Case Study | How Air Solutions Canada Secured $90,000 in Save on Energy Funding for an Ontario Refractory Plant

Resources Case Studies Refractory manufacturing facility

Refractory manufacturing facility

Client:

Ontario Refractory Manufacturing Facility

Solution:

Air Demand Analysis, (ADA) Desiccant Air Dryer Compressed Air Filtration ECO Condensate Drains Drain Traps

Industries:

Packaging

Benefits:

$90,000 in Save on Energy incentive funding secured
$55,000 in annual energy savings at current Ontario hydro rates
294 CFM returned to the compressed air generating station
45 kW in compressor motor power conserved
Extended air compressor service intervals
Improved compressed air quality with visual dew point monitoring
Air Dryer Desiccant Regeneration, on an “as and when required” Dewpoint dependent energy saving controller

About the Company

The client is a refractory manufacturing facility in Ontario, producing powders, ramming mixes, and gunning mixes for industrial furnaces. Compressed air sits at the heart of their operation, from conveying and blowing refractory materials to driving the pneumatic valves and cylinders throughout the plant. Two 100 hp (75 kW) rotary screw compressors carried the main load, with a 75 hp (55 kW) unit on standby.

In a refractory plant, air quality is everything. Moisture in the system can clump dry materials, prematurely hydrate cementitious binders, and clog hoses and conveyors. In furnace applications, the consequences are even more serious. Water can turn to steam during heat-up and cause cracking, spalling, or structural failure of the lining.

The Problem

Energy costs were trending higher than expected, and our compressed air energy conservation specialist, Buzz, suspected that the compressed air system was a major contributor. The compressors were working harder than they should have been, while moisture risks remained a concern. Incremental changes had been made over the years, but without hard data and clear KPIs, there was no way to justify a capital project or build a business case for leadership and finance to consider.

Two specific culprits were hiding in plain sight. The existing twin-tower heatless desiccant dryer was purging on a fixed five-minute cycle regardless of actual conditions, throwing away compressed air and all the energy used to generate it. On top of that, multiple timed solenoid drain traps were expelling compressed air on a fixed schedule, whether condensate was present or not. Timed solenoids were originally designed for water and fuel, not compressed air, and every unnecessary blowdown cycle was direct energy down the drain.

Technical scope:

To support the facility's production and furnace reliability requirements, we specified and installed a new compressed air treatment system built around Kaeser equipment.

Desiccant Dryer:

- 1 x Kaeser KBD Blower Purge Desiccant Dryer

Filtration:
- Lower differential pressure filtration assemblies, upstream and downstream of the dryer
Controls and Dew Point Management:
- Dew point switching control, regenerating desiccant as and when needed
- Visual display of compressed air pressure dew point for operators
Condensate and Drain Rationalization:
- Timed solenoid drain traps removed and replaced with appropriate zero compressed air loss, demand-drain solutions

$Refractory (1)$

The Result

A massive 294 CFM was returned to the compressed air generating station, conserving an unbelievable 45 kW in compressor motor power and delivering $55,000 in annual energy savings at current Ontario electricity rates.

Air compressor service intervals will be extended, with less compressed air being generated and fewer running hours occurring on the rotary screw compressors. Operators now have a visual display of the compressed air pressure dew point, drain alarm notifications, and filter element conditions. Lower pressure drop and greater oil and particulate removal result in improved compressed air quality and pressure throughout the plant.

With $90,000 in incentive funding secured, the plant's leadership team now has a clear before-and-after story backed by real data. The numbers speak for themselves.

Related products

Blowers

Kaeser blowers are built for a lifetime of high performance, low energy costs, and best in class performance, with flow rates between 170 ICFM and 2603 ICFM.

Dryers

Selecting the right dryer and filtration to ensure your facility receives clean, dry compressed air consistently, depends on many things. Our clean air selection process is based around ISO 8573.1 quality class standards.

Condensate Management

Disposing of the compressed air oil/water condensate byproduct, created by your compressor station, carries big legal, and environmental responsibilities. The person knowingly discharging oil to drain, is responsible.

Filters

If you are looking for assistance in the filtration of dirt, oil, water, bacteria, hydrocarbons, oil odor or vapor, we have a filter, or an element to capture unwanted contaminants you need to stop. Compressed air, inert gases, liquids, ambient air, and water filtration is what we do best.

The ultimate guide on rightsizing your compressed air system

Choosing the right compressed air system is crucial to minimize the total cost of ownership. How do you calculate the air demand in flow rate (CFM) and pressure (PSIG), what's the power requirement (V), and how does that translate in a compressed air system with one or more compressors (hp)?

Download our Comprehensive Guide for Choosing the Right Compressor Size!

Case Study: A Compressed Air Desiccant Dryer Retrofit Nets an Ontario Refractory Plant $145,000 in Year One