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Shell's saving well with new compressor system from Thorite

Shell's saving well with new compressor system from Thorite

Friday 26th October 2012

The Shell Lubricants manufacturing plant at Stanlow near Ellesmere Port utilises compressed air in important stages of the production process. Engineers at the plant were concerned that the existing compressors and dessicant dryers were being asked to operate beyond their service life and called in Thorite for help and advice on installing energy-efficient pneumatic equipment.

Thorite is the UK's biggest distributor of fluid power solutions and started the project by having their Engineering Design Team carry out a power logging exercise at the plant, to determine precise compressed air site usage patterns. This indicated that the three existing compressors, each supported by a dessicant dryer, were operating far from efficiently. Shell Lubricants demand high standards of purity from the compressed air produced, so it was vital that any new equipment could meet or exceed these standards.

Thorite's solution was to install a highly efficient HPC DSD202SFC oil-flooded, variable speed compressor, sufficiently powerful to run the main plant under all load demands, but supported by two of the original compressors for emergency backup. Thorite also installed an HPC Hybritec Dryer to replace the existing three dessicant dryers. The HPC Hybritec Dryer is a revolutionary concept, complete with an intelligent control system which oversees both a refrigerant dryer and a dessicant dryer, all neatly packaged on a compact skid mounting. The control system allows either the refrigerant or dessicant dryers to maintain a set dewpoint, providing minimal power consumption combined with high compressed air purity standards.

Rounding the project off, Thorite also installed a SAM4 controller with full visualisation which gives Shell's engineers remote access and clearly demonstrates that the new fluid power system is optimising energy efficiency at all times. A Thorite 5 Year "No Quibble" Warranty is also in place to ensure the system continues performing to the highest standards.

Chris Turner, Shell Chemicals' Engineering Project Manager, is delighted with the installation and said: "The new compressed air generation system not only offers outstanding quality, but also gives us great peace of mind. Better still it is well on track to provide energy cost savings of around $70K per year."

The Engineering Design Team can be contacted by email at info@thorite.co.uk or by freephone on 0800 034 2511.

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