Gas Efficiency In Manufacturing

The Challenge:

Provide a Connecticut manufacturer of die-cast electrical fittings relief from their massive monthly gas bill. As a large-scale user of natural gas, Bridgeport Fittings was spending an average of $31,000 a month to run 21 burners across 13 zinc holding furnaces. They approached ETTER Engineering to assist them with a project designed to lower their monthly gas bill while increasing the efficiency of their operations.

The Solution:

ETTER Engineering tapped Jamie Feagain, one of our most experienced Combustion Technicians, to look at Bridgeport Fittings operations and come up with a plan to reduce their gas usage while increasing their energy efficiency. Jamie’s recommendation was to upgrade the burners, fuel trains, and burner flame safeties across the 13 zinc holding furnaces. A combination of Kromschroder equipment was used, including BIO 65 HB Tube Fired Burners, IC 40 Actuator Motors, BCU370 Flame Safeguards, and ValVario Modular Gas Trains. ETTER provided the labor and installed all the parts, piping, electrical wiring, and performed the start-up. The work was completed in two days, allowing the plant to minimize the impact of the project to their operations.

With a final quoted price north of $200,000, the opportunity to reach out and secure utility incentives was integral to getting this project green lighted. The local utility approved an energy incentive of $85,000, worth nearly 40% of the total project. The simple ROI on the project equaled out to 16.4 months. Frank Timmeny, Bridgeport Fitting’s Director of Manufacturing, noted that the incentive provided was “one of our biggest energy incentive checks to date.”

The bottom line – Bridgeport Fittings monthly gas bill went from $31,000 a month in 2011 to $25,000 in 2012, and $23,300 in 2013 – a savings of 25-30%.

Testimonial:

As Timmeny pointed out, “There’s a ton of combustion going on [here], and I trust ETTER Engineering 100% to get the job done right, saving me time, money, and providing me with peace of mind that my equipment is running at peak efficiency.”