34 food & drink processing
☞
the plant operational requirements in
detail. From this meeting we were able
to establish accurate estimates for the
possible savings and create a clear strategy
for delivering and maintaining tangible
energy, cost and carbon savings.”
Graham Coats, Director of EnergAir
Solutions Ltd, adds “PET bottling plants
tend to work on far higher pressures
than normal automated production
lines, typically 40bar as opposed to ~7bar,
requiring more power and often providing
a greater opportunity for energy saving.
With the recent rises in energy costs
and the experience we had gained form
systems we have completed on other PET
plants, we were confident significant
savings could be realised.”
Fig. 2. EnergAir SX control units manage the sequencing and duty cycles
The table below summarises the
of the compressors.
improvement in system performance and sequenced start routine including all the parameter
since the introduction of the compressor management/ checks and power switching. This improvement not only
control system. The system has achieved the energy gains saves time for the operating crew, but it also contributes
by optimising the installed compressor set, stabilising towards increased plant safety.
the system pressure and allowing a careful but precise The compressor control elements were supplied
reduction in the system operating pressure. Further by (EnergAir sister company) CMC Controls based
energy gains are expected in the short term through in Belgium. Once installed, the energy savings are
effective management and fine-tuning of the system. derived from applying a combination of system pressure
This installation also presented a number of practical optimisation principles, matching air generation closely
challenges for EnergAir to overcome, not least that the to demand, ensuring compressors are working at their
original control cabinets for the four original high- optimum efficiency and only running when they are
pressure reciprocating piston type compressors had needed.
to be replaced in order to update to the new control Air pressure sensors are fitted throughout the system
technology. A recently installed fifth compressor was and used to feed live data into EnergAir ‘EnerSoft
also integrated into the system and only required the – Analysis’ data manager software that is hosted on
replacement of its PLC controller. an onsite PC, this collates and records all the data
The previous control system required a complex and makes it available online to ACT Ltd. where it
sequenced start-up and shutdown procedure that is compiled into specific Key Performance Indicator
required a long list of checks and switches to complete. (KPI) reports. For day-to-day maintenance monitoring
The complete compressed air system,
kpis result
from compressor, through to the dryers,
cooling system and out across the plant
1 generation efficiency improved on average by 5.46%
is represented visually on screen in a
Windows XP environment using EnergAir’s
2 cost per delivered m3 decreased on average by 5.26%
EnerSoft – Visual software package, with
key indicators such as system pressure and
3 Annual generation costs decreased by 29.36%
efficiency displayed clearly on screen as
analogue style dials.
4
The data is updated every few seconds
Annual kWh used net saving of 1,797,131 kWh
and so the information seen on screen is
virtually live, Britvic are able to predict
5 net annual carbon saving saving of 772 tonnes
and plan for any changes made to the
plant and report effectively on incremental
Note: All summary calculations are based on the cost per unit of electrical energy @ £0.032/
positive changes made to keep efficiency
kWh and is based on the system being operational for 8,400 hours/annum.
maximised. p
Now, the process has been automated to the point where EnergAir Solutions Ltd is based in Woking, Surrey, UK.
a single physical start button pressed either locally or www.energair.co.uk. Air Compression Technology Ltd is based
on virtually the PC will carry out the complete timed in Sandygate, Sheffield, UK. www.aircomptech.com
www.scientistlive.com
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