Feature Energy management
Oil-free technology cuts energy costs
Merck KGaA, a paint manufacturer based in Gernsheim, Germany, has turned to CompAir’s, oil-free Quantima compressor technology to help lower energy costs and reduce cost of ownership
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riginally Merck planned to pur- chase a single Quantima Q-52 machine to replace an existing turbo compressor. However, after achieving dramatic energy sav- ings from its initial installation, the company decided to add two more Quantima models to the network. As a result, Merck is now on track to save €60,000 a year in energy savings. Merck’s performance material department develops and produces pigments for effect paints, for use on high-end luxury cars, including spe- cial glimmer and multi-colour effect paints. The development process requires high-quality air to avoid any contamination issues, making the 100 per cent oil-free Quantima technology a suitable choice. Previously, Merck used standard turbo compressors but found Quantima’s gearless driveline and simple compression technology made the system considerably more cost- effective. A speed-regulated, high- speed electric motor drives a rotor shaft that is directly connected to an impeller at each end.
The rotor shaft is supported by mag- netic bearings and is literally floating on air resulting in no mechanical con- tact and therefore reducing wear on components and helping to lower maintenance costs.
Merck says it has been able to cuts energy costs by €60,000 with CompAir's Quantima compressor 2/2
Efficient package
The first Quantima Q-52 package included a desiccant dryer that uses the waste compressor heat for full- flow, hot-gas regeneration. This pro- vides high-efficiency because the heat required to regenerate the adsorption material is provided with no addi- tional energy outlay. To make the greatest possible use of the thermal energy, there is also no aftercooler installed, enabling the compressed air to be discharged into the full flow using a hot gas outlet.
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A nine-month success story Following the success of the initial installation, when a large turbo com- pressor in the second compressed air station needed replacing due to old age, it was a logical choice for Merck to upgrade to two smaller Quantima machines.
Demand in this compressed air station fluctuates dramatically in short intervals, so the speed-regulated Quantima system provided a suitable opportunity to match compressor output to varying factory demand. With volume capacities of 2500m3/h and 3100m3/h respectively, the compres- sors are now able to operate in line with the actual air requirements at all times, providing further energy savings. CompAir T: 01527 838200
www.compair.com Enter 300
Paint manufacturer Merck is on track to save thousands a year in energy savings thanks to CompAir
pirax Sarco has launched Spirax Rental to help steam users make the energy-saving investments they need to save money and reduce their carbon footprint without delay. Capital budgets are being squeezed across the board, making it difficult for many steam system operators to invest upfront in projects that could otherwise be saving them money. Spirax Sarco now offers rental options to help operators carry out projects sooner and immediately reap the benefits of eliminating wasted energy. The resulting savings are said to effectively make many projects self-funding. “Many organisations are wasting money operating and maintaining ageing,
Energy efficiency with no upfront costs S
energy-inefficient plant and equipment,” says Steve McKie, national specialist sustainability, Spirax Sarco. “That’s real money already being spent every month. That makes no sense when the money could be used to reduce energy consumption by installing products that will deliver energy savings and reduce maintenance costs.”
Depending on the scope of the project, monthly payments under the new scheme can be used to cover the cost of design, new equipment, installation and removal of old equipment.
Steam users can choose several options at the end of their rental agreement. For example, private companies may opt to pay a peppercorn rent to continue using the equipment, or they may choose to purchase the equipment outright for just one per cent of the original cost. Public sector users have the added option of reducing their monthly payments by agreeing a particular residual value for the project, in which case, extension payments will reflect that residual value. Spirax Sarco Rental Services T: 07977 506029
www.spiraxsarco.com
Enter 301 SEPTEMBER 2012 Factory Equipment
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