JITMAP Activities and Achievements- Compressed Air System -SAITO TSUKASA
Fellow, Institute for Global Environmental Strategies (IGES)

What is compressor?

at homeCompressors are used for air conditioners
and refrigerators in home.
inside the factory
Air compressors are used in every factory.

These products use a high proportion of electrical energy.

1Energy consumption by sectors...Examples in Japan

Transportation sector 18 Twh 2% Agri, Fisheries 10 TWh 1%

Home sector

Work and other sector

250 TWh 27%

315 TWh 34%

Industrial Sector
336 TWh 36%

Air compressor

Air conditioningfacilities

20 - 25 %Lighting
facilities

Water supply/
drainage facilities
Electric heating
facilities

FY2019 Total Approx. 929 TWh

Total power

Power facilities

Productionfacilities✓ Energy consumed for the industrial sector (factories): About 36% of the total energy
consumption and about a quarter of that amount by air compressors in Japan.
✓ Since energy consumption by air compressors can be relatively reduced easily, there is astrong need for energy conservation through inverter control and multiple unit control(volume control).
✓ The effects of these activities can reduce CO2 emissions and help protect theenvironment in India, where the industrial structure is relatively similar.

2

BEE’s Energy Conservation Guidelines for MSME & FS (Walk through）

Energy Conservation Guidelines for MSME Sector

First step;*understand the current situation.
*Walk-through to check not only
the compressor room but also
the factory situation.

3

Which units of the air system have the potential to save energy?

Visualizing the energy distribution of an air compressor.
① Energy generation unit (air compressor): Installing an inverter compressor and unit control arehighly effective. If pressure fluctuation is controlled by
the size of the air tank, the energy-saving effect is big.
② Energy transmission unit (piping system): Piping size is directly related to pressure loss.
A well-balanced air system minimizes pressure loss.
③ Energy consumption unit: Air volume, supply pressure and efficiency of consuming equipment
need to be considered.
Pneumatic equipment

Energy conservation on the power side(air compressor)

Improvement
Energy generation unit

Air compressor

Energy transmission unit
Pipes
Auxiliaryequipment• Dryer• Filter• Air tank

Energy consumption unit
Air consumingequipment

Air control valve• Cylinder• Nozzle• Ejector, etc.

Air cylinderImprovement
Energy conservation on the consumption side(pneumatic equipment)

Vacuum equipment

4

JITMAP activities on Compressed Air⚫ 8 on-site missions from FY 2016 to 2019 and a Follow-up survey forprevious activities by TERI in FY 2020.

⚫ FS was conducted mainly for MSME as well as for several large
companies upon their requests.

Feasibility Studies (FS): a total of 25 companies
Trainings for energy auditors & managers: 5 times(220 participants)
Awareness Workshops: 5 times (360 participants)
Multi-Stakeholder Meetings: 2 times➢ Lessons learned through these on-the ground activities: Japanese technological products are still
not well known and trusted in the industrial sector.

➢ Our ultimate goal: To match machine and equipment (hard-technology) with the appropriate
operational practices (soft-technology)
Our challenge: To make it a reality.
➢ In order to achieve this, we need to continue our activities and act in a way that will benefit

both India and Japan.

5Results obtained from JITMAP activities

1. Realization of CO2 emission reduction in Indian companies:
1-1. Contributed to raising their awareness that the efficient use of compressed air saves energy.
→Appropriate measures were taken by understanding about where there is waste and whatkind of effects can be obtained.
1-2. Establishment of various appropriate operational practices of technology (soft-technology) :→CO2 emissions and energy consumption were significantly reduced.
1-3. Increased recognition of effectiveness of technologies such as inverters (hard-technologies)→Many cases have been reported in which air compressors have actually been introduced andeffective.

2. Results of the activities:
2-1. Certain evaluation of activities such as FS, workshops, trainings, etc. by Indian governmentand companies.
2-2. Raising environmental consideration and awareness (co-benefits).
・Reduction of NOx and Sox in proportion to reduction of electricity consumption.
・Reduction of air and soil pollution and pollutants in wastewater.
◆ Environmental impact of drainage in oil
・Reduction of waste: extended maintenance intervals, reduction of maintenance parts, regularmaintenance.

6Results obtained from JITMAP activities (Continued)

3. Building reliability:- Many cases where Indian companies have understood our improvement proposals andimplemented them, resulting in reducing CO2 emissions and energy consumption.
- Several companies presented these success stories elsewhere or came to us to report on them, which
can be examples of recognition and trust in our activities.

Examples of follow-up results in energy conservation （FY2019）7

A: Forging Factory (MSME)
Compressor ratio; 35%

B: Textile Company (PAD DC)
Compressor ratio；15%

C: Textile Company (MSME)
Compressor ratio；25%

・Stopping unnecessary units --review ＯＦ operational control.
・Stopping buried pipes.
・Measures against air leakage.
・Maintenance of air equipment.

・Optimization of operation・・・
Centrifugal as base＋Variable Screw
・Indoor ventilation measures.
・Measures against air leakage.
・From Grove Valve to Needle
Valve.

・Pressure optimization・・・Reducing
fluctuations.
Introduction of receiver tank at
the end・Introduction of high performance

4000000
3000000
2000000
1000000
0
1
Before2After

4600000
4400000
4200000
4000000
3800000
3600000
1
Before2
After・Measures against air leakage.
Energy reduction effects
552,750kWh/y 14.2%
CO2 reduction effects 514t/y
Annual total power consumption (kWh)5000000

Energy reduction effects
514,107kWh/y 11.5%
CO2 reduction effects 478t/yAnnual total power consumption (kWh)Annual total power consumption (kWh)Energy reduction effects
1,790,245kWh/y 36.2%
CO2 reduction effects 1,665t/y

drain traps

4000000
3800000
3600000
3400000
3200000
3000000
Before1

After2

Latest Update of Activities: FS at Polymer Industries➢ Was invited by Indian Polymer industries supplying products to major Japanese industries.
➢ Operating two plants in India for 24H/Day and 365 days, and very positively working onenergy efficiency and environmental improvement with obtaining ISO14001 certificate.
➢ Using three compressors for driving injection molding machine.
➢ Electricity consumption of injection molding machines accounts for more than half ofthe total electric energy usage in the company, and the one of the air compressors is 5.4%.

[Recommendations based on FS]
1) Energy Efficiency aspect
・ Improving piping system
・ Re-constructing air
・ Detecting and reducing air leakage
2) Environment Protection aspect
・ Drain treatment
・ Installing oil-free compressors
3) For Further Improvement
・ Energy and operation monitoring

8Transitioning to Business to Business (B to B) from the research stage

The following solutions are suggested to be continuously discussed and implemented undercooperation between the governments of India and Japan for further facilitating the transition
to business-to-business.
SolutionsContents

１ Gradual reduction of importtariffs

Act on Special Measures Concerning Imports of High
Efficiency Products, etc.

２ Introduction of the Energy
Conservation Law

evaluation system on business classification,
establishment of annual energy reduction.

３ Top-runner system

Dissemination of high-efficiency products, IE3

４ Environmental Protection Law

Water pollution prevention, air quality laws (clean air),waste reduction

５ Indian version of subsidy
systemDiagnosis and proposal forms, incentives

６ International exhibitions

Improvement of technology and exchange

７ Strengthening interactions

Ministries, local governments, and organizations(forging industry, textile industry, etc.)

9 Specific activities that are recommended to be conducted in B to B
- What Japanese companies are recommended to do when doing business with Indian companies -Activities

Contents

1

Recognition of Japanese productsFirst, it is important to let people know about them.

2Communication and mutual
understanding

Building a sense of trust with the people of India.

3

Introduction of high-efficiency
methods and systems

Soft technology; energy efficiency diagnostic
methods, optimized control.

4Promotion of high-efficiency products

Inverters (VSD, VFD), etc.

5

Introduction of concept of LCC (LifeCycle Costing)Concept of cost merit

6

Long life product development

Proper maintenance and parts supply, Re-Use, etc.

7

Short-term or long-term monitoring

Status Monitoring

8Monitoring through the application ofIoT technology

Energy conservation and preventive diagnosis
through mutual communication

9

Continuous education

Strengthening workshops and trainings.

10 Meetings to exchange opinions

Energy auditors, customers, etc.

Continuous activities・・・Improvement of diagnostic techniques in India
through OJT and dissemination activities

Thank You for yourattention!