ENERGETSKI MONITORING KOMPRESORSKE POSTAJE TALUM - potencial za učinkovito rabo energije. Avtorja: Milan Žumbar mag.
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1 ENERGETSKI MONITORING KOMPRESORSKE POSTAJE TALUM - potencial za učinkovito rabo energije Avtorja: Milan Žumbar mag. Boštjan Korošec
2 Vsebina predstavitve: - Obstoječe stanje kompresorske postaje - Energetski monitoring in posodobitve - Možnosti prihrankov - Predlagani ukrepi - Energetska, ekonomska in ekološka upravičenost predlaganih ukrepov - Sklep
3 Obstoječe stanje kompreskorske postaje
4 Hladilni sistem kompreskorske postaje
5 Obstoječe stanje kompresorske postaje Osnovni tehnični podatki: Atlas Copco: 4 x - tip: ZR - 4B - delovni tlak: 7 bar - vhodna kapaciteta: 29 Nm 3 /min - moč elektromotorja: 200 kw - specifična poraba el. energije: 0,098 kwh/nm 3 Ingersoll Rand: 2 x - tip: C47Mx2-2rH - delovni tlak: 6,5 bar - vhodna kapaciteta: 44 Nm 3 /min - moč elektromotorja: 350 kw - specifična poraba el. energije: 0,118 kwh/nm 3
6 Obstoječe stanje kompresorske postaje Značilnosti sistema: - nazivna zmogljivost kompresorske postaje: 204 Nm 3 /min - dejanska zmogljivost kompresorske postaje: 184 Nm 3 /min - obratovalni tlak: 6,4 bar - sistem obratovanja: ON-OFF - prioritete obratovanja: menjave med kompresorji - velika poraba električne energije v pavzi - sušilni sistemi: visoka točka rosišča od -20 do -60 C - hladilni sistem: zaprti krog hladilne vode - razvod do porabnikov: m - veliko število porabnikov - veliko potencialnih mest puščanja
7 Tedenski diagram proizvodnje stisnjenega zraka
8 Dnevni diagram proizvodnje stisnjenega zraka - delovnik
9 Urni diagram proizvodnje stisnjenega zraka - delovnik
10 Dnevni diagram proizvodnje stisnjenega zraka - vikend
11 KZ (Nm 3 ) HC (Nm 3 ) Hala C1 Hala C2 Hala C3 Hala C HC skupaj Čistilna I Čistilna II Silos glinice
12 Poraba komprimiranega zraka za leto 2013 Aluminij Ulitki Talum Skupaj Mesec Hala C1 Hala C2 Hala C3 Hala C4 Čistilna I Čistilna II Silos glinice proizv. AB pečenje AB anode sestavlj. Skupaj Livarne Izparilniki Rondelice Litje ulitkov Finalizacija ZHS poraba KZ Jan Feb Mar Apr Maj Jun Jul Avg Sept Okt Nov Dec Skupaj
13 Energetski monitoring in posodobitve Aktivnosti: - celovita ureditev sistema meritev porab za vse energente, - monitoring in poročilni sistem porabe vseh energentov, - priprava in prenos energetskih podatkov v PIS za mesečno razdelitev stroškov na stroškovne nosilce, - okoljski monitoring z okoljskimi kazalniki, - sistem Ciljnega spremljanja rabe energije (M&T, CuSum) z vidiki posameznega stroškovnega nosilca (specifične porabe), - poročilni sistem za vodstvo, - URE: pričakovani prihranek 5% na komprimiranem zraku.
14 Energetski monitoring in posodobitve El en za KZ (kwh) - za 5% manjša poraba El en (cilj) y = 0,1656x R² = 0,
15 Jan 11 Feb 11 Mar 11 Apr 11 Maj 11 Jun 11 Jul 11 Avg 11 Sept 11 Okt 11 Nov 11 Dec 11 Jan 12 Feb 12 Mar 12 Apr 12 Maj 12 Jun 12 Jul 12 Avg 12 Sept 12 Okt 12 Nov 12 Dec 12 Jan 13 Feb 13 Mar 13 Apr 13 Maj 13 Energetski monitoring in posodobitve El en CuSum (kwh)
16 Energetski monitoring in posodobitve Primerjava regresijskih premic po letih y = 0,1287x R² = 0,
17 Možnosti prihrankov Prioritete: - uvedba energetskega monitoringa, - zamenjava kompresorja s frekvenčno regulacijo, - zamenjava manjših enot z velikimi, zagotovitev n-1 (varnost obratovanja) - nadzor in zmanjšanje (odprava) puščanj, - preventivno vzdrževanje porabnikov, - točka rosišča, - obratovalni tlak, - hlajenje kompresorjev, - izraba odpadne toplote hladilnega sistema.
18 Predlagani ukrepi Prioritete: - CSRE: monitoring in URE, - optimalno obratovanje posameznih kompresorjev v ON-OFF režimu, - frekvenčna regulacija novega kompresorja - regulacijski režim 30 Nm 3 (2%) - zamenjava majhnih enot z velikimi 80 Nm 3 /min (10%) - meritve puščanja in odprava napak, cilj 15%, uvedba sistema - preventivno vzdrževanje porabnikov, - točne meritve proizvodnje in porabe zraka ter električne energije, - optimalna nastavitev tlaka, - optimalna nastavitev točke rosišča??? - optimalna nastavitev sistema hlajenja.
19 Meritev puščanja z UZ merilnikom Slika lokacije 2 Lokacija okvare Povezava sušilnik 1 in sušilnik 2 (NKP) Vrsta okvare Jakost puščanja [db] Puščanje [m 3 /dan] Povezava - prirobnica 37 77,0
20 Primer izračuna cene stisnjenega zraka. April 2013 Stroški Vrednost ( EUR) Količina KZ(Nm 3 ) Cena EUR/Nm 3 Stroški materiala 1.961,35 Stroški energije 72% ,94 Stroški storitev ,89 Amortizacija 1.582,81 Ostali stroški Proizvodnja KZ Skupaj stroški ,99 0,01492
21 Upravičenost predlaganih ukrepov Obstoječe stanje: - letna poraba komprimiranega zraka: 45 mio Nm 3 - letna poraba električne energije za kompresorje: MWh - letna poraba vode za dopolnjevanje hladilnega sistema: m 3 - lastna cena komprimiranega zraka: 0,016 /Nm 3 - letni strošek za komprimirani zrak: > specifična poraba električne energije: 0,17kWh/ Nm 3 - Pričakovani prihranek:15% - 5% z uvedbo monitoringa - 10% z zamenjavo kompresorja in optimiranje obratovanja,puščanje
22 Upravičenost predlaganih ukrepov Potenciali: - varčevanje z električno energijo: MWh letno - zmanjšanje stroškov: letno - zmanjšanje emisij CO 2 : 500 t letno - stroški naložbe: (en kompresor z sušilnikom) - doba vračanja: 1,8 let
23 Sklep ORGANIZACIJA Obveza vodstva, viri, načrtovanje, spremljanje Za uspešno izvedbo je nujno ravnotežje vseh treh TEHNIKA Razumeti svojo porabo energije in kako jo kontrolirati LJUDJE Razvoj kulture za energetsko učinkovitost podjetja
24 Ustvarjamo pogoje za tiste, ki prihajajo za nami!
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