Plant Applications: Improved air circulation cuts heating bill at lubricant plant

April 14, 2011

Situation

Employees at the 45,000-sq.-ft. Amsoil synthetic lubricant plant in Superior, Wis., are used to cold working conditions, especially with winters averaging 10 to 15 degrees F. Inside the facility, temperatures at the occupant level remained at 45 to 50 degrees F, while the temperature at the 30-ft.-high roof deck averaged 75 to 80 degrees F.

Plant Manager Jack Swonger wanted to find a way to bring the warm air down to the occupant level so that the difference in temperature from ceiling to floor could be reduced.

Resolution

Amsoil installed eight large-diameter, low-speed Powerfoil®X fans from Big Ass Fans® to destratify the air in the space. The fans slowly circulate the trapped heat at the roof line down to the occupant/thermostat level before it can escape from the building. Their speed is low enough to prevent drafts while still circulating the air.

Even though the thermostat setpoint remains the same, the heating system does not have to work as hard to maintain the given setpoint. Winter thermostat readings typically average 62 to 64 degrees F since the installation, said Swonger.

The fans "knocked our gas consumption for heating down about 35 percent right from the get-go," he added, while simultaneously regulating temperatures. "The heaters hardly ever kick on anymore."