Manufacturer of semiconductors saves $16000/year thanks to Optimizer 4.0
A semiconductor manufacturer's compressor room was suffering from inefficient sequencing. The customer contacted Atlas Copco to solve this problem.
The Challenge
The customer has a compressor room with seven compressors monitored by an ES16 Central Controller. Due to frequent communication losses between the Central Controller and the compressors, the system was suffering from inefficient sequencing.
The Solution
The Atlas Copco team visited the site and conducted a track study to analyze the compressor’s operating pattern and the efficiency of the existing ES16 Central Controller. As such, the data revealed an annual energy loss of 77 MWh (77 000 kWh) due to unloaded energy inefficiencies.
To solve this issue, the existing Central Controller was replaced with an advanced Optimizer 4.0 Central Controller through a Try & Buy program.
The Optimizer 4.0 offers enhanced software support and upgraded algorithms, allowing it to automatically determine the optimal combination of machines at any given time.
This upgrade reduces both loaded and unloaded operating hours, improving overall efficiency within the compressor room.
Thanks to the Try & Buy program, no initial investment was required by the customer.
During a period of three months, the energy consumption in unloaded state was reduced to approximately 200 kWh, which is 800 kWh per year.
Energy consumption of three months with new Optimizer 4.0
The Outcome
The energy consumption in unloaded state dropped from 77 000 kWh per year to just 800 kWh per year, representing a 99% reduction.
Thanks to the new Optimizer 4.0, annual energy savings of more than 76 000 kWh were achieved, which is equal to USD 16 000 per year. Additionally, this improvement resulted in a CO₂ emissions reduction of 31 tons per year.
