New energy calculators launched

The Managing Carbon Consortium has launched two new energy calculators for energy statements and combined heat and power.

The two new energy calculators fit in with the Schools, Offices and Homes calculators that Managing Carbon already provide.

An IOA was carried out for a small printing company.

One of the recommendations of this study was to install a voltage optimising transformer off the main feed to the site. A further part funded detail study was carried out. Site electricity profile demand measurements were carried out on the two LV networks. Accurate installation costs were obtained and economic calculations provided.

A performance specification was produced and detailed supplier proposals requested. A Carbon Trust Energy Efficiency Load was applied for and granted and the project has been implemented.

The agreed objectives of this study at a chemical works were to identify and prioritise actions that can be undertaken by the site to reduce the energy required for compressed air generation and treatment and to save carbon.

The factory produces various chemicals including acrylonitrile and a range of nylon intermediates. The factory employs approximately 450 people and has a total energy spend of approximately £35m. The compressed air is generated at a nominal pressure of 7.0 barg in a central location close to the main boilers by two water-cooled, oil free rotary screw compressors. There is a basic control system, which uses pressure control and loads/unloads the compressors and brings in the second compressor when required.

Following generation the air is routed for treatment by filtration and steam heated desiccant drying. The air is distributed to the using areas by a comprehensive piping network. The annual cost of compressed air generation and treatment is currently estimated at £151,000.

The action plan included measures with aggregated savings of up to 35.6% reduction in energy consumption for generating and treating the compressed air. These equate to cost savings of up to £53,824, which ranslates into additional profit for the works and a reduction of CO2 emissions of 574 tonnes.

In addition, there is believed to be the potential of a further 828 scfm of leakage. At the current generation efficiency this equates to savings of £58,760 and a reduction of OC2 emissions of 739.2 tonnes. The terms of reference for the study were:

• Carry out performance tests on the compressors
• Measure the air demand and pressure on the compressor stations over a one-week period
• Measure the air demand and pressure from the main users over a one-week period

• Establish the quality of the air being delivered to the site;
• Review the compressed air generation and treatment systems;
• Conduct a leakage detection survey using ultrasound;
• Establish areas of use and misuse;
• Provide recommendations on energy and carbon saving opportunities;
• Provide a written report giving findings of the investigation, identified savings and recommendations for the future strategy;
• Conduct a post survey briefing on the findings of the investigation to the site engineers.