Industrial Energy Savings    

Industries

In recent years, there have been many changes in wastewater treatment. Most modern processes control three cycles: DO, NH4, and NO3, and all of the processes require high volumes of air. Undeniably, the low pressure air system uses more electrical power than the rest of the wastewater treatment plant combined. The blower packages in these systems can be equipped with low noise enclosures, fixed speed or variable speed drives, and can include all the instrumentation needed for self-protection.  

Auto

This northeastern U.S. automotive manufacturing facility spends $269,046 annually on energy to operate their compressed air system. This figure will increase as electric rates are raised from their current average of .019 cents per kWh. The set of projects, in this system assessment, reduce these energy costs by $110,166 or forty percent. Reliability of compressed air quality, however, is the main concern in this plant and the primary focus of this system assessment.

Bulk

The plant air system consists of eight, single-stage, lubricated, Sullair rotary screw compressors. All units are in good working order.  Units 2, 3, 4 and 7 are water-cooled and units 6, 8, 9, 10 and 11 are air-cooled. The main plant air system has two primary compressed air dryers, a Thompson Gordon model TG 2000 refrigerated dryer, and a Sullair model SAR 1350 heatless desiccant dryer.  Both units are working according to their design. The TG 2000 uses approximately 11.2 kW and is a non-cycling type unit, and the SAR 1350 uses approximately 200 cfm of purge air to regenerate the wet tower. 

Food

Using suction cups and air-driven vacuum pumps is a preferable gripping and handling method of corrugated cardboard materials and boxes in carton-machines like case/carton erectors and rotary cartoners. Robot based applications, like palletizing and de-palletizing, are other examples where the best practice technology for gripping and handling is by suction cups and air-driven vacuum pumps.  

Medical

In the U.S. as an example, the NFPA has taken the view that if your compressor draws in good clean ambient air, the air stays clean through the compressor, is then dried and filtered, when you deliver it to the patient it will be entirely satisfactory. After all, when you went into the hospital that’s what you were breathing and when you leave you will breathe it again!

Metals

The 2013 edition of FABTECH was held November 18-21 at McCormick Place in Chicago. The five FABTECH co-sponsors represent a wide variety of expertise and include: SME, the American Welding Society (AWS), the Fabricators & Manufacturers Association International (FMA), the Precision Metalforming Association (PMA), and the Chemical Coaters Association International (CCAI). Together, these associations bring unmatched technical proficiency and industry insight to FABTECH.

Paper

Pneumatic air cylinders play a major role in allowing a modern sawmill to produce at the high-speed production rates required. Stable air pressure is critical to allow the air cylinders to respond in a timely manner and avoid any production delays.

Pharmaceutical

The United States accounts for roughly half of the global pharmaceutical market. This certainly keeps the Food and Drug Administration (FDA) busy in its oversight of pharmaceutical safety and effectiveness, including with the production processes. As the pharmaceutical industry has grown, so too has its utilization of compressed air for breathing air, operation of equipment and instrument air.

Plastics

Two years ago, sales were picking up and we began operating six extrusion lines on most days. We had to bring in some portable chillers, to keep up, and we started looking at buying a larger cooling system. We wanted to get rid of the portable chillers and have room to grow into four more extrusion lines. The new system we looked at was a 100-ton system that would have cost us around $150,000 in capital and installation and with a larger monthly electricity bill. We were about to buy the new 100-ton chiller when our President, Abe Gaskins said, “Hold-on, can we replace the Liquid Ring pumps with something that doesn’t consume water”? That was our “Eureka!” moment.

Power

Nuclear power plants produce electricity for people, business and industry.  Electricity is produced in a similar fashion as fossil fuel (i.e., coal, oil, etc.) power plants, using steam to drive a turbines which spin an electrical generator, producing the electricity. 

Printing

The Trinity Mirror Group print works on Oldham is one of the UK’s largest newspaper printers. The nine presses in the facility produce around 1million papers every day, including the Independent, the Daily Mirror and a range of local, regional and sports titles. Printing on this scale does not come cheap in energy terms, however. The plant’s annual electricity bill is in the order of £1.5millon. With energy prices on the rise, and a strong desire to improve environmental performance and reduce its carbon footprint, the plant’s management has recently embarked on a project to cut energy use substantially.

Transit

Smith is one of the world’s leading manufacturers of all-electric commercial vehicles, which are zero-emission and less expensive to own and operate when compared with traditional diesel trucks. The company produces trucks for multiple industries, including food & beverage, utility, telecommunications, retail, grocery, parcel and postal delivery, school transportation, military and government. Smith’s customers include many of the world’s largest fleet operators, including PepsiCo’s Frito-Lay division, FedEx, Staples, TNT, Sainsbury’s, Coca-Cola, DHL, and the U.S. Military.

Wastewater

Compressed Air Best Practices® Magazine interviewed Mr. Omar Hammoud, the CEO and President of APG-Neuros. APG-Neuros was founded in 2006 in Quebec as a result of seeing an opportunity for innovation in the North American blower market. Our mission is to distribute, manufacture, provide aftermarket support and continued development of high-efficiency turbo blowers and complete Aeration Systems for the municipal and industrial markets in North America and Europe.
This paper mill currently spends $1,747,000 annually on energy to operate the compressed air system at their plant located in the southwestern region of the U.S. The set of projects recommended, in this system assessment, could reduce these energy costs by $369,000 or twenty-one percent (21%). Estimated costs for completing the projects total $767,900, representing a simple payback of 25 months. More importantly, these projects will improve productivity, quality and maintenance costs - many associated with poor compressed air quality.
Based on the air system operating 8,760 hours per year, the group of projects recommended below could reduce these energy costs by an estimated $170,718 or 56% of current use.  In addition, these projects will allow the plant to have a back-up compressor and help eliminate the rental expenditure for compressor maintenance or downtime.
Nutriom sets the bar high when it comes to producing its premium quality natural powdered egg products Ova Easy® and Egg Crystals®, that are sold at outdoor retailers such as REI, and online merchants such as Amazon.com; so, when the screw conveyor in their FSIS USDA facility required regular unexpected attention, Leonardo Etcheto, Plant Manager at the Lacey, WA facility knew it was time to look for a better solution.
This is a corn mill processing cornstarch, sugar, and other byproducts. Ambient air is contaminated with extremely high levels of dust due to the manufacturing processes and material handling. Average electric rates at the plant are $0.04 / kWh. The actual plant electric cost for compressed air production is $553,630 per year.
This food & beverage plant is a large (500,000 sq ft) meat processing plant with twenty packaging lines and nine palletizers. The compressed air system is supplied from three separate rooms with seven individual lubricant-cooled, single and two-stage rotary screw compressors. The plant has four blower purge desiccant dryers designed to deliver a - 40°F pressure dewpoint.
It was the Fall of 1997 in Germany. I was just another guy working in the German compressed air industry. East Germans were still being looked down on - seven years after unification, the Euro was launching in little over a year - forcing marketing managers like me to scramble and create unified european Euro pricing strategies, European Cohesion Funds were flowing out of Germany and into the Mediterranean (not literally), and the diminutive Mercedes “Smart Car” was the cool car for space-challenged urban dwellers. With this going on, you can imagine the surprise of the compressed air industry when compressed air was featured in “Der Spiegel”, a “Newsweek-like” weekly magazine in Germany with national distribution.
The 2013 edition of FABTECH was held November 18-21 at McCormick Place in Chicago. The five FABTECH co-sponsors represent a wide variety of expertise and include: SME, the American Welding Society (AWS), the Fabricators & Manufacturers Association International (FMA), the Precision Metalforming Association (PMA), and the Chemical Coaters Association International (CCAI). Together, these associations bring unmatched technical proficiency and industry insight to FABTECH.
TIGG Corporation, a manufacturer of activated carbon adsorption vessels, custom air receivers and other steel tanks and pressure vessels, substantially reduced its energy costs after implementing equipment, labor consolidation and procedural changes resulting from a compressed air energy audit. The audit was performed at TIGG's 155,000 square feet manufacturing facility in Heber Springs, Arkansas to determine the efficiency of the existing compressed air system and to set a baseline for TIGG's participation in Entergy Arkansas’ Large C&I Custom Incentive Program.
The 86th annual Water Environment Federation technical exhibition and conference, known as WEFTEC 2013, was held October 5-9 in Chicago’s McCormick Place. Show organizers reported record preliminary numbers with 22,598 attendees, 971 exhibitors, and a total net square footage of exhibit space of 297,400. As usual, I donned my “roving reporter hat”, took my “budget camera” and visited as many of the aeration blower vendors as I could.
Air gaging relies on a law of physics that states flow and pressure are directly proportionate to clearance and react inversely to each other. As clearance increases, air flow also increases and air pressure decreases portionately. As clearance decreases, air flow also decreases and air pressure increases.