Overview
This Alfa Laval case study highlights how Chemgas S.R.L., an industrial gas producer based in Brindisi, Italy, transformed its cooling process to meet rising oxygen demand during the Covid-19 pandemic, while significantly reducing water usage, energy consumption, and operational costs.
The Challange
As demand for bottled oxygen surged across hospitals and care facilities, Chemgas needed to increase production capacity quickly and efficiently.
Their process relied on Atlas Copco compressors, which increased air pressure to 6 bar, generating temperatures of over 120°C. This compressed air then required a two-stage cooling process:
- Cooling tower water for initial temperature reduction
- Chilled water for final cooling and moisture removal
However, the existing system posed several challenges:
- High consumption of potable water
- Increased electricity usage due to inefficient cooling
- Risk of pressure loss during cooling
- Rising operational costs under increased demand
Maintaining pressure was critical, as compressing air is highly energy-intensive.
The Solution
To address these challenges, Chemgas implemented advanced gasketed plate heat exchanger technology.
WideGap heat exchangers were installed at both stages of the cooling process, delivering highly efficient heat transfer with minimal pressure drop, just 2 kPa on the air side.
How The System Works
Stage One Cooling:
- Compressed air is cooled from 127°C to 45°C using cooling tower water
- Moisture condenses and is removed via a cyclone separator
Stage Two Cooling:
- Air is further cooled using chilled water
- Remaining moisture is removed, producing ultra-dry air
This optimised process ensured efficient cooling without compromising pressure or performance.
The Results
Following installation, system performance was verified and confirmed to meet design expectations, with excellent flow distribution and minimal pressure drop.
Key outcomes
- Reduced potable water useage
- Lower electricity consumption through improved heat transfer
- Reduced maintenance costs due to accessible heat exchanger design
- Lower chilling running costs by maximising use of cooling tower water
- Improved cooling efficiency, achieving air temperatures as low as 8°C
- Ultra-dry air output with two-stage separation
- Interchangeable components, simplifying maintenance and spares
Supporting Increased Demand
This Alfa Laval case study demonstrates how Chemgas successfully scaled operations during a period of unprecedented demand.
By improving cooling efficiency, they were able to:
- Increase production capacity
- Maintain system reliability
- Control operational costs
Sustainability Benefits
Beyond performance improvements, the upgraded system delivered strong environmental benefits:
- Reduced water consumption
- Lower energy usage
- Improved overall resource efficiency
These changes supported Chemgas’ sustainability goals while enhancing operational performance.
Final Thoughts
This Alfa Laval case study shows how upgrading heat transfer technology can deliver measurable improvements in efficiency, cost savings, and sustainability.
For operations relying on compressed air systems, optimising the cooling process is a key opportunity to improve both performance and environmental impact.
Get in Touch With Premier Separator Services
If you’re looking to improve your system efficiency or explore heat exchanger solutions, Premier Separator Services can help. Contact our team today to discuss the right approach for your application.