LUBRICANT REDUCES ENERGY CONSUMPTION AND CARBON EMISSIONS
A synthetic lubricant specifically developed by BP for rotary-screw air compressors and machine gearboxes operating under severe conditions, has been shown in recent trials to also reduce energy consumption and carbon emissions.
BP Enersyn RC-S is a synthetic lubricant with properties similar to those of Castrol‘s high-performance automotive engine oils – notably better oxidation resistance, extended lubricant life and a facility to work at higher temperatures. Its high viscosity index enables it to maintain a stable viscosity across a wide range of operating temperatures, making it ideal for industrial equipment such as compressors and gearboxes that are operating continuously in arduous environments.
It is also well known that synthetic engine oils such as Castrol SLX are more energy efficient than conventional products. Until recently it has not been possible to evaluate this aspect of Enersyn RC-S’s performance, as opportunities to make accurate comparisons in an industrial environment are limited. It was also felt that the traditional ‘before and after’ trial that seeks to establish base-line data before the lubricant changeover and compares the results with data recorded when running on the new oil, would not provide the necessary accuracy. This is due to normal variations in atmospheric conditions such as temperature, humidity and pressure of the atmosphere, which can change the density of the air and therefore the mass being moved by the compressor.
However, when a customer asked for advice on an oxidation problem he had been experiencing with a mineral oil, BP’s Paul Cox saw an opportunity to solve the problem and run an accurate trial to establish what energy savings could be gained when using Enersyn RC-S.
The plant used for the evaluation provided a unique opportunity to compare a large 6-stage, geared centrifugal compressor filled with Enersyn RC-S, against an identical unit filled with a high quality mineral oil. The compressors were operating in tandem, running identical duties and were balanced before the trial to eliminate inaccuracies.
Analysis of the data collected indicated that a power saving of 1.57%, equal to a 0.265 MW reduction, was achieved when operating under normal production conditions. Based on the 24/7, 357 day (8580 hours per annum) plant utilisation the saving recorded was 2276 MWhs per annum, which at prevailing energy costs represents an annual saving of £48,150 in electrical power costs and an approximate 600 tonnes per annum reduction in the greenhouse gas production (assuming natural gas powered generation).
The cost of filling the compressor’s lubrication circuit with 10,100 litres of Enersyn RC-S equates to a payback period of around six months for the lubricant change, after which the energy savings contribute directly to reducing the cost of operation of the plant.
In addition, a lower running temperature and reduced bearing vibration were also noted, and it is estimated that over time these factors will provide further benefits in terms of reduced stress on both the lubricant and the equipment, leading to longer life and reduced maintenance.
The customer has also reported significant benefits that are leading to an overall improvement in machine reliability and availability.
These include a reduction in routine maintenance due to cleaner compressor internals and longer lubricant change intervals; extended compressor service life due to the excellent anti-wear performance of Enersyn RC-S under arduous conditions of heat and moisture; excellent anti-corrosion characteristics that reduce moisture contamination and oil filter blockage; and rapid separation of water, air and lubricant in coalescer equipment, with consequent longer air filter life and less carry-over of lubricant.
Summing up, Paul Cox says: “The savings on energy costs and emissions resulting from the change has more than justified the trial and the subsequent use of Enersyn RC-S in the system.”
Ends
Home | About Us | Portfolio | Approach | Contact Us | Sitemap
16 The Cornhill, Stroud, Gloucestershire GL5 2JT | Tel: +44 (0) 1453 755 551 | Fax: +44 (0) 1453 751 525
Copyright © 2011 Cantillion King Advertising