due to artificial demand and overproduction (not knowing how much compressed air the operator actually needs), air leaks and poor practices. A supply and demand side audit, as well as a system leak evaluation, can yield tremendous ben- efits. Savings are typically realized in low-capital activities, such as leak repairs, piping changes, air storage sizing and proper compressor sequencing. Ask the following questions to reduce overproduction of


compressed air: • Do you know your actual demand (i.e. how much air you need)?


• Does this need vary throughout the production schedule, or is it constant?


• What air pressure do you need? • What quality of air do you need? All air leaks are wasted production and should be tagged


for repair. One metalcasting facility that began to diligently monitor and repair leaks and air production discovered sig- nificant overproduction and was able to take 375 horsepower of compressed air production offline, resulting in an annual savings of approximately $170,000.


Plant Lighting Plant and office lighting can be a significant source of


energy savings, although some capital costs will be required. Today’s lighting fixture designs drive light deeper into the plant and provide truer colors for better employee com- fort. Proper engineered lighting fixture layout can improve efficiency. Motion sensing and centralized automated control also offer opportunities for significant improvements in energy savings and maintaining consistent levels of light. One U.S.-based aluminum casting facility had approxi-


mately 360 high pressure sodium light fixtures, covering more than 200,000 sq. ft. of space. Since the bulbs con- sume about twice as much energy as T8 fluorescent fix- tures, the facility identified an opportunity to reduce elec- trical consumption and receive an energy rebate through a state sponsored energy program. Working with a local lighting provider to find the best fixture and appropriate replacement for each area of the plant, the metalcaster installed 360 six- and four-bulb T8 fluorescent fixtures. Low traffic areas, such as the warehouse space, were outfit- ted with motion sensors to provide further reductions. Te total cost of the lighting investment and installation was $70,000, and the company received a state rebate of $33,615. Te estimated savings using the new lighting is more than $55,000 per year with a return on investment of about eight months, including the rebate. Te estimated electrical power reduction will decrease the plant’s carbon dioxide output by about 400 metric tons per year, 2 metric tons of sodium dioxide per year and 1 metric ton of nitro- gen oxide per year, the equivalent to saving 211,000 liters of gasoline or removing 109 cars from the road.


Reuse of Waste Heat Te reuse of waste heat can net energy savings of 15-25%


or more. While technologies exist for converting waste heat energy to electric power, a simple and less costly approach is


送往往是低效的，在工艺中失去三分之一的压缩空气 功率。行业研究显示金属铸造厂平均生产比实际需求 多50%的压缩空气，这是由于人工提需求和生产过 剩（因为不知道实际需要多少压缩空气）、漏气、经 验不足引起的。因此，进行供需审计和系统泄漏评价 将能够产生巨大的效益。节约通常可以通过低成本的 活动就可以实现，例如泄漏修复、管道变动、空气存 储量大小、正确的压缩机排序。


自问以下问题可以减少压缩空气的生产过剩。 • 你是否知道自己的实际需求（你需要多少压缩空 气）？


• 在生产进程中压缩空气需求是变化的，还是恒定的？ • 你需要什么压缩空气？ • 你需要怎样质量的空气？


所有漏气都是浪费生产，应该立即修补。一个金属铸 造厂认真监测和修复渗漏和压缩空气生产，可以发现生 产过剩，并能够在空气压缩机离线的情况下获得375马 力的压缩空气，每年约节省17万美元。 车间照明


尽管得花一些资金成本，车间和办公室照明可以是节 能的重要来源。今天的照明灯具设计使光可以照到车间 更深的地方，并给员工提供更舒适的真实光彩。正确的 工程照明灯具的布局可以提高效率。灯具对动作的感知 技术和集中自动化控制技术可以显著改善节能，保持稳 定的光线。


一个美国的铝铸造工厂约有360个高压钠灯灯具， 占用20万平方英尺以上的空间。由于这种灯具消耗 能量是T8荧光灯的两倍，工厂发现了一个可以减少电 力消耗并获取国家能源计划的能源回扣的机会。该铸 造厂与当地照明灯具供应商合作，为车间各个区域寻 找最适合的灯具固定物，并适当替换部分，金属铸造 厂安装了360套六个灯泡以及四个灯泡的T8荧光灯。 低人流区域如仓储空间，配备运动感应进一步实现 节约。该照明改造计划的总投资和安装费用为7万美 元，该公司收到国家33615美元的回扣。使用新的照 明灯具估计每年可以节约55000美元以上，包括八个 月的投资回报和回扣。耗电的减少估计每年可以减少 车间排放443吨二氧化碳、2吨过氧化钠、1吨氮氧化 物，等于节省了55716加仑汽油或少在路上跑了109 辆车。


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