DirectAIR® Reduces Energy Costs by 52.6% for Ohio Chemical Plant

DirectAIR® Reduces Energy Costs by 52.6% for Ohio Chemical Plant

An Ohio chemical plant saved 52.6% in energy costs and eliminated high compressed air maintenance and repair costs—all with help from Air Technologies® DirectAIR® solution.

The plant was maintaining a fleet of five centrifugal air compressors, two oil-free rotary air compressors and a number of desiccant air dryers to support its 5500 CFM demand. Because it was running multiple compressors under part load to provide adequate plant air pressure, electrical costs were excessive. In addition, the company was experiencing a number of costly maintenance issues with its compressed air system. In the winter months, the system’s air lines would freeze, which meant the company needed to rent air compressors for several months each year. Its air dryers were not running optimally due to air leaks from all of the open valves.

Air Technologies® had serviced the plant’s two rotaries as well as multiple desiccant air dryers for many years. In 2013, the company looked to Air Technologies® DirectAIR® utility service for a better cost-savings solution with 100% reliability.

Air Technologies® installed a state-of-the-art DirectAIR® compressed air facility at the company’s site. There, Air Technologies® owns, operates and maintains the plant’s compressed air system with a continuous quality air supply and zero downtime. The DirectAIR® solution has proven to increase system efficiency and dramatically reduce energy costs by supplying compressed air on-demand as a utility.

Since the installation, DirectAIR® is delivering a 52.6% energy cost reduction, which will save the plant over $300,000 annually. The energy savings alone will pay for over 75% of the total cost of the DirectAIR® service. In addition, DirectAIR® eliminated the high maintenance and repair costs. There are no production interruptions due to wet air and frozen pipes, and the company no longer has to rent air compressors during the winter months.

To see if DirectAIR® is the best solution for your plant, contact Air Technologies® today.