Cement Energy Environment

75 Even small leakage offers the potential for significant savings. The table below shows how much air is lost as a result of leakages with a specific hole diameter and what additional costs are incurred: How much do leakages cost? Note: 1 Euro equals 88.65 Indian Rupee as on 25-02-2021 Table 1/2: Leakage costs within one year for operation 24 h/365 days, calculated using compressed air costs of 1.9 ct/Nm³. The point at which a leakage is identified as a loss depends on the ratio of leakage to overall consumption. Major leakages – where the air leak is clearly audible – are costly and supposed to be rectified immediately. Similarly, medium and small leakages (leakages with a hole diameter of less than 0.5 mm) which can be detected simply by using professional leakage detection equipment are also supposed to be rectified promptly. It is a thumb rule that 20% of the detectable leakages in existing systems account for up to 80% of the avoidable costs. Therefore, it is felt prudent that leakages be fixed immediately which will ultimately save energy as well as cost of production. We at IISPL, took this issue as a challenge and started identifying the ways for eliminating routine wastes, which cause higher energy consumption in cement process industry. We also studied on means to provide best and economic solution to cement industries so as to save production cost as well as conserve natural resources. Having done in depth study, Invotech Industrial Solutions Private Limited has recently developed a product called Arrest Master ABS for enhancing energy efficiency. It can be used to cool down the area rapidly with less air consumption but gives output 7 to 8 times as compared to normal air consumption. It is a special design Nozzle, works on COANDA EFFECT. Arrest Master ABS uses little amount of compressed air to deliver high volume output. Arrest Master ABS, is a compressed air boosting device, which has been designed in a way so as to give trouble free & maintenance free service as there is no moving part in it. It can also be used to cool down bearing housing, cutting hot material, cooling of lathe machine jobs etc. Energy efficient solution 3 bar 4 bar 5 bar 6 bar 7 bar 8 bar p1 (rel.) 9 11 14 16 18 20 0.5 mm 36 45 54 63 72 81 1.0 mm 81 102 122 142 163 183 1.5mm 145 181 217 253 289 325 2.0 mm 226 282 339 395 452 508 2.5mm 325 407 488 569 651 732 3.0mm Leakage rate in Nl/min 3 bar 4 bar 5 bar 6 bar 7 bar 8 bar p1 (rel.) € 90 € 113 € 135 € 158 € 180 € 203 0.5 mm € 361 € 451 € 541 € 632 € 722 € 812 1.0 mm € 812 € 1,015 € 1,218 € 1,421 € 1,624 € 1,827 1.5mm € 1,444 € 1,805 € 2,166 € 2,527 € 2,888 € 3,248 2.0 mm € 2,256 € 2,820 € 3,384 € 3,948 € 4,512 € 5,076 2.5mm € 3,248 € 4,061 € 4,873 € 5,685 € 6,497 € 7,309 3.0mm Costs/year