Trust Proves Cutting Energy Use Isn't Just a Lot of Hot Air

Article excerpt

Industrial Air Power Ltd is the authorised distributor for Ingersoll Rand Industrial Technologies products throughout Wales and the SouthWest of England. The two companies have made a dramatic shift frombeing suppliers of equipment to providers of solutions.

We are fully conversant with all aspects of air generation and equipped to carry out energy audits on any installed system, regardless of size or manufacturer.

A full system audit includes leak detection, measurement of energy consumption, and flow measurement including pressure, temperature and final air quality.

As utility rates continue to rise and firms continue to look to green initiatives, energy consumption has become a growing concern for manufacturers.

One of the largest energy users within a plant is the compressed air system. Energy recovery provides a cost-effective way for manufacturers to reduce their energy bills while simultaneously benefiting the environment by capturing the thermal energy created through the compression process and putting it to work. Where the heat produced from a compressor can be fully utilised, simple payback periods of less than two years are frequently achieved.

Having already worked with Carbon Trust on a variety of projects, Terramcalled on its expertise when faced with rising energy costs. The specialist manufacturer of geosynthetic materials, employing 95 staff at its manufacturing plant near Pontypool, worked with Industrial Air Power to eliminate energy inefficiencies and redesign and install a new air compressor system. The result was an industry best in terms of energy usage and savings of pounds 202,000 per annum. It also produced:

Energy savings of approximately 11.25 million kWh over five years

Cost savings of approximately pounds 1m in five years

Emission savings of 7,390 tonnes CO2 in the same period

Payback of approximately 24months David Roberts, control engineer at TerramLtd, said: "The savings we are seeing now are unbelievable but just as important is the fact that we are reducing our carbon emissions and therefore benefiting the environment."

Although Terramhad already started to investigate the costs for new compressed air systems, it hadn't looked at where, when, how much air was being used.

Carbon Trust helped it identify this and used Industrial Air Power to design a system to meet its needs.

Having a tailor-made system installed in turn allowed Terram to capitalise on secondary savings such as heat recovery and compressed air leak reduction.

Ongoing monitoring of the fully automated system allows the savings to be quantified. Monitoring also ensures that the focus on savings is maintained and remains a high priority for Terram.

The new compressor system was located into the steamboiler house. This enabled Terram to recover the waste heat generated by the compressors and use this to raise the temperature of the water in the hot well, which feeds the boiler. Increased water temperature in turn reduces the amount of gas needed to generate steam.

The aggregated savings from the installation of the new system and implementation of the measures identified represented an 11. …