Interlocking smoker doors with exhaust fan (with additional timer) allowed to save an estimated $30-40K on electricity on exhaust fans alone. Great result for a $5K upgrade. However, this was icing on the cake of real savings:
- Reduction of air exhaust from refrigerated room reduced cooling load and eliminated need for refrigeration plant upgrade – $180,000 of CAPEX
- An upgraded refrigeration plant would have used an estimated extra $112,000 in electricity to run
Heat exchanger reduced CAPEX from $200K to $75K at a chemical manufacturer
This chemical plant produced liquid product that required heating and cooling. Growth of production volume was limited by undersized boiler and cooling tower that was too small for previously upgraded compressors.
When a facility is short of both heating and cooling an energy efficiency opportunity just waits to be found. Audit suggested using hot gas from refrigeration plant to preheat liquid product through a heat exchanger. With heat transfer from hot gas to product, less heating was required from boiler and less cooling was required from refrigeration plant’s condenser, which, in turn reduced load on cooling tower.
A $75K heat exchanger eliminated a need for a $150K boiler upgrade and for a $50K cooling tower upgrade.
Saving of natural gas and water came as a welcome extra.
These examples were suggested by our partners at Enviro-Stewards.