TABLE OF CONTENTS.

Overview of air compressor & Dryers.

Plant lay out.
Process flow chart of air compressors.
process flow chart of air dryers.
Operating parameters.
Good practices in compressed air quality
management.

Future planning.

OVER VIEW
1) Air compressor (3 nos.) water cooled, electric motor driven
screw compressors which compresses air in two stages
a.
b.
c.

Type
Make
Capacity

:
:
:

Screw
Atlas Copco, Pune
1020 lps each(2161 cfm)

2) Air Drying
a.
b.
c.
d.

Type
Desiccant
Make
Capacity

:
:
:
:

Heat of compression
Silica Gel
Gaso Engg. , Pune
4500 m3/hr. (2650 cfm)

3) Chemically treated water (From cooling tower ) is used in

inter coolers & after coolers with water pH 7.2 to 7.3

Plant lay out.

Flow Chart of Air Compression

Temp 170 - 175

10 - 12
m bar

Air

Temp

45 - 50

Temp 165 - 170

Press.

2.2

Press. 6.5 - 6.8

Inter cooler

LP
2.8 Kg/cm2.
Filter

Oil cooler.

COOLING
TOWER

Temp

300C

Press.

4.5 Kg

Flow

110 m3/hr

HP

To Air
Dryer

Operating Parameters of Air

compressors & Dryers.
1) Air Compressors
a) Inter Cooler air temp.
b) Inter cooler air press.
c) Compressor disc. press.
d) Compressor disc. temp.

: 45 to 500C
: 1.9 to 2.2 Kg/cm2.
: 6.5 to 6.7
: 165 to 170 0C

2) Air Dryers
a) Air inlet temp.
b) Regen. Bed temp.
c) Cycle time
i) R - D
ii) C - D
iii) S - D
d) Final air temp.

: 165 to 1700C
: 1200C.
: 3 hours
: 50 to 55 min
: 70 min
: 60 min
: 45 to 48 0C

GOOD PRACTICES IN AIR

QUALITY MANAGEMENT

Periodic check on performance monitoring of air

compressor & dryer.

Monitoring of air leakages in the plant.

Monitoring of pressures at various section of air

distribution network

Minimum usage of flexible or screwed joints wherever

possible. Weld joints preferred.

Use clean & low temp. water as possible for cooling in heat
exchangers.

Periodic condition check of desiccant in dryers.

Monitoring of dew point after air dryer.

Use suitable air filters to maintain low pressure drop.

Use suitable accessories like drain traps, air filters, water

separators, pressure regulator for maintaining the air
quality, effective utilization and enhancing energy
efficiency.

FUTURE PLANNING

To convert the existing compressor & dryer cooling water

system into close loop to minimise scaling problems in the
heat exchangers.

Use of bypass cooler as after cooler for instrument air to

reduce the final air temperature.

To extend the existing air intake ducting to out doors to

improve the compressor performance.

PROPOSED CLOSED LOOP COOLING

WATER SYSTEM

AIR CONSUMPTION PATTERN

60 %
2700 cfm
(Metered)

PP
325 cfm
(metered)

7%

Process
2400 cfm

53%

IA

4450 cfm
Compressor

40 %
1700 cfm
(Metered)

PP
1200 cfm
(metered)

25%

Process
600 cfm

15%

SA