Dedusting modernization – energy savings and improved working conditions

Modernization of the dedusting system – energy savings and improved working conditions

Thanks to the modernization of the dedusting system and the use of automation, we reduced energy consumption by 3.38 GWh and cut costs by more than PLN 1 million annually. At the same time, we improved working conditions in the wood processing plant.

The challenge

In the wood industry plant, a dedusting system was installed to reduce dust and improve working conditions. During the energy audit, it was found that the installation was not functioning efficiently. As a result, the dedusting devices consumed electricity unnecessarily, generating high operating costs.

Problems identified by the DB Energy engineering team

Lack of performance adjustment to actual needs.
Fans running at full load regardless of the number of active workstations.
Lack of automation of dedusting dampers.
High electricity consumption without added value.

Our approach

DB Energy auditors recommended modernizing the system through:

using speed control of dedusting motors with frequency converters (inverters),
installing sensors at workstation dampers that automatically respond to the start-up or shutdown of a workstation,
introducing full automation of dampers – pneumatic opening and closing adapted to operator activity,
using flow, pressure, and duct cross-section sensors for optimal system control.

Solution

Thanks to the implementation of an intelligent control system, the dedusting installation began to operate in a mode adapted to actual demand, rather than – as before – in continuous 100% load operation.

This change in the system’s operation not only significantly reduced energy costs but also improved system reliability and operator comfort.

The investment costs, including the purchase of inverters, sensors, and installation works, amounted to PLN 3.25 million.

Effects

The actions taken by DB Energy resulted in:

annual energy savings: 3.38 GWh,
reduction in energy costs: PLN 1.04 million,
adjusting the dedusting system operation to actual production needs,
improving ergonomics and workplace safety,
reducing losses caused by unnecessary operation of electric motors.

Conclusions

Optimization of dedusting systems through the use of inverters and control automation enables significant energy and cost savings. Modernization improves the plant’s energy balance and increases the efficiency of the dedusting process, resulting in better working conditions and employee safety.

Nasze najnowsze realizacje, które Cię zainteresują

The largest LNG-powered cogeneration unit in southern Poland – Schumacher Packaging Myszków

The largest LNG-powered cogeneration unit in southern Poland is now operating at Schumacher Packaging in Myszków. Thanks to an investment of 21.8 million PLN, the facility has achieved nearly 80% energy independence, producing almost 9 MW of electricity and significant amounts of heat. The project, implemented by DB Energy, demonstrates how an energy audit can serve as a starting point for a comprehensive energy transformation of a factory – from modernization of existing heat sources, through energy recovery, to the implementation of advanced cogeneration.

Przejdź do artykułu

Higher production and lower emissions – a chemical industry client on the path to net zero

At a chemical plant in southern China, we developed a 4-month strategy to reduce emissions by 70%, enabling increased production while lowering energy consumption and laying the groundwork for achieving net zero by 2035.

Przejdź do artykułu

Zero-emission in practice – emission reduction in pharmaceutical chemistry

Zero-emission in the chemical industry is not theory but concrete action. For a client in the pharmaceutical sector, we prepared a CO₂ reduction roadmap and implemented an incinerator modernization with heat recovery. The result? 12 GWh of thermal energy saved, a reduction of 2,172 tCO₂, and a quick payback period.

Przejdź do artykułu