Project Overview
At Sichuan Xinhua Torch Chemical, the compressed air system plays a critical role in supporting energy-intensive chemical production processes. The original station consisted of four 160 kW fixed-speed screw compressors, with aging equipment resulting in a specific energy consumption of 0.1577 kWh/m³ and overall station efficiency of only 34.74%. With increasing energy costs and stricter environmental requirements, the plant required a comprehensive modernization solution capable of improving energy efficiency while reducing operating costs and environmental impact.
SIND delivered a turnkey high-efficiency compressed air station solution, combining duty-matched two-stage screw compressors with intelligent control, low-loss piping, optimized filtration, and zero-air-consumption condensate management. The upgraded system was designed to automatically respond to real-time air demand, optimize compressor loading, minimize pressure losses, and eliminate unnecessary compressed air consumption. As a result, the station achieved a specific energy consumption reduction of more than 30% and improved its energy-efficiency classification from Level 5 to Level 1.
Core Equipment
The retrofit replaced the original fixed-speed compressor fleet with high-efficiency, duty-matched two-stage screw compressors supported by an intelligent control and optimized air distribution system. The two-stage compressors provide efficient base-load and trim air for the chemical production processes, while the intelligent interlock system continuously monitors demand and automatically adjusts compressor operation to maintain efficient system performance.
| Component | Role in the station | System contribution |
|---|---|---|
| Two-stage screw compressors | Base-load and trim air for chemical processes | Power efficiency ≥60% |
| Intelligent interlock control | Continuously monitors demand and adjusts operation | Efficient system performance |
| Low-loss pipeline and filtration | Minimize pressure losses | Total system pressure loss ≤0.3 bar |
| Zero-air-consumption drains | Remove condensate without wasting compressed air | Eliminates unnecessary compressed-air consumption |
The upgraded station also incorporated low-loss pipeline routing and filtration, limiting total system pressure loss to ≤0.3 bar, together with zero-air-consumption drains to remove condensate without wasting compressed air. Through the combination of efficient compression technology, intelligent controls, and optimized system design, compressor power efficiency increased to ≥60%, compared with approximately 35% from the original station.
Measured Outcome
Post-retrofit measurements demonstrated substantial improvements in the station’s energy performance. Specific energy consumption decreased from 0.1577 kWh/m³ to 0.105 kWh/m³, representing an energy saving of more than 30%. Overall station power efficiency increased from 34.74% to 60%, while the energy-efficiency classification improved from Level 5 to Level 1.
| Metric | Before | After |
|---|---|---|
| Specific energy consumption | 0.1577 kWh/m³ | 0.105 kWh/m³ (>30% reduction) |
| Station power efficiency | 34.74% | 60% |
| Energy-efficiency classification | Level 5 | Level 1 |
| Estimated annual CO₂ reduction | — | ~280 tons (equivalent to ~15,000 trees) |
The improved efficiency also generated measurable environmental benefits, with estimated annual CO₂ emissions reductions of approximately 280 tons, equivalent to the carbon absorption of approximately 15,000 trees. The reduction in electricity consumption directly lowered the plant’s operating expenses, accelerating the investment payback and creating continued energy savings throughout the system’s operating life.
Client Benefits
The SIND solution delivered lower operating costs through optimized compressor selection, system design, and intelligent control, while providing a more reliable and efficient compressed air supply for the plant’s continuous production requirements. SIND’s independently developed compressor technology provides performance benchmarked against leading international brands, while its one-stop project delivery model integrates system design, equipment selection, engineering, and implementation under a single scope. The resulting energy and CO₂ reductions also support the plant’s broader energy-conservation and Dual-Carbon objectives, demonstrating the long-term value of high-efficiency compressed air system modernization.
“Choosing SIND’s products enabled us to achieve our energy-saving transformation goals, reducing electricity costs by approximately RMB 430,000 annually. We hope to contribute to China’s Dual-Carbon objectives, starting with the high-efficiency compressed air station at New Torch.”
— Plant Representative, Sichuan Xinhua Torch Chemical
FAQ
Specific energy consumption decreased from 0.1577 kWh/m³ to 0.105 kWh/m³, representing an energy saving of more than 30%.
Overall station power efficiency increased from 34.74% to 60%, while the energy-efficiency classification improved from Level 5 to Level 1.
The solution combined duty-matched two-stage screw compressors, intelligent control, low-loss piping, optimized filtration, and zero-air-consumption condensate management.
Estimated annual CO₂ emissions reductions were approximately 280 tons, equivalent to the carbon absorption of approximately 15,000 trees.