MagLev / Multistack Compressors and Chillers

Both the MagLev Retrofit compressors and the compressors utilized in Multistack chillers are Dan Foss Turbocor oil free compressors.  Whether just changing out a compressor or replacing the entire chiller MagLev compressors and Multistack chillers are applicable on larger space cooling or process cooling systems (60 tons and up) to affect up to 35% energy savings on water cooled and up to 50% energy savings on air cooled systems.  Our MagLev Compressors run on magnetic bearings and require no oil in their refrigerant system which is 134A.  Our MagLev compressors can be retrofitted into a R-22 system and the existing refrigerant oil will be evacuated.  However, R-11 or R-123 refrigerant systems cannot be retrofitted as these systems operate on low pressure.  Therefore, on R-11 and R-123 systems we must do a complete Multistack chiller change out which will be operating on 134-A refrigerant.  MagLev compressors are 25% the size and generally less than 20% the weight of typical chiller compressors making change-outs much easier as two men can maneuver a MagLev Compressor on an elevator.  In replacing an existing compressor with a MagLev compressor, eddy current tests should be run on the existing evaporator and condenser tubing to check the integrity of the tubing.  DX air to air A/C compressors, 60 tons or over, are also ideal for possible MagLev Retrofit Compressor installations and these applications can produce up to 50% energy savings.  Special Note:  MagLev / Turbocor compressors or Multistack chillers for process cooling loads which require a glycol mix are designed at this time for chilled water temperatures above 32 degrees.

Dedicated Heat Recovery Chillers

These modular chillers are ideal where a constant chiller load is needed at the same time hot water is also needed.  Examples are hospitals or nursing homes where the chiller can maintain a constant base cooling load while producing hot water from 110 to 180 degrees that can be used for a variety of purposes.  Another example could be a constant load computer room where the building has hot water for some purpose.  These chillers have proven to be as much as 3 times more efficient than gas boilers.

Setting Up the Most Efficient Boiler Operations

Using state of the art boilers for new facilities or replacing outdated inefficient boiler systems with high efficiency systems which can promote significant natural gas savings

Heat Recovery for Boilers and Other Processes

Our patent pending boiler stack and blow down recovery heat exchanger system can recover significant waste heat that is being thrown away.  Our systems can be 2 to 3  times more efficient than conventional economizers in recovering waste heat.  Good applications are large boiler systems and large furnaces that are sending millions of BTU’s per hour out their stacks which can translate to thousands of dollars per day in heat losses.  Uses for our stack gas heat recovery can be preheating boiler feed water or routing heat to other processes that need preheated water or air.  The recovered heat can also be used to generate chilled water by way of absorption chillers .   In addition ORC (Organic Rankine Cycle) equipment can be driven using hot oil from the heat recovery process which can generate electricity.  Straight line paybacks for some of our heat recovery systems can fall well within two years.

Air to Air Heat or Cooling Reclaim

When incoming fresh air makeup and outgoing exhaust air streams are relatively close in proximity, non-contaminant, cross flow heat exchangers can be used to capture or recover as much as 80% of the energy being wasted to the outside air exhaust.  Good examples to look for are areas which need heavy fresh makeup such as areas in hospitals or clean rooms in commercial or industrial facilities.

Variable Frequency Drives

Many motors are running at a constant speed which is not necessary.  Examples are fans and pumps.  If the speed or rpm’s can be reduced for less than full load requirements, for every unit of speed reduction, the energy is reduced by the power of three.  As an example if a fan can be operated at 80% of its capacity, the energy saved can be 50%.  In many processes constant speed motors turning fans or pumps moving fluids such as air and water are designed to continually operate at maximum capacity and maximum capacity is only needed part of time, if ever.

Retrofit High Tech Lighting

Energy saving lighting systems are available that utilize the latest fluorescent, LED, and induction lighting for commercial and industrial interior and exterior applications.  In addition motion sensor systems can be incorporated into the retrofit lighting system to shut down individual or groups of light fixtures in lightly traveled areas, especially warehouses.

Air Compressors

Air compressors on average comprise quite a bit of the electrical load in industrial / commercial manufacturing plants.  From our multiple visits to plants the air compressor systems are generally wasting quite a bit compressed air through leaks and blow offs which in turn is wasting a lot of energy dollars.  For example with a plant that is running its air compressors at 100 pounds of air pressure, a quarter inch leak in a compressed air system can cost a company in excess of $14,000 per year.  On multiple occasions we have witnessed quarter inch to half inch air compressors blow offs that are venting through a machine room wall to the outside where someone either left a valve open by mistake or a blow off solenoid has failed open.  In some of the larger plants we have visited we have seen 500 to 800 horsepower of compressors that must run all the time just to make up for the leaks in the compressed air system.  We are happy to review these systems and make recommendations on ways to increase efficiency and eliminate as much wasted air as possible.

New Products and Systems to Improve the Efficiency of Packaged A/C Systems

ConServ Energy engineers and contractors are working on some new technologies that show promise of being able to increase the efficiency of packaged A/C systems by 15% to 25%.  Our “Dyna Mizer” System will be tested in the summer of 2012 along with another system for precooling intake air may also be tested in the summer of 2011.

High Tech Ceramic Coatings Can Prevent Substantial Heat Loss or Heat Gain

Ceramic coatings can be installed on boilers, pipes, tanks, walls, and even metal or membrane roofs used in conjunction with world class rust preventatives will greatly reduce unwanted heat gain or heat loss.  Ceramic coatings are available for application on a wide range of surface temperatures, saving major monies on natural gas & electric.

Downdraft Gasifiers are Available to Convert Organic Waste to Heat Energy

With the escalating costs and increasing restrictions of taking waste products to landfills, new patented downdraft design gasifiers can be used to eliminate and convert organic waste to a syn gas that can be burned with specially designed nozzles to produce useful heat energy.  This heat energy can then be used for preheating purposes through heat exchangers and or it can be used to drive ORC electric generation equipment.

All Types of Energy Credits, Grants, and Low Interest Loans Are Available

With all the products and systems that ConServ Energy Group represents, there are many cases where energy credits, tax credits, grants and special low interest 10 year loans are available.  Heat Recovery is considered as renewable Green Energy.  Credits or grants can also give a real boost on paybacks and if monies are available, they need to be pursued.   Example is a situation where a $500,000 investment in a heat exchanger to capture waste heat can produce $250,000 in yearly natural gas savings, but the benefiting company does not want to use its capital in these tight economic times.  This is a great opportunity for a 5% loan that can go out multiple years while paying for itself from the excellent energy cost savings that is created.

Financing for Our Heat Recovery Systems is Available

All of ConServ Energy Group’s energy cost saving systems have been pre-approved as to where financing is available over multiple years.  If desired, budget neutral financing can be utilized as to where the savings can be utilized to pay off these systems and company capital can then be used for other purposes.  Some companies require for energy cost saving projects to provide paybacks within 2 years and where this is possible with some systems, we certainly feel this thinking is somewhat short sided.  The reasons are that with the robust energy cost saving systems that we install, they will continue to provide solid energy cost savings for years to come with proper recommended operation and maintenance.   If financing can be utilized to allow the energy savings from any system to pay for itself within a 5 year period of time, there is no financial burden on the company and after 5 years all the savings minus operations &maintenance will be going straight to a company’s bottom line.  In addition energy costs for both electricity and natural gas will possibly be escalating at 2% to 3% per year.  This is especially true for electricity as the EPA passes more and more burdensome regulations on the electric utility industry to shut down all their coal fired operations.  With natural gas and the movement of transportation vehicles and electric utilities’ generation to natural gas, the supply of natural gas will get tighter and the cost per MCF or MMBtu will begin its rise from the bottom.