From breakdown to breakthrough: a chemical plant’s journey from diesel to electric
When a critical compressor broke down at a major chemical production site, the clock started ticking. Every minute of downtime meant losing productivity and rising costs. The team needed compressed air, fast. That’s where Atlas Copco Specialty Rental came in.
Customer challenge
A critical compressor failure at a major chemical plant stopped production, demanding an immediate solution to restore operations and avoid downtime.
Our solution
We quickly delivered a diesel-powered compressor to restore operations, then partnered with the customer to explore a long-term electric solution through a full analysis of the site's power capacity.
The result
The plant achieved a seamless transition to electric, cutting energy costs by nearly 50% and significantly reducing CO₂ emissions — transforming an emergency response into a sustainable operational upgrade.
A rapid response with diesel
Our priority? Get the plant back online and reduce its downtime. Within hours, a diesel-driven compressor was delivered and installed, restoring operations and giving the team valuable time. Diesel remains the go-to solution when speed is of the essence. It’s mobile, powerful, and doesn’t rely on grid access. In emergencies, it’s the hero that gets the job done.
But once the dust settled, the our team shifted focus and asked, “What if there’s a smarter solution?”.
Rethinking the solution: is electric an option?
With operations stabilized, we sat down with the customer to explore a more sustainable and cost-effective compressed air solution. The answer? Electric.
The PTS1600 Stage V, although the most efficient of its class, consumes around 13 000 litres of diesel per week at full load, producing around 36 300 kg CO2 emissions weekly when using conventional diesel. In conrtrast, the electric alternative, the ZT315, consumes about 47.6 MWh per week under the same load profile, resulting in significantly lower operating costs and environmental impact.
When translated into costs, instead of energy, the diesel option in Belgium runs around €10,2k per week (€0.80 per liter diesel), while the electric compressor costs nearly half, about €5,200 per week. This saving doesn't account for fuel refills, Diesel Exhaust Fluid or CO2 pricing. Depending on the electricity provider, switching to electric it could also mean a nearly CO2-neutral solution, avoiding additional carbon costs.
Switching to an electric compressor delivers multiple benefits: lower operational costs, reduced maintenance, and a significant drop in local CO₂ emissions. For a site already focused on improving its environmental footprint, the switch made perfect sense.
Is switching to electric an option for you?
Not every site can make the switch from diesel to electric. Some lack access to the right voltage. Others face infrastructure limitations. That’s why we don’t just deliver equipment; we deliver insights.
Our expert team conducted a full grid connection analysis to ensure the site could handle the load. We checked voltage compatibility, transformer capacity, and safety protocols. Only when everything was greenlit did we proceed with the switch. The result? A smooth transition from diesel to electric, with zero disruption to production. The customer now benefits from a quieter, cleaner, and more cost-efficient setup, without compromising performance.
Your turn?
If you’re facing a breakdown, diesel is often your fastest soltuion. But once operations are back up, it’s worth considering whether electric could be your next step - and we're here to help! We'll guide you through assessing your options, evaluating your grid and making sure your next move is the right one for your operations.
P.S. Don’t wait for a breakdown hits. Download the contingency planning guide and be prepared for the unexpected.
Want to learn more about what we can do for you? Reach out to you Atlas Copco Rental expert.
At Atlas Copco, we have been turning industrial ideas into business-critical benefits since 1873. By listening to our customers and knowing their needs, we deliver value and innovate with the future in mind.
Great ideas reinforce sustainable development. At Atlas Copco Specialty Rental, we team up with our customers to set up state-of-the-arttemporary air, flow, steam and nitrogen solutions. Our passionate experts have extensive application and equipment knowledge. We understand our customers' needs and can provide a total solution for any industry, no matter if it is for emergencies or planned projects. We are a division of the Power Technique business area, headquartered in Boom, Belgium and offer specialty rental solutions under several brands around the globe.