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Automotive industry

More compressed air with less energy for shock absorbers – thanks to heat recovery

Startseite Industries & Applications Automotive industry More compressed air with less energy for shock absorbers – thanks to heat recovery

Production of shock absorbers for the automotive industry

Inefficiency of a compressed air station and a large amount of unused energy. These were the reasons given by a customerof KAESER Compressors to replace the existing compressed air system. Thanks to individual project planning and solutions, costs were reduced and the waste heat was put to good use.

At the customer’s site, 30,000 shock absorbers are produced daily on three production lines. Production lines that do not stop, not even overnight. Only at the weekend does production stoop, only to start up again on Sunday evening. Any standstill in production would eat up vast sums of money.

Challenge

The existing compressed air system looked more like an engine on a Mississipi streamer. The existing compressed air system was a collection of various individual components that were repeatedly added to over the course of time. The system was outdated and wasted a lot of energy. The estimated investment sum was in the six-figure range. The focus was definitely on paying off the costs.

Solution statement

  • Urgently needed flexibility and risk minimisation through KAESER SIGMA AIR UTILITY operator model for security of supply and minimum downtime.
  • Heat recovery for ecologically sensible use
  • Gutting and complete refurbishment of the existing machine room
  • Installation of five KAESER compressors and four KAESER refrigeration dryers
  • Installation of pipelines and stainless steel pipes for conducting hot water to the cleaning bath. Here, the temperature must be kept constant at 60 °C.
  • Hydraulic balancing and adjustment of the pump and temperature sensors as well as optimisation of the heat meter by a specialist company

Customer value

  • Achieving an optimum heat recovery rate
  • Savings of 114,000 EUR energy costs per year
  • Savings of 34,000 EUR from heat recovery: This corresponds to the heat for 40 single-family houses per year plus 25,000 EUR maintenance costs
  • CO2 savings of approx. 1,667 kWh per tonne: This corresponds to 760,000 kWh of electricity together with the waste heat recovery of 960,000 kWh; in total a reduction of CO2 emissions of around 1,000 tonnes per year
  • The new plant now operates extremely effectively and economically.

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