CompAir provides missing link at Astrum foundry
CompAir provides missing link at Astrum foundry
Astrum, a steel components manufacturer in County Durham, UK, has significantly reduced its compressed air energy costs and increased productivity by installing two regulated-speed compressors from CompAir. The installation was funded by an interest-free loan from the Carbon Trust due to the high energy efficiency of the new system.
- Client: Astrum
- Location: Stanhope, County Durham, UK
- Application: Steel foundry
- Products: L75 RS/L160 RS regulated-speed compressors
- Customer Benefits: 50% energy savings, high production reliability
Astrum specializes in making components for military vehicles, construction tools, and mining industry wear parts. Rising energy prices in 2008 prompted Astrum to improve energy efficiency, focusing on its critical compressed air system. CompAir distributor, Air Energy Management, assessed Astrum's air requirements and demonstrated potential cost savings through a tailored system design.
Astrum secured an interest-free loan from the Carbon Trust's Big Business Refit scheme, enabling the installation of a system that reduces power consumption and improves business efficiency. The loan is expected to pay for itself within four years through energy savings.
Air Energy Management, in collaboration with Astrum and CompAir, developed a bespoke system that replaced old compressors with two efficient CompAir models. The L75 RS and L160 RS compressors feature regulated-speed technology and are monitored by a Delcos 3100 electronic control system. The system includes a flow measuring system for monitoring airflow and cost allocation, and energy-efficient dryers. The new setup reduces energy demand by 1,255,000 kWh, saving over £80,000 annually.
The L75 RS compressor provides air at 7.5 bar for a bore blast machine, with the potential to serve a second machine. CompAir overhauled an existing compressor for redundancy, reclaiming 80% of energy lost in compression. Hot air is ducted into the foundry in winter and vented in summer, saving £10,000 annually in heating costs. The L160 RS compressor supports the main foundry receiver, with a control valve to prevent leakage. The number of air receivers was reduced from sixteen to three, and a desiccant dryer was added for extra dry air. The system includes low-pressure drop piping and a leak detection program.
- 50% reduction in compressed air energy costs, saving over £80,000 annually
- High quality, extra dry air
- Increased productivity
- Backup compressor for increased reliability
- Hot air ducting saves £10,000 annually in heating costs
- Reduction of air receivers from 16 to 3
Catalog excerpts
CASE STUDY MANUFACTURING CompAir provides missing link at Astrum foundry Overview Client Astrum Two regulated-speed compressors from CompAir have helped Astrum, a steel components manufacturer, to cut its compressed air energy costs by more than a half and increase productivity at its foundry in County Durham. Stanhopem County Durham, UK Astrum was able to benefit from an interest-free loan from the Carbon Trust to fund the installation, thanks to the high energy efficiency of its new compressed air system. Application Steel foundry Customer Benefits 50% energy savings/high production reliability Application Details Based in Stanhope, County Durham, Astrum is a specialist steel foundry making components and assemblies for military fighting vehicles, ground engaging tools for the construction industry and wear parts for the mining industry. In 2008, due to rising energy prices, Astrum embarked on a programme of improving the energy efficiency of its processes. Mike Hutchinson, operations director at Astrum explains, “One of our key areas of spend is our compressed air system, which is critical to the performance of our plant and is fundamental to our processes for moving sand around the foundry and for operating industrial equipment. As part of our programme of improving the energy efficiency of our processes, we looked to replace existing compressors and approached CompAir distributor, Air Energy Management to assess our air requirements.” “Air Energy Management was able to demonstrate that by looking at the overall efficiency of the existing system, and making sure it is designed specifically for our needs, we could save a significant amount of mone
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CASE STUDY MANUFACTURING Carbon Trust To accelerate its investment plans, Astrum approached the Carbon Trust and was awarded an interest free loan through its Big Business Refit scheme, which aims to provide businesses with zero-cost capital to invest in new high performance, energy efficient equipment. Hutchinson comments, “The Carbon Trust loan enabled us to install a system that will not only cut power consumption, but will also improve the efficiency of our business. The loan will pay for itself within four years through energy savings alone, and has provided a cost effective way for us to...
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