Air Station Saves 1 Million kWh a Year at a Power-Technology Company in Zhejiang

The Power Technology Company in Zhejiang is a leading enterprise in the lead-acid starting battery industry. The company's air compressor station was originally equipped with nine 132KW and two 75KW air compressors, primarily water-cooled. The station required seven 132KW and one 55KW air compressors for normal operation, with two backup units. The station faced issues such as energy waste from poorly configured piping (a pressure loss of about 2%) and leaks in the compressor room and at the point of use, which wasted compressed-air flow (about 7% of generation).

Equipment: SIND SILVERLUBE-VPM series PM VSD screw compressors

SIND provided a customised solution for the air compressor station. The company designed and manufactured the air compressors with a focus on reducing energy consumption. Key components were selected without cost constraints, and the compressors were customised based on specific pressure requirements. The company also increased the size of the intake filters and heat exchangers to reduce resistance and improve heat exchange efficiency. Additionally, the internal fluid resistance of the compressors was minimised, and high-standard safety coefficients were used for critical components to reduce the probability of failures. The pipeline was also upgraded with aluminium super pipes to minimise pressure loss during gas transmission.

SIND's IoT system was integrated into the station, allowing real-time monitoring and optimisation of the station's operation data.

After the renovation, the Power Technology Company in Zhejiang achieved an annual electricity savings of over 1 million kWh. The most noticeable change was that the same production volume could be achieved with fewer compressors: from seven 132KW and one 55KW compressors to four 132KW and one 75KW compressors. The station also achieved a constant pressure of 0.66 Mpa, which met the pressure requirements and was more stable than the original 0.7 Mpa. The client was very satisfied with the results, highlighting three main points: 1) more stable and safe pressure with controllable costs; 2) reduced need for human and material resources, enabling light asset operation; 3) deeper understanding of the importance of professional management and achieving cost reduction and efficiency improvement alongside digitalization of the air compressor station.