Chemical industry

Energy saving made to measure

Decentralisation of a compressed air station in polymer production

Trelleborg, a town at the southern tip of Sweden on the Baltic coast – the starting point for many ferries to Germany and Poland. It is also the headquarters of a multinational corporation specialising in polymer technology. The customer of KAESER Kompressore SE manufacturers polymer technology solutions for sealing, damping and protecting sensitive equipment in demanding environments. The product portfolio also includes damping and sealing systems as well as tyers for commercial vehicles.

Challenge

Due to the company’s global expansion at a rapid space, its existing infrastructure no longer met the energy requirements of a modern industrial enterprise. The company set itself the goald of optimising its energy consumption worldwide. The two existing compressors currently generate three times as much compressed air as is actually needed for the company’s operations. KAESER Kompressoren was therefore tasked with decentralising the compressed air generation and installing water-cooled compressors.

An additional compressor unikt for the steam power plant is to ensure the compressed air supply for the production operation independently of other areas in order to avoid 24/7 operation. In order to save costs in the area of building heating, the thermal energy from the compressors is to be used to feed the heat pump.

Solution statement

  • KAESER Kompressoren initially carried out a detailed consumption and pressure analysis to determine the correct compressor configuration.
  • This ensured that perfectly dimensioned machines with exactly the right volume flows were used.
  • KAESER selected three energy-saving CSD 105 T SFC fluid-cooled KAESER screw compressors with attached dryers in space-saving modular design and speed control for this project.
  • In addition, a BSD 65 T KAESER screw compressor with attached dryer was selected for the mixing area and a KAESER ASD 50 T SFC with attached dryer and speed control for the steam power plant.

Customer value

  • The installation of the new system saved 280,000 kWh per year. This corresponds to a CO2 reduction of 168 tonnes and an improved energy efficiency of 1.52 kW per cubic metre of compressed air.
  • 90 % of the thermal energy is recovered from the cooling water, which leaves the compressors at 70 °C and increases the efficiency of the heat pump accordingly.

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