The System Assessment
Oil & Gas
A pharmaceutical product manufacturer spends an estimated $137,443 annually on electricity to operate the oil-free air compressors in its compressed air system. The compressed air system operates well and is providing the level of purification required. Our team visited the plant and identified a group of projects which could reduce compressed air demand and reduce energy costs by $42,248 – or 31% of current use.
A large pharmaceutical company needed huge flow rates of 30 psig air to aerate multiple fermentation processes which create food-grade materials. Flow could vary from about 12,000 scfm to 35,000 scfm. There were a variety of batch processes, mostly running independently. An hour-by-hour schedule for anticipated air flow is developed every afternoon for the next day. Based on that schedule, the boiler operators run the air compressors that can handle the load range for the whole day. In reality, the peak flow can be higher than anticipated.
Compressed Air Best Practices® Magazine interviewed Mr. Warwick Rampley, the National Sales Manager for Sydney (Australia) based, Basil V.R. Greatrex Pty Ltd. It’s not every day one is asked to deliver a system able to provide both a reliable compressed air dew point of -80°C (-112°F) and high purity nitrogen. We work with some excellent technology suppliers and have engineered a rather interesting system. Although our firm was founded in 1919, this application is one of the most demanding we’ve encountered. Basil V.R. Greatrex is a unique company as we focus only on compressed air measurement, compressed air quality and compressed air efficiency.
The Lafarge Cement Distribution terminal located in Winnipeg, Canada has significantly reduced the site electrical demand and energy charges by changing the way they transport their cement. Two new low-pressure rotary screw air compressors have replaced two large high-pressure air compressors that previously powered their dense phase transport system. The resulting power reduction has saved the company 46 percent in transport operating costs.