Massive Energy Savings Thanks to Expert Advice

30 Jul 2008

Airchannel has replaced 4 fixed speed compressors at Haani Cables with a new CompAir L75SRF compressor, saving the Company an estimated £10,000 annually in energy costs.

The Hartlepool based electric cable manufacturer was keen to save on their energy usage and asked Airchannel to conduct an air usage audit and suggest the best combination of equipment for savings and life cycle costs. 

Haani was looking to save a minimum of 10% of the energy costs associated with the compressed air systems, but Airchannel advised that far greater overall savings could be made. It suggested and subsequently installed a CompAir LSRF rotary screw compressor which incorporate a variable speed switched reluctance drive system, and an integral refrigerated dryer.

The CompAir SR technology and build quality speak for itself, and it has the added benefit of being the most energy efficient solution on the market today. Airchannel estimates that the LSR speed-regulated compressor can produce savings in excess of 25% in energy and operational costs by eliminating energy loss during periods of unloaded running and precisely matching power consumption with air demand.

With a typical oil lubricated rotary screw compressor operating at 70% load, energy costs can account for 82% of the cost of ownership, compared to 62% with an LSR. Equally, maintenance and service for the LSR stands at 5% of the cost of ownership, as compared with 8% for fixed speed and the LSR systems are sequence managed by a Delcos control system. 

Additionally, Airchannel were asked to advise on the cooling water system. This had been positioned inside the factory and was consuming over 120 Kw of energy per hour with two large refrigerant chillers. Experts in this field, Airchannel and Delimon working in partnership recommended the installation of Delimon airblast aftercooler complete with moisture inhibitor for warmer days. 

Airchannel fitted the new system outside, and consequently Hanni is now using just 22Kw of electricity per hour on it’s cooling operations.