Energy-efficient compressors for an engineering plant

Since 2014, one of Ukraine’s leading machine-building plants, PJSC Dneprotyazhmash, which manufactures equipment for the mining and metallurgical industries, has been developing measures to reduce the cost of compressed air production. Given the constant high demand for high-quality compressed air, its production costs account for a significant share of the company’s total production costs.

Until 2016, the company operated Atlas Copco oil-injected screw compressors and a reciprocating compressor. After analyzing the load schedules, it was decided to introduce modern compressors to reduce the cost of compressed air production: a centrifugal compressor with a capacity of 100 m3/min at 7 bar with a constant pressure maintenance system, and a screw compressor of about 50 m3/min, 315 kW with frequency control of capacity. To increase the economic effect, it was decided to implement a heat recovery system for the screw compressor.

After the technical solution was selected, tender procedures were held. More than 10 compressor companies took part in the tender. The main criteria for choosing the equipment were high energy efficiency, quality of components, reliability, availability of developed service support in Dnipro, price, payment terms and delivery time. After a detailed study of the proposals, Dalgakiran Compressor Ukraine LLC was selected as the winner.

The equipment was delivered to Dneprotyazhmash and put into operation within the agreed timeframe:

• Centrifugal compressor (turbocharger ) Cameron (USA), model TA 3000, with a capacity of 100 m3/min at 7 bar, complete with a closed-circuit cooling tower.
• Dalgakiran oil-filled screw compressor (Turkey), model Inversys 315 Plus, with a built-in heat recovery unit.

As a result of the modernization of the compressor station, the customer managed to significantly reduce the specific energy consumption, which before the modernization was about 125 kW/1000 m3. After the launch of the new equipment, the specific energy consumption decreased to 90…100 kW/1000 m3.

In addition, the use of a heat recovery system has resulted in significant savings. For example, in April-May 2016, the heat recovery system provided hot water equivalent to 105 Gcal/month of heat output.

Currently, the equipment is in constant operation, fully meeting the compressed air needs of Dneprotyazhmash’s production. The purchased compressors have proven to be efficient and reliable.

Project manager: Yevhen Sergienko

Read the review of PJSC Dneprotyazhmash