Pipework helps deliver Carbon Trust loan for foundry
July 01st 2010

The efficiencies of Teseo Air Systems’ compressed air delivery systems have helped UK manufacturer, Astrum in Stanhope, Durham, to secure a prestigious £400,000 Carbon Trust loan – the largest interest-free loan awarded for a compressed air project in the UK.

As a direct result of the Teseo-enhanced system, Astrum will save 1,253,800kWh which equates to £80,560 per annum. Teseo UK’s hollow bar system (HBS) and aluminium profile (AP) compressed air delivery products satisfy efficiencies and regulatory requirements and provide a 100% leak free system, combined with valved zoning. In an industrial application this versatility means that individual production areas can be automatically isolated when not in operation to eliminate air leakage, useful when seeking the maximum energy efficiencies.

Teseo’s aluminium extruded piping has an external rectangular section with tee slots and a fine, smooth internal bore making it an attractive solution as well as practical. A wide selection of angle and straight joints & quick clamping pieces make this system totally flexible in layout and quick to install.

Lighter than traditional steel airlines to install, thus reducing stress on buildings, Teseo lines are energy efficient due to higher flow rates of a smooth profiled aluminium tube (typically 30% higher than steel) which equates to a lower pressure drop and overall energy and cost savings compared to traditional galvanised systems from day one.

Air Energy Management is an independent company whose aim is to reduce energy costs associated with compressed air systems. Implementing Government directives, it specialises in reducing compressed air demand on main factory air compressors while maintaining air supply necessary for production requirements.

As part of a general drive to reduce manufacturing costs and increase production efficiency Air Energy Management was commissioned by Astrum to undertake an independent compressed air energy audit. Whereas most upgrades might focus on the compressor side of the system, AEM measure wastage from the system starting from the user interface and working back towards the power plant. Having finished the survey, the resulting proposal hung on the strengths of the Teseo product.

Richard Dainton, managing director of AEM, explains why Teseo was so important to the project: “The Carbon Trust will not approve the loan unless they are sure that the energy savings are achievable. I put together a project justification to save energy through reduction of air leakage and effective pressure control.

"I included Teseo pipe work because it is 100% leak free and has low pressure drop which means less power is needed to push the air around the system.”

“The Teseo product was also anodised so the performance will remain constant over time as it will not corrode. Another consideration was that the roof would not take the weight of heavy steel pipe; Teseo is light weight which also makes it quick to install.”

In general, for every 1 bar reduction in air pressure 7.5% of compressor power can be saved. When combined with correctly sized receivers and effective pressure control significant energy savings are easily achievable.

Sean Connolly, managing director of Teseo UK, says: “The Carbon Trust approval of our product in the Astrum/AEM proposal gives credence to our assertion that compared to other galvanised steel products and plastic offerings on the market Teseo offers better energy efficiencies, lower pressure drop, a leak-proof, lighter and easier to install system.”

Mike Hutchinson, operations director at Astrum, concludes: “Our compressed air system is critical to the performance of our plant and the quality of our products. We use compressed air for making sand cores and moulds for our castings as well as control air and vacuum. The air delivered must be clean, free of contaminants and dry. We took the advice from AEM as to working benefits of the Teseo system but did go out into the market to compare products and it was clear that the Teseo product offered efficiencies in the installation and set-up process.”

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