Challenge

A plate glass manufacturer was using compressed air to aspirate their furnace using 105 psig plant air and regulating down to 8 psig for the aspiration application. Based upon observation and flow metering, the aspiration demand was estimated at 110 cfm.

Solution

Zorn Compressor evaluated the entire system and sized a blower package to provide approximately 140 cfm at 10 psig.

Solution Offering:

• VFD was incorporated to provide turn down when the full demand of the blower was not required or all aspiration zones were not being used
• Proposed blower had a 10 hp motor and was estimated to require about 9 bhp at actual demand conditions
• Installed new piping system to accommodate the 10 psig air with minimal pressure drop
• Incorporated current plant air/regulator system for back up

Benefits

The furnace is aspirated approximately 6500 hours per year and the application of the blower is expected to reduce power by 108,000 kwH annually. At a blended electrical cost of $0.09/ kwH , annual savings are estimated at $9,720.00 per year. Additionally, the load reduction will keep a second compressor from running and lower the maintenance on their lead compressor.

The entire project investment was $20,000. FOE provided a $6,500 load shedding incentive which created an estimated 16 month ROI.

Estimated annual electrical savings at a blended electrical cost of $.09/kwH.