Challenge
Our customer manufactures engineered wood-based panel products. Production requirements include pneumatic components such as actuating cylinders, valves, palletizers and large dust collectors.
The customer required new air drying equipment as the existing dryers were nearing the end of their life cycle. They were beyond economical repair and wet air was becoming present downstream. They are also responsible for carbon levies which impact their fuel costs, and are required to purchase carbon credits under EUETS. They are also seeking ISO5001 energy standard to assist in driving through energy improvements. Their official figures recently published show they are looking to reduce carbon emissions by 10% and energy use by 5% produced by 2020 based on the 2010 figures. Energy consumption has increased by 2.9% since 2013, and by 6.5% since 2010.
Therefore the customer wanted an energy-efficient, reliable and cost-effective solution.
The customer also needed an improvement in compressed air quality to guarantee process reliability. The main issue was due to the increased maintenance requirements of the air handling equipment, valves, pipes, dust lines, and general downtime to repair leaks. The value of this upgrade for the customer will be their increased production capacity, owing to the decrease in maintenance requirements, as well as the direct reduction in the running costs.
Engagement
PSI performed a site wide survey to ascertain exact flow rates and required compressed air quality. PSI through condition monitoring and technical expertise were able to match the correct equipment to the customer’s need without any expensive pipework or compressor house modifications.
Solution
PSI recommended the installation of 3 large Omega refrigeration air dryers which were optimally sized to the compressor outputs. Compressed air quality is critical to the operation of the plant and the solution offered an excellent price-performance ratio with the main focus on the guaranteed compressed air quality, on-going operating costs and not the initial purchase price.
Benefits
The solution provided a reliable, economical and energy efficient drying performance in a challenging dusty environment. The customer benefited from upgraded drying technology which has been seamlessly integrated within their existing compressed air system.
Operation of the dryers is monitored by DMC15 electronic controllers which provides an early alarm warning indication of any issues. The dryers also have a stand-by facility for reduced energy consumption and the consumed amount of energy is adjusted to the required drying performance. The expected savings from energy efficient dryers is a 50% reduction in previous drying energy costs over a 5 year period.
The Omega dryers are backed by a manufacturer two year hardware warranty to highlight confidence in the product.
