Power Factor Correction - Case Studies

Power factor describes the amount of real power transmitted along a transmission line relative to the total apparent power flowing in the line. In AC circuits, it is the ratio of real power (used to perform work) to apparent power (total power drawn from the source). Bringing PFC into your site can help lower your energy bills, helping you become more efficient.

Energy Ace is a leading manufacturer of Energy Saving Systems for industrial, commercial, and residential clients worldwide. Their solutions are designed to specifically reduce energy consumption and reduce the demand on the client's electrical system, with the use of power factor correction, voltage optimisation, and many more.

With the help of Energy Ace, we have been able to implement PFC into a variety of different businesses and here are the results.

Case Studies

Plastic Manufacturer

British Polythene Industries has developed over the last decade to strategically become one of the largest producers of polythene film products worldwide. One of their sites was suffering from harmonic distortion caused by a high degree of non-linear loads like inverters. Energy Ace’s detailed survey helped to reveal that the site was non-compliant with regard to distortion emissions, and most of the power factor correction capacitors had failed, leading to very poor efficiency across the plant and a considerable increase in energy consumption. With the use of PFC, the plan has seen the following impact:

Annual Savings Achieved 

• £13.598.00
• 55.07 Tons CO₂

Payback – R.O.I.

• 11 Months

Benefits

• Reduction in energy costs
• Compliance with legislation
• Improved efficiency 
• Removal of Reactive Power Charges

Data Centre 

The data centre looked into all the different options when it came to energy efficiency and improving its carbon footprint. Through the introduction of EnergyAce PFC energy saving system, they were able to create a whole site energy saving, remove penalties from electricity bills and reduce carbon emissions.

Annual Savings Achieved

• £4,323.80
• 18 Tons CO2

Payback

• 2.04 Years

Benefits

• Reduction in energy costs
• Improved efficiency
• Removal of Reactive Power Charges

NHS

One of the Trusts in the NHS was having issues with its energy savings. After an initial survey and consultation, they were introduced to the saving system, which encompassed new equipment and the modification and repairs of existing systems to keep costs to a minimum.

Annual Savings Achieved 

• £15,066.00
• 61 Tons CO2

Payback

• 1.8 Years

Benefits

• Reductions in energy costs
• Improved efficiency 
• Removal of Penalty Charges

Vinyl Floor Manufacturer

A world leader in vinyl floor manufacture, the company has an annual electrical energy spend in excess of 7 million pounds per annum on a 6Mw site. The project implemented by EnergyAce provided new power factor correction equipment and repairs to existing equipment to achieve an overall electrical efficiency of around 98% from a precontract 85%.

Annual Savings Achieved 

• £42,929.00
• 253.27 Tons CO2
• 169,685 kW/h site
• 471,600 kW/h inc transmission

Payback

• 11 Months

Benefits

• Removal of Reactive Power Charges
• Reduction of 1,496 Amps per phase
• Reduction of 1,076 kVA Demand
• Improved utility

Port/Sea 

The Port handles more than 2 million passengers each year. After an initial survey, the PFC energy saving system was implemented, encompassing new equipment and modification and repairs of existing systems to keep costs to a minimum. Payback may have taken 2 years, but a reduction in maintenance costs and the protection of all electrical appliances, plant and machinery will improve the real payback considerably. 

Annual Savings Achieved

• £9,949
• 40 Tons CO2

Payback

• 2 Years

Benefits

• Reduction in energy costs
• Improved efficiency
• Removal of Penalty Charges

These case studies show that power factor correction offers real savings for businesses. By correcting poor power factor, sites can reduce wasted energy, avoid supplier penalties and take pressure off their electrical systems. EnergyAce PFC energy saving systems help do just that and are a practical upgrade that adds value for your customers. 

To learn more about Power Factor Correction, check out our article here.