Smart Air Station Cuts Energy 33.4% at a Ceramics Plant in Hebei

Dream Porcelain, a renowned ceramic and bathware manufacturer in Hebei, faced several challenges in managing its compressed air systems. The production schedule was divided into multiple time periods, each with varying air demand. This required constant manual intervention for starting and stopping the compressors, leading to inefficiencies and significant energy waste. Additionally, the existing system lacked real-time monitoring, leading to inaccurate data collection and higher maintenance costs due to uneven equipment usage.

Equipment: SIND SILVERLUBE-VPM series PM VSD screw compressors

SIND provided a comprehensive solution that included the installation of SIND SILVERLUBE-VPM series PM VSD screw compressors, advanced post-treatment equipment, and a digital management system. The system was designed to optimise air supply and demand, ensuring that the compressed air station operated at peak efficiency. Real-time monitoring of energy consumption was enabled through the installation of flow meters, electricity meters, and pressure sensors. This allowed for precise control over the station's energy usage and enabled the system to automatically adjust to varying demand levels.

The implementation of the SIND solution resulted in a 33.41% reduction in energy consumption, with the unit energy consumption dropping from 0.130476 kWh/Nm³ to 0.086878 kWh/Nm³. The station now operates at Grade-1 energy efficiency standards and has achieved digital management. Key improvements include:

• Automated start-up based on real-time demand, ensuring that the correct amount of compressed air is produced. – Intelligent rotation of equipment to ensure even usage and reduce maintenance costs. – Constant station pressure, reducing energy waste. – Intelligent linkage between compressors and post-treatment equipment, ensuring high-quality air supply.

The improvements were certified by a national quality supervision institution, and Dream Porcelain received a Grade-1 energy efficiency certificate for the compressed air station.