Doubling Nitrogen Capacity and Maximising Efficiency Over a Single Weekend
Project Overview
A manufacturing client recently contracted Design Air for a complete overhaul of their plant room’s compressed air system. The customer was expanding their operations and needed to significantly increase their compressed air supply to accommodate additional on-site nitrogen generators.
Our scope of works included the complete strip-out and safe removal of their legacy equipment, followed by the supply, installation, and commissioning of a state-of-the-art, high-capacity Atlas Copco system.
The Challenge: Expanding Capacity Without Disrupting Production
The primary challenge for this project was executing a major infrastructure upgrade without causing costly downtime for the client’s manufacturing processes. The old system had to be entirely dismantled and removed from the plant room before the new, larger system could be installed and commissioned.
Furthermore, while the client needed to feed new nitrogen generators, they were highly conscious of the potential increase in electrical running costs that typically accompanies a scale-up in air production. We needed to deliver a solution that provided maximum capacity, strict energy control, and zero interruption to their standard working week.
The Solution: A Complete Plant Room Overhaul and Smart Control
To meet the tight timeframe and strict efficiency requirements, our engineering team meticulously planned a weekend outage. We executed the complete strip-out and full installation over a single weekend, ensuring the facility had compressed air and nitrogen fully restored and available first thing on Monday morning.
The upgraded system featured premium Atlas Copco equipment designed for maximum output and minimal energy waste:
Atlas Copco GA75LVSD+ Compressors
The core of the new supply. These highly advanced Variable Speed Drive (VSD+) compressors adjust their motor speed automatically to match the fluctuating air demand of the nitrogen generators, eliminating the energy waste associated with idling fixed-speed machines.
CD Cerades Desiccant Dryers
To protect the sensitive nitrogen generators, we installed innovative Cerades solid desiccant dryers. This technology provides ultra-dry compressed air while offering a significantly lower pressure drop than traditional loose desiccant, further reducing energy consumption.
Galvanised Air Receivers
High-capacity receivers were installed to provide adequate buffer storage, smoothing out demand peaks and ensuring a consistent feed to the nitrogen generation skids.
Advanced Filtration & Oil-Water Separator
We integrated comprehensive in-line filtration to guarantee air purity, alongside a new oil-water separator to ensure the safe, environmentally compliant disposal of condensate.
Optimiser 4.0 Central Controller
To manage the entire expanded network, we integrated the Optimiser 4.0. This master control system monitors the plant and intelligently selects the most efficient combination of compressor speeds to meet the exact air demand at any given second.
The Results: 20% Energy Savings and Zero Downtime
The meticulous planning and premium equipment selection delivered immediate, transformative results for the client’s operations:
- Doubled Nitrogen Production: The robust new compressed air supply allowed the client to successfully bring their additional nitrogen generators online, more than doubling their total on-site nitrogen production capacity.
- Significant Energy Reductions: Despite the massive increase in production capacity, the combination of GA75LVSD+ compressors, Cerades dryers, and the Optimiser 4.0 controller resulted in reported energy savings in excess of 20% compared to their old, smaller system.
- Zero Production Loss: By executing the complex strip-out and installation entirely over the weekend, the client experienced absolutely no loss of production time.
The Design Air Standard
As Scotland’s compressed air specialists, we understand that utility upgrades cannot come at the expense of your manufacturing schedule. From precision project management to specifying the most energy-efficient technology on the market, our goal is to future-proof your facility while actively driving down your operational costs.
If you have a requirement for anything compressed air, nitrogen, vacuum, or process cooling related, please get in touch with us at Design Air to see how we can help.