24 Apr

What Savings Are You Missing?

We are all about optimizing the process and boiler room of a plant, saving funds, energy and time for our clients. When plant managers are looking for savings using cutting edge technology, we have what they need. Yet, many factories aren’t aware of the savings they could reap. They run in less-than-optimal conditions, venting steam, wasting money and adding unnecessary emission into the air. The elements of that plant may not be optimized, causing plant managers and engineers to miss crucial warning signs or  areas that need improvement.

 

How does a plant manager find a solution when so often they are unaware of the issues? The answer is simple: have the plant tested for overall efficiency. Boiler efficiency visits from combustion experts will pin-point all the issues that are draining money and productivity.

 

Specifically, an expert boiler efficiency visit will provide measurable numerical values for the following:

 

• the money that could be saved through optimization

• The plant’s carbon footprint

• How much steam (and therefore energy) is being vented and wasted

• Emissions and improvements to reduce them

• Where energy is being used and for what purposes.

 

Each of these elements is essential for the optimization of a plant. If energy is being used inefficiently or other elements of the plant are less than optimal, money is being wasted somewhere. Consider what you could do with the information from a boiler efficiency visit. Monetary gains are certainly high on the list of benefits, right next to increased plant safety and productivity.

 

If you are wondering where you are losing money in your plant, contact us today. One boiler efficiency visit from one of our combustion engineers is all it takes for you to reap the benefits.

 

 

03 Apr

Safety and the Value of Risk Assessments

The control of combustion elements in a boiler system is similar to controlling an explosion. Within any process system, where specific elements need to maintain their prescribed balance, small miscalculations can be devastating. This is why safety is one of Synergy’s top priorities. While optimization and efficiency are of great importance, none of it matters if a system isn’t safe.

Regular risk assessments and timely inspections are essential in order to maintain plant safety. The illusion of a safe environment is often created by the fact that no harmful incident has happened. The time to consider a risk assessment is not after an employee or system has been severely injured, but before.

Like every other area of a plant, safety can be optimized for the greatest efficiency. Synergy’s safety measures, including our PLC systems and valve trains, have redundant controls to make sure that processes in a plant continue to operate optimally, even in the event that one small part malfunctions. In addition, we have perfected safety optimization to dramatically reduce nuisance trips.

The highest standard of safety is essential in a workplace to ensure the well-being of employees and equipment. That doesn’t mean you have to pay the highest price. Our combustion and engineering experts would be happy to perform an assessment of your plant and provide you with custom, optimized solutions for your safety, budget and goals.

13 Mar

New Elements of Life Cycle Cost

New Elements of Life Cycle Cost

BusinessDictionary.com defines Life Cycle Cost as the “sum of all recurring and one-time costs over the full life span… of a good, service, structure or system.” This is a term often used in our industry, where process equipment and boilers are purchased with the intention of running them decades into the future. The rapid pace of technology, along with growing environmental concerns, has added additional elements to the calculation of life cycle cost. For example, a product with a long life may become obsolete before its end. Another concern is environmental laws. While a systems may be compliant with emission laws right now, changes in the future could hold even stricter emission restrictions.

Upgrading typically requires the replacement of a few parts while maintaining a whole system or product. That is changing with technology’s ever increasing advancement. Upgrading can mean different things depending on the product you purchase. If advanced technology is already being sold in the marketplace, other products may become obsolete as the newer technology takes hold. In a few decades, an upgrade may require complete replacement of some equipment. The latest technology tends to have a higher cost, which much be weighed in terms of the product life cycle. More than likely, a plant is better off choosing the latest technology because it will take a significant amount of time before it becomes obsolete. In the end, less money will be spent throughout the life cycle with a product that remains at the forefront of technology for years to come.

Today’s cutting-edge technology, such as intelligent HMI and variable frequency drives, many benefits, which much also be taken into consideration. Greater efficiency, less maintenance and a smaller environmental footprint are all elements of new technology that save money in a system. Such benefits may be necessary in the future. Our culture has only become increasingly concerned about industrial emissions. It can be assumed, then, that the future will see a gradual tightening of restrictions on emissions. A sure way to avoid negative impacts from future emission restrictions is to ensure your plant surpasses current standards. Installing an economizer can be a simple and cost effective way to begin. In addition to reducing emissions, it saves fuel and energy cost by harnessing the energy that would otherwise be lost up the stack. For these reasons, Synergy’s Economizer Solutions provides the fastest return on investment out of all of our products. At the end of the day, any steps in upgrading or optimizing that can reduce emissions can also reduce the cost of running a system. Such ‘green’ elements should weigh heavy in any life cycle cost analysis.

When it comes to calculating the life cycle cost of your next big business purchase, remember to consider more than purchase price, maintenance and life. Additional concerns, such as environmental impact and whether or not the product will be obsolete in the near future should carry a lot of weight in your decision.

~You aren’t alone in this decision. Synergy’s expert combustion engineers are always available to provide advice on whatever project you may be planning. Contact us at 630–724-1960, extension 12.