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Energy savings

Johno12345
Hi


I'm looking at my factory for some avenues to save energy, and have certainly come across some projects that have saved thousands on energy, but with an obvious cost to implement. 


The obvious ones like LED lighting, timers etc are all done, so I have started thinking a bit further.


I have 11 charge air blowers, which are 11kW or 13kW, are all pretty old, and have been rewound several times. They cant be changed to variable speed, as the air volume needs to be constant, and need to remain individually controlled. As these things run all day and night, its a significant cost. 


I seem to be a bit sceptical when someone tips up at the door saying they have super energy saving motors, especially when they cant quantify their claims.


Has anyone come across something that gave tangible results on things like this? 


Another one is that someone said putting VSD on pumps and fans, even running them at 100% will give a good energy saving


Thanks, just having a ponder since its Friday
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  • Former Community Member
    0 Former Community Member
    You can get "more efficient" motors - efficiency classes IE1, IE2 etc


    A VSD drive may be an energy saving as the motor is never exactly matched to the load - so whilst you may want constant volume output from the air chargers, the actual volume you need may well be different to the motor/fan efficiency point which you are controlling with valves or dampers - so even if you are running a few Hz lower on the motor, there will be a saving in energy as you aren't throwing it away across the damper/valve


    Is there a use for any recovered heat from the compressors, or means of making any air cooling/drying more efficient.


    Basically, it's just a case of following the energy flow through the various conversion processes and grabbing any waste from "efficiency" for re use or another use.


    As an example, we've recently been able to show a client big energy savings by changing from high temperature hot water (roughly 20 bar) as the inner charge for tyre moulding, to using super heated nitrogen for the same purpose - basically we heat the nitrogen from a waste stream off the exhausts of the electrical aero turbines. (basically aircraft engines bolted down and burning gas to provide electricity - gas is cheaper to import than electric)


    Regards


    OMS
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  • Former Community Member
    0 Former Community Member
    You can get "more efficient" motors - efficiency classes IE1, IE2 etc


    A VSD drive may be an energy saving as the motor is never exactly matched to the load - so whilst you may want constant volume output from the air chargers, the actual volume you need may well be different to the motor/fan efficiency point which you are controlling with valves or dampers - so even if you are running a few Hz lower on the motor, there will be a saving in energy as you aren't throwing it away across the damper/valve


    Is there a use for any recovered heat from the compressors, or means of making any air cooling/drying more efficient.


    Basically, it's just a case of following the energy flow through the various conversion processes and grabbing any waste from "efficiency" for re use or another use.


    As an example, we've recently been able to show a client big energy savings by changing from high temperature hot water (roughly 20 bar) as the inner charge for tyre moulding, to using super heated nitrogen for the same purpose - basically we heat the nitrogen from a waste stream off the exhausts of the electrical aero turbines. (basically aircraft engines bolted down and burning gas to provide electricity - gas is cheaper to import than electric)


    Regards


    OMS
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