Out with the Old, and in with the New
#oilmist #metalworkingfluids #HSE #levscotland #circulareconomy #energyreduction #carbonreduction #businessesinscotland
A large manufacturer of gas turbine engine manufacturer had 6 inefficient dry dust collectors using significant energy during the energy crisis. The project was to reduce energy and servicing costs quickly and dramatically.
Over the years changes to operations meant changes to the ducting layout. Alterations and addons had been done without calculations, and this had created very inefficient airflows.
These changes meant they needed much less airflow to control the contaminant and stay compliant with HSG 258 and COSHH regulations.
Many businesses change ducting layouts but seldom think of the pressure on the LEV system. This can dramatically increase energy costs and add to running costs.
What did we do?
- We completed a careful redesign of the ducting system inside.
- We spent time with the client mapping the process, understanding working practise, calculating future state actual airflow requirements versus current state.
- We calculated, specified, designed, and installed a fast ROI set of replacement systems.
- We arranged independent energy data logging to understand actual energy use.
- We reduced large belt driven motors from 32 and 22Kw to 18 and 11kw highly efficient direct drive motors reducing the need for belts and more PPM time.
- We installed smaller LEV. By reworking the ducting we were able to reduce the number of filters needed each year from 216 to 98 significantly reducing year on year costs and PPM time, reduced down time, reduced waste to land fill and reduced inbound transport costs.
- The project outcome: 6 significant upgrades. Cost saving of £250K per annum on energy alone. New machines with a 15 to 20 year expected life span paid for in less than 2.5 years. Year on year added value to the business via reduced energy, carbon footprint and we returned warm air back to the facility.
- The ROI was under 2.5 years at current costs. 20 year projection, 5 million saved on energy.