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Unlike most people, Brian Cross doesn’t mind being called a control freak. In his capacity as Manager of Technical Services for Zochem, Canada’s largest zinc oxide manufacturer and distributor, Cross is overseeing the installation of sophisticated control systems and devices at the company’s Brampton plant. And according to Cross, these technological enhancements are already resulting in significant process improvements, output increases and energy savings. “We started by analyzing our processes and then investing in the best technology available,” he said. “These can be high-cost items, but they give excellent process control capability.” Established in 1933, Zochem is a division of an integrated copper and zinc company, Hudson Bay Mining and Smelting Co. Limited, which began mining and smelting operations in Flin Flon, Manitoba in 1927. Capable of producing a number of oxide grades, Zochem supplies a broad range of industry sectors. Its products are used to manufacture everything from rubber tires, brake pads and industrial lubricants to animal feed, crop fertilizers and surgical tape. Like most manufacturers, Zochem is always on the look-out for ways to improve the efficiency, and cost-effectiveness, of its operations. While natural gas fuels most of Zochem’s production stages, nearly 70 per cent of its electricity consumption stems from the use of induction fans and air compressors used to clean filter cartridges. One major change implemented in recent months is the replacement of five large fans with 23 smaller ones, which allow Cross’ team to focus the air flow exactly where it’s required. More targeted air delivery has already translated into reductions in energy consumption. Traditional polyester felt filters in the “baghouse” have also been replaced with Gore-Tex. Rather like a glorified vacuum, the baghouse is simply a device that removes solid particles from exhaust gases as they flow through a large cloth bag. A durable, breathable, easy-to-clean material that resists degradation at high temperatures, Gore-Tex has improved the overall effectiveness of the filtration process, resulting in better efficiency and fewer emissions. Control of all major production equipment at Zochem has also been shifted to programmable logic controllers (PLCs). These specialized computers are typically used in the automation of industrial processes, and allow components to beturned on and off remotely. “It’s extremely wasteful if you have machines running when they’re not required,” Cross said. “PLCs have allowed us to reduce our electricity usage as well as our equipment maintenance and repair costs.” Cross is also installing variable frequency drives (VFDs) on the facility’s induction fans and air compressors. VFDs are electronic controllers that adjust the speed of an electric motor by modulating the power being delivered. They provide continuous control, matching motor speed to the specific demands of the work being performed and allow operators to fine-tune processes while reducing costs for energy and equipment maintenance. After a two-year payback period, Cross expects to see annual electricity cost reductions in the range of $30,000, for a typical 100 horsepower (hp) compressor – substantial savings for a company with annual electricity costs in excess of $700,000. Similar results will be expected when this is applied to our induced fans (greater than 900 hp). Plant operations will soon be controlled by a SCADA (Supervisory Control and Data Acquisition) system, which will allow Cross to monitor equipment status and measure electricity consumption at key points in the system. While the cost of the SCADA system is not insignificant, Cross feels the investment is worthwhile. “You can’t make good decisions without good data,” said Cross. “By identifying which processes consume the most energy, the SCADA system will give us a good roadmap for how to pursue future energy savings opportunities.” Energy conservation and waste reduction are absolute priorities for the company and its management team. “Environmentally, financially and ethically we must take energy efficiency seriously,” Cross said. “We cannot continue to take this critical resource for granted.” |
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