GEORGIA SPECIALTY CHEMICALS PRODUCER
A globally recognized specialty chemicals and sustainable technologies company enlisted SMARTCAir to assess the compressed air system at its Savannah, GA facility. The objective was to identify inefficiencies and reduce the high energy costs and carbon footprint of the plant’s 24/7 compressed air operations.
Current Issues
High Energy Consumption
Inefficient Compressor Use
Inefficient Compressor Use
The existing air compressors used about 3.6 GWh of electricity per year, costing roughly $500,000 annually, with a substantial carbon impact of over 1,100 tCO2e per year.
Inefficient Compressor Use
Inefficient Compressor Use
Inefficient Compressor Use
Out of a multi-compressor setup, three units provided 94% of the output, often with a large 200 hp compressor modulating and a smaller 100 hp unit kicking in unnecessarily. This led to suboptimal specific power (energy per unit of air) and wasted energy.
Pressure Drops
Leaks and Meter Inaccuracy
Leaks and Meter Inaccuracy
The facility experienced pressure fluctuations – the main receiver saw pressure as low as 65 psig – indicating potential distribution bottlenecks and prompting higher pressure setpoints (and thus higher energy use) to compensate.
Leaks and Meter Inaccuracy
Leaks and Meter Inaccuracy
Leaks and Meter Inaccuracy
A significant baseline of air flow (estimated 60 CFM) was attributed to leaks. Additionally, flow meters were found to be reading about 18% higher than actual flow, masking the true efficiency and making the system seem more efficient than it was.
Proposed Solution
Leak Detection & Repair:
Find and fix compressed air leaks, which were estimated to be consuming about 60 CFM continuously. Repairing leaks would immediately cut waste (about 410,000 kWh/year saved).
Optimized Compressor Controls:
Reconfigure how the compressors are staged. The largest compressor (200 hp) should remain fully loaded as much as possible, and the small 100 hp compressor should only run when absolutely needed. This avoids inefficient simultaneous operation and keeps each unit in its best efficiency range.
Pressure Reduction:
Improve the air distribution (e.g. by correcting undersized piping or adding a loop) to stabilize pressure. This allowed the average supply pressure to be reduced from ~103 psig to 80 psig without risking production, since short-term demand spikes would be better handled. Lowering the pressure setpoint directly cuts energy use (roughly 1% energy savings per 2 psi reduction).
Instrumentation Calibration:
Re-calibrate or replace flow meters to ensure accurate measurements for ongoing monitoring. Correct data would help maintain optimal performance long-term.
Savings
Energy Savings:
Energy Savings:
Energy Savings:
About 1.22 GWh per year of electricity saved, roughly a 34% reduction in compressed air energy consumption.
Cost Savings:
Energy Savings:
Energy Savings:
Approximately $171,000 saved per year in electricity costs (at $0.14/kWh). The plant’s annual compressed air energy bill drops from ~$500k to ~$329k.
Emissions Reduction:
Operational Benefits:
Operational Benefits:
An estimated 400 tonnes of CO2 emissions eliminated annually by using less power. This is a ~36% cut in the facility’s carbon emissions from 1,100 tCO2e down to around 700 tCO2e.
Operational Benefits:
Operational Benefits:
Operational Benefits:
The system runs with more stable pressure and with one less compressor in frequent operation. This reduces wear-and-tear on the backup machine and improves overall reliability.
Conclusion
By partnering with SMARTCAir, our customer achieved a more efficient and reliable compressed air system. The recommended fixes – from repairing leaks to revamping compressor sequencing – translated into over 30% energy savings and significant cost reductions. In addition, the facility’s carbon footprint was markedly reduced. This comprehensive air system tune-up not only saves our customer hundreds of thousands of dollars annually but also improves production stability (no more pressure drops) and supports the company’s sustainability goals.
SMARTCair
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