Bengali
Customer Background
As a core supplier to General Motors and Ford, the enterprise specializes in the casting of aluminum alloy wheels and engine blocks. Its factory in Ohio is equipped with 6 electric arc furnace casting production lines, and it needs to adopt oxygen-enriched combustion technology to increase the furnace temperature and reduce natural gas consumption.
Core Pain Points
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Natural gas prices have soared (the U.S. industrial natural gas price rose by 35% year-on-year in 2024), resulting in high fuel costs under the traditional air-fired mode;
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U.S. standards require that the noise level of industrial equipment should be ≤ 85dB, and the equipment must be equipped with a complete emergency shutdown and safety early warning system;
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The production lines operate intermittently, so the oxygen generation equipment needs to support quick start-up and shutdown (≤ 30 minutes) to avoid energy waste.
Solution
GNEE customized two sets of 2000Nm³/h (purity: 88%) VPSA oxygen generation systems for the enterprise, adopting the scheme of "pre-furnace oxygen enrichment + modular integration":
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Oxygen is directly connected to the inlet of the combustion-supporting fan of the electric arc furnace, without the need for additional pressurization equipment, and the oxygen-enriched concentration is increased to 28%-30%;
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Low-noise vacuum pumps and sound insulation covers are adopted in the design, reducing the operating noise of the equipment to 78dB, which meets the relevant standards;
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Equipped with a dual-loop redundant control system, it supports remote monitoring and one-key start-up and shutdown, and the energy consumption is reduced by 90% when the equipment is in shutdown state. Meanwhile, to meet the requirements for subsidies, complete equipment energy efficiency test reports and certificate of origin are provided.
Application Effects
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Significant Cost Reduction: The thermal efficiency of the furnace is increased by 25%, the unit consumption of natural gas is reduced by 32%, and the annual fuel cost savings exceed 2 million US dollars;
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Flexible Adaptation: The start-up and shutdown response time of the equipment is 18 minutes, which perfectly matches the intermittent mode of the production line (three shifts with two working teams), and the annual electricity savings in non-production periods exceed 400,000 kWh;
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Safe and Reliable: The equipment has been operating continuously for 12 months with zero failure rate. The safety early warning system has successfully avoided 2 pressure abnormal risks, and the enterprise has won the title of "Annual High-Quality Supplier".
In addition to VPSA Oxygen Generators, we also produce PSA Oxygen Generators, storage tanks, heat exchangers and other products. If you are interested in VPSA Oxygen Systems or other products, please feel free to send an email to info@gneeheatex.com. We will be very happy to serve you.
