A Fini rotary screw compressor was supplied by Compressed Air Centre Ltd. (CAC), Drogheda and installed at Apple Ireland, Cork in 2000. It was last serviced in May of this year (2011). Since it’s installation, it has run daily, sometimes 24 hours a day and clocked up over fifty thousand hours yet is still performing today with 100 % efficiency. The combined hours on this air compressor equates to approximately 100 hours per week. It is not unusual for Fini compressors to clock up such high hours, in fact, the harder the FINI compressor works the less it costs you to run per hour.
It was installed and serviced by Compressor Services, Cork and has been maintained almost religiously by Brian O’Rourke. Brian had extensive training at Compressed Air Centre Ltd. (CAC) here in Drogheda and at Fini Italy along with two of our engineers. They received intensive training in the care of all Fini products. Of course the meticulous attention to detail and environment demanded by this magnificent globally successful company plays a large part in the longevity of all equipment used by Apple.
Compressed Air Centre install Compressor that Saved €156,750 Annually for Electronics Manufacturer!!
Bourns Electronics Ireland, located in Cork produced an extensive range of ceramic-based resistors and resistor networks for the European market. Some years ago, Compressed Air Centre Ltd Drogheda, co-operated in a company-wide energy-savings system that yielded significant savings. The system installed was a water-cooled Sullair Two Stage tandem rotary screw compressor. This installation provided both air for manufacturing processes and recycled the cooling water through a heat recovery system.
Because of its own emphasis on quality, Bourns set rigorous standards for its equipment suppliers; Compressed Air Centre Ltd (CAC) more than met these high standards. Compressed Air Centre (C.A.C.) of Drogheda, the original Sullair distributor in Ireland and worked closely with Bourns throughout the project, right up until the end of the nineties. Energy costs had a major bearing on the company’s competitive market position and on it’s worldwide manufacturing operations. In 1994, in an effort to reduce energy costs, Bourns undertook an Energy Utilization Survey at the Cork plant. During the survey’s 12-month period (1994-95), Bourns’ total equivalent energy consumption amounted to 52,050 GJ (The gigajoule (GJ) is equal to one billion (109) joules) at a total cost of €703,633 ($928,797 USD).
The two main energy sources used on the site were electricity and natural gas. It was found that compressed air used 20.8% of the electricity at the plant. The Energy Utilization Survey concluded that a 22.8% reduction in site energy could be achieved. C.A.C. was engaged to evaluate the company’s compressed air system, optimise the existing system and propose an improved alternative.
Compressed air was targeted for improvement for a number of reasons; The existing equipment was inefficient at 26 hp per every 100 cfm used. It was also unreliable and prone to failure. There was no spare capacity and there were production restraints. Also the distribution and plant room were poorly engineered so that maintenance costs were unnecessarily excessive.
The priority: To improve the compressed air facility with potential for optimising heat recovery.
Phase 1
Select a new compressor system with specific design criteria:
• 2000 cfm capacity,
• 20 hp per every 100 cfm performance,
• Varying load efficiency characteristics,
• Quality: -40 C pressure dew point (not atmospheric) with less than 1% purge loss,
• Heat recovery potential from water cooling transfer,
• Central Plant Room with best possible distribution,
Phase 2
Achieve the best possible results for potential heat recovery:
• Minimise reliance on gas usage in industrial water usage,
• Reclaim heat from process water effluent,
• Eliminate need for high flow/high power water heaters in process,
Phase 3
Install Building Energy Management System (BEMS) to control Networks building:
• Utilise heat recovery wherever possible,
• Achieve primary process control,
• Control all air conditioning in the building,
For Phase 1, C.A.C. recommended a Sullair TS Series 32/25 400 hp (300 kW) water-cooled
two-stage tandem rotary screw air compressor with 2200 cfm (62.3 m3/min) capacity.
For Phase 2, C.A.C. recommended Alpha-Laval heat exchangers, Lowera pumps and
Siemens fully programmable speed control.
For Phase 3, a complete building energy management system was installed.
In June, 1995, the Sullair compressor began taking up the plant load for compressed air.
The savings on electrical energy were immediately obvious. On full load, the machine was
developing 19 hp per every 100 cfm (14 kW/100 cfm). In the first 12 months of operation,
the electrical savings were €37,625 ($49,665 USD) compared to the previous compressed air system.
The objective of Phase 2 was to utilise the primary heat recovery from the compressor system. Heat recovery was constant, due to the action of the Sullair compressor’s spiral valve. In 1996, the heat recovery system saved €21,770 ($28,735 USD) in natural gas cost and €28,125 ($37,125 USD) in electrical water heating cost. The total savings for energy and maintenance at Bourns plant in 1996 were: Electricity savings: €75,856 ($100,130 USD) Natural gas savings: €21,768 ($28,735 USD) Maintenance Savings €59,125 ($78,045 USD).Compressed Air Centre was proud
to have been a part of Bourns’ highly successful energy-saving project through dedicated team-work, innovative product offerings and exceptional customer service. C.A.C. offers customers throughout Ireland the most energy-efficient solutions for their compressed air systems.
In 1997, Bourns Electronics Ireland received a prestigious award recognizing its achievements in energy conservation. The company was selected as the National Technology Winner for Efficient Compressed Air by the ESB (Electricity Supply Board of Ireland).
To this day this is our proudest achievement,
Brian - Apple Computers, Cork