Industrial Utility Efficiency    

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The System Assessment

Food

According to the Compressed Air and Gas Institute (CAGI) and the International Organization for

Plastics

A plastic product manufacturer spends an estimated $245,000 annually on electricity to operate the

Paper

Rockline Industries is one of the largest global producers of consumer products, specializing in

Printing

Several days prior to our visit, during a cold winter evening, the lead air compressor in one

Pharmaceutical

A large pharmaceutical company needed huge flow rates of 30 psig air to aerate multiple

Auto

Compressed air optimization measures adopted by PTMSB have reduced the consumption of compressed

Bulk

The Lafarge Cement Distribution terminal located in Winnipeg, Canada has significantly reduced the

Transit

In aerospace manufacturing, tiny details matter most. For instance, if proper torque is not applied

Metals

Paying close attention to compressed air use is paramount for identifying potential energy-saving

Medical

In the U.S. as an example, the NFPA has taken the view that if your compressor draws in good clean

Power

Nuclear power plants produce electricity for people, business and industry.  Electricity is

Oil & Gas

Petro Chemical Energy, Inc. (PCE) specializes in energy loss surveys for the refining and chemical

Wastewater

Aeration tanks use bubble diffusers to distribute oxygen within the wastewater. Fine bubble
Compressed air is used in more than 70 percent of all manufacturing activities including supplying breathing air to personnel using supplied air respirators. Hazardous breathing conditions exist in many routine industrial operations, such as chemical manufacturing, hospitals, abrasive blasting, paint spraying, industrial cleaning, and arc welding. In these and other operations that introduce contaminants into the workplace, supplied-air respirators, air filtration systems and carbon monoxide monitors are frequently used for worker protection.
Petro Chemical Energy, Inc. (PCE) specializes in energy loss surveys for the refining and chemical industries. We’ve been providing Compressed Air Leak Surveys, Nitrogen Leak Surveys, Steam Leak Surveys and Steam Trap Surveys – for over twentyfive (25) years. We operate totally independent of all equipment manufacturers to ensure our clients receive a complete and unbiased report of the leaks in their facility. PCE has conducted compressed air leak surveys for hundreds of customers at thousands of sites. Undetected, compressed air and gas leaks rob efficiency in manufacturing and processing industries. As a result, businesses lose millions of dollars annually in energy costs and lost production time.
A newly constructed ethanol plant experienced control gap issues shortly after comissioning.  This article discusses the cause of the issue and how the problem was solved.
A chemical plant spends an estimated $587,000 annually on electrical energy to operate their compressed air system. In addition, the plant has an expenditure on rental air compressors of equal or greater size - but this will not be covered in this article. The plant was built in the 1940s and modernized in the 1970s. The plant generates its own power and serves many processes. The average cost per kWh is $0.0359.