Project Description:
- The initial meeting and tour of the factory and the compressor room were conducted to collect relevant data on the factory's operations and the compressors, to characterize the need and the potential savings.
- Detailed calculations and in-depth characterization were performed for the factory’s air needs, the current state, and the operation of the existing air system. Suitable products with high energy efficiency were selected, and all components of the compressor room were characterized with upgrade options prepared to reduce energy waste while improving the operational condition of the room.
- A relevant pricing proposal was prepared, along with accompanying documents such as current air production costs, post-upgrade air costs, and an investment return outlook.
- After receiving the client's order, work began on a plan for installation and calibration of the operation of the new air system.
Summary:
In this project, I initially visited the client with a completely different goal than upgrading the air system. However, after the tour and seeing the amount of compressed air used in the factory, I requested a tour of the compressor room. In the compressor room, I saw six screw compressors, each 50 HP, all with fixed speed. As I observed the operation, I immediately identified the room had high potential for energy savings.
I collected all the relevant data and prepared an estimate of the current energy cost versus the projected savings and investment return after the recommended upgrade.
Before the upgrade, the air system operated between two to four compressors, with some of the compressors switching between compression and idle mode, indicating wasted energy that could be saved by using a variable speed compressor that adjusts its output to air consumption.
We performed a comprehensive upgrade to the compressor room, removing four old compressors and replacing them with two ELFD100HP screw compressors with a permanent magnet electric motor and variable speed, manufactured by EL-AV Compressors in Israel.
In addition to upgrading the compressors, we replaced four line-filters with EF series filters. We also upgraded the entire drainage system in the room, which initially consisted of eight timer-controlled water drains that wasted a lot of energy. We installed four electronic intelligent drains and four mechanical drains, all of which discharge liquids only without air, thus saving wasted energy.
Before the upgrade, the energy consumption of the compressor room was approximately 612,000 kWh / $65,760 per year (assuming 1 USD = 3.72 ILS).
The estimated savings submitted to the client were between 216,000 and 250,000 kWh per year / $23,226 to $26,881 per year.
In the first few weeks, the average energy consumption decreased by about 30 kWh, indicating an average annual savings of at least 240,000 kWh / $26,881.
- *kWh = kilowatt-hour.
- **The monetary savings were calculated based on the client's electricity cost of 0.108 USD per kWh (subject to change between clients).