Heat Recovery Innovation Yields Greater than 100% Energy Savings. Yes, Greater Than 100%!

Our engineering team recently devised an efficiency solution that potentially applies to every manufacturing plant using air-cooled oil-injected air compressors.

The concept focuses on the re-engineering of compressors into a cogeneration system producing high-grade heat recovery from both the oil cooler and aftercooler. 

How to Stay in Control of Your Controls

Most of our mechanical design and build work involves retrofitting existing facilities with customized systems that require nuanced energy and data management. As you would expect, sophisticated digital controls are an essential facet of every project. Unfortunately, the cost and ease with which controls can be added to an existing mechanical framework varies greatly—from being “a piece of cake” to you may as well “fuhgeddaboudit.”

Should the Company that Designed It, Build It?

Single Accountability is the crucial factor in the smooth sailing of a design/build engineering project. 

It seems out of fashion to take responsibility for one’s actions these days. The lack of accountability in today’s society has become an epidemic…

We offer a refreshing contrast by proactively taking comprehensive responsibility for all facets of design-build projects, from start to finish. As many customers have discovered, using multiple firms for different functions is often a recipe for disaster.

The Perfect Marriage of Science with Engineering

In high school, one of my science teachers had a penchant for trying to inspire students with clever quotations. One of his favorite proclamations was that “many a beautiful theory is ruined by one ugly fact.” The actual quotation by the famous biologist Thomas Huxley gets to a crucial point that most engineers miss. Applying the following scientific process immeasurably improves the creativity and results of engineered systems.

The Shocking Truth About Steam’s Efficiency

This 6,000,000 BTU 220°F hot water plant is replacing a 13,000,000 BTU 100 PSI steam plant.

Using steam to create heat is the equivalent of using an incandescent bulb to create light. So why do engineers continue to use steam? The most common response is: “because we’ve always done it that way.” This blog briefly explains the shocking inefficiency of steam plants, and why hot water should always be utilized when possible.

Cogeneration: the simultaneous generation of two different forms of useful energy using one single primary energy source.

125 HP VSD air compressor custom modified to co-generate 173 F° hot water

The most familiar concept of co-generation is using a generator to make electricity and using the waste heat for other thermal usages. This form of cogeneration is more accurately described as Combined Heat and Power - CHP. However, by definition, this is only one form of cogeneration.

Hitting the Gas on Energy Efficiency Incentives

It's an historic time for New England manufacturers to take advantage of huge gas incentive increases from utility companies.

Recent regulatory changes, especially in Massachusetts, have made increased amounts of rebate and grant money available through the utility companies for natural gas energy conservation. These windfalls for industrial customers have been truly remarkable. In one recent measure, upwards of $1 million was awarded to help defray costs of a large project, with a complete ROI payback in less than one year.

Use industrial FREE COOLING in cold climates for big savings

Being located in the cold climate of New England, we often witness manufacturers who run expensive chillers in an attempt to cool fluids to 50°—when its 30° outside! It’s analogous to using an air conditioner on a cool day instead of opening a window. Even in an industrial application, it's more efficient and effective to let Mother Nature do the cooling for you.

The Hidden Cost of a "Free" Energy Audit

In this challenging business environment, individuals and companies from a range of professions have begun offering Free Energy Audits as an enticement to attract customers. If you want an energy audit and are finding the “free” offer attractive, be careful which entity you choose. The expertise of firms ranges from incompetent to extraordinary and you need to work with the “extraordinary” end of the scale. Incompetent “free” energy audits come at a high cost of lost time and potentially lost dollars should you attempt to implement faulty or incomplete recommendations.

Water source heat pumps convert cooling system waste heat into comfort heat

Cooling systems for industrial plant machinery like hydraulics, compressors, and chillers produce exiting cooling system water of 90-100 degrees. This low-grade heated "waste" water exits with high BTU potential that rarely is utilized for ambient "comfort" heat -- until now.

In recent work, we've had success efficiently extracting heat from cooling system waste water with water source heat pumps, with eye-opening results. On average, an industrial facility can save 75% on heating costs by using a heat pump system in comparison to burning heating fuel.