5.7 5.8

AVG 5.4 5.2 5.2
Min 4.8 4.8 4.7

Savings:

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 6.3 Scenario 4:

Screw Elevator:

Savings:

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7 Conclusion

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8 Notes:

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