scrubbers and an electrostatic precipitator, Tri-Star has been using two gas-fired air
makeup units, each with a capacity of 40,000 cubic feet per minute (cpm) to balance
the airflow. Since these operated at a fixed rate, the facility is continuously operating,
even during non-production hours.
Aside the operating energy being consumed by this facility, flow-rate air makeup
units also required the air conditioning or heating systems to work overtime such that
the units blow hot, humid air into the facility during summer and heat up the air
blown in during winter, thus resulting in a concentrated heat source that causes
nonuniform high temperature in the facility, in which thermostats are shut down in
some areas in the facility and making the cold areas colder.
Tri-Star uses state-of-the-art variable speed controllers, which could be retrofitted
to the makeup air units, because of its alliance with the gas and electric companies.
Using the variable speed controllers, the flow rate is determined based on the air
exhaust rate from the exhausting equipment. Through this, significant savings in
electric and gas bills were realized. An outstanding feature of this project is that it
requires no capital investment; the new equipment was supplied by the electric and
gas company.
The annual savings on gas and electricity by the facility are estimated to be
$22,900 and $15,600, respectively. Also, energy savings of 31,000 therms and
192,800 kilowatt-hours (KWH) through the project caused reduction of air pollution,
which translates to annual reductions of CO 2 (global warming) of 212,100 pounds,
SO 2 (acid rain) of 1,700 pounds, and NOx (acid rain and smog) of 600 pounds.
Tri-Star examined compressed air in its energy conservation project. The industry
had been using two 100 HP and two 50 HP compressors to provide the facility with
compressed air. However, these units did not meet the compressed air demand.
Investigation of the facility’s compressor by “Energy Initiative” program conducted
by the electric company (Mass Electric) resolved into addition of a reserve air tank,
replacement of the four compressors of 300 HP combined capacity with three 50 HP
energy efficient compressors (150 HP combined capacity), and setting up of units to
cycle, based on the compressed air demand in the facility.
Based on these changes Tri-Star was able to save energy and eliminate the
problems of meeting the facility demand for compressed air. Annual energy cost
savings from this project are estimated to be $13,300, based on a 164,800 KWH
reduction in electricity use. This translates to annual reductions of CO 2 (global
warming) of 181,300 pounds, SO 2 (acid rain) of 1,500 pounds, and NOx (acid
rain and smog) of 500 pounds. These energy use reduction projects have improved
plant operations, saved money, and reduced virgin oil consumption, waste oil
(hazardous waste) generation, and air pollution to the community. Tri-Star’s pollution prevention project that goes beyond regulated materials has led to water
conservation in the industry.
Tri-Star expanded their fabrication business to add assembly operations and the
facility considered the different types of systems that could be used to clean flux
residue from the wave solder unit. The facility discovered that hot deionized
(DI) water could equally clean the boards just as effectively as the chemical-based
cleaning systems. Thus, the facility purchased a closed-loop DI water generation
4 Electrical and Electronic Wastes Treatment
193
makeup units, each with a capacity of 40,000 cubic feet per minute (cpm) to balance
the airflow. Since these operated at a fixed rate, the facility is continuously operating,
even during non-production hours.
Aside the operating energy being consumed by this facility, flow-rate air makeup
units also required the air conditioning or heating systems to work overtime such that
the units blow hot, humid air into the facility during summer and heat up the air
blown in during winter, thus resulting in a concentrated heat source that causes
nonuniform high temperature in the facility, in which thermostats are shut down in
some areas in the facility and making the cold areas colder.
Tri-Star uses state-of-the-art variable speed controllers, which could be retrofitted
to the makeup air units, because of its alliance with the gas and electric companies.
Using the variable speed controllers, the flow rate is determined based on the air
exhaust rate from the exhausting equipment. Through this, significant savings in
electric and gas bills were realized. An outstanding feature of this project is that it
requires no capital investment; the new equipment was supplied by the electric and
gas company.
The annual savings on gas and electricity by the facility are estimated to be
$22,900 and $15,600, respectively. Also, energy savings of 31,000 therms and
192,800 kilowatt-hours (KWH) through the project caused reduction of air pollution,
which translates to annual reductions of CO 2 (global warming) of 212,100 pounds,
SO 2 (acid rain) of 1,700 pounds, and NOx (acid rain and smog) of 600 pounds.
Tri-Star examined compressed air in its energy conservation project. The industry
had been using two 100 HP and two 50 HP compressors to provide the facility with
compressed air. However, these units did not meet the compressed air demand.
Investigation of the facility’s compressor by “Energy Initiative” program conducted
by the electric company (Mass Electric) resolved into addition of a reserve air tank,
replacement of the four compressors of 300 HP combined capacity with three 50 HP
energy efficient compressors (150 HP combined capacity), and setting up of units to
cycle, based on the compressed air demand in the facility.
Based on these changes Tri-Star was able to save energy and eliminate the
problems of meeting the facility demand for compressed air. Annual energy cost
savings from this project are estimated to be $13,300, based on a 164,800 KWH
reduction in electricity use. This translates to annual reductions of CO 2 (global
warming) of 181,300 pounds, SO 2 (acid rain) of 1,500 pounds, and NOx (acid
rain and smog) of 500 pounds. These energy use reduction projects have improved
plant operations, saved money, and reduced virgin oil consumption, waste oil
(hazardous waste) generation, and air pollution to the community. Tri-Star’s pollution prevention project that goes beyond regulated materials has led to water
conservation in the industry.
Tri-Star expanded their fabrication business to add assembly operations and the
facility considered the different types of systems that could be used to clean flux
residue from the wave solder unit. The facility discovered that hot deionized
(DI) water could equally clean the boards just as effectively as the chemical-based
cleaning systems. Thus, the facility purchased a closed-loop DI water generation
4 Electrical and Electronic Wastes Treatment
193