Industrial Energy Savings    

Technology

When it comes to conserving energy in compressed air nothing is sexier than a big, old, oil-free 300 horsepower variable speed drive air compressor coupled with a heat of compression dryer tied to an energy management system with all the trimmings. If you’re like me, it’s hard not to let out a manly grunt after reading that sentence.

Air Compressors

A paper mill in Wisconsin reduced its’ yearly water consumption by 547.5 million gallons and reduced its’ yearly air compressor maintenance costs by $470,000.  

Air Treatment

Desiccant dryers are commonly used to bring the pressure dewpoint well below freezing (commonly -40°F) in order to prevent moisture from precipitating in the compressed air system and production equipment.

Blowers

A leading soft drink bottling manufacturer’s compressed air needs were threatening to exceed its Michigan plant’s compressed air capacity. Faced with the cost of buying a new compressor, the soft drink bottling manufacturer re-assessed their compressed air use to identify compressor and energy savings opportunities. In the audit, the soft drink bottling manufacturer identified the use of compressed air in a gap transfer as a source of compressed air and energy inefficiency.

Compressor Controls

We are finding significant changes in industry with regards to which managers are involved with our discussions.

Instrumentation

The secret to success is to understand the nature of what type of leak produces a detectible ultrasound and what does not, along with the techniques that can be used for effective leak identification.

Pneumatics

Swiss brush company Ebnat-Kappel uses non contact transfer technology from Bosch Rexroth to automate a problematic section of its packaging production process.

Vacuum

The roots of our company start with my father, Jan Dekker, who was heavily involved with oil-sealed liquid ring vacuum systems used in the gold mines of South Africa. This was in the mid-1970’s when gold prices were going up. Vacuum systems (in the mines) were optimized by improving vacuum levels using oil instead of water and by adding vacuum boosters.

Cooling Systems

It is widely recognized that compressed air systems account for ten percent of all electricity and roughly sixteen percent of U.S. industrial motor system energy use. Seventy percent of all manufacturing facilities in the United States use compressed air to drive a variety of process equipment.

Industry News

CompAir announced a new line of variable speed rotary screw compressors from 50HP to 180HP (37kW to 132kW). The L37RS, L45RS, L75RS, L90RS, and L132RS compressors have incorporated the latest in variable speed technology producing exceptional kW/100 cfm performance across a wide turn-down range.
Since the cost of energy has dramatically increased during the past few years, it seems that energy audit companies have opened shop on more city street corners than coffee shops in Seattle.  In addition to the mass numbers and abundant varieties of these energy savings promoters, there have been an equal number of energy audit articles written for the engineering magazines.  
Tencarva Machinery Company announced the acquisition of Greensboro-based Electric Service and Sales Company Inc. (ESSCO), a division of Enerphase Industrial Solutions Inc., as of May 28, 2010, according to Rod Lee, president.
Kaeser Compressors, Inc. announced its US headquarters building has earned the ENERGY STAR Label! Kaeser became an ENERGY STAR Partner in 2009, and its headquarters in Fredericksburg, Virginia earned the label this year with a rating of 83 – well above the national average and exceeding ENERGY STAR requirements.
Atlas Copco’s industrial compressed air systems can enable project teams to earn credits for the LEED® Certification of New Construction Projects, Major Renovations, or Existing Buildings, according to a third-party LEED Accredited Professional with ABOVE Green LLC. “Atlas Copco’s Variable Speed Drive (VSD) compressors offer approximately 35 percent energy savings versus the use of conventional air compressor systems,"
Atlas Copco Compressors LLC, has purchased certain assets of American Air Products, Inc. The acquired business has been a long-serving, Atlas Copco compressor distributor for many years in the states of Minnesota, North Dakota, South Dakota as well as areas of Wisconsin.
This article will examine in detail four of the five acceptable WAGD implementations under NFPA 99, along with some alternative ways they may be implemented. This article will not deal with passive implementations.
Hazardous breathing conditions exist in routine industrial operations, such as hospitals, abrasive blasting, paint spraying, industrial cleaning, and arc welding. In these and other operations that introduce contaminants into the workplace, supplied-air respirators are frequently used for worker protection.
The most abundant contaminant in any compressed air system is water. This can be in either liquid or vapour form. Atmospheric air is already very wet, and becomes saturated when compressed. This water vapour will condense when the temperature drops, after the compressor, and will damage air receivers, pipework and equipment. For this reason coalescing filters and then dryers are used to remove the bulk of this water.  
A good-size hospital with 200 beds and ten operating rooms can have a medical air system, a laboratory air system, and pneumatic air systems. The medical air systems must all follow the NFPA 99 guidelines. We follow these guidelines, from the beginning, when we assess the demand for air in a hospital.
Located in the bowels of most hospitals, you will find the source of the Level 1 Medical Air compressed air system. Per the NFPA Section 99 Specification (National Fire Protection Association), Level 1 air compressor systems provide air for human consumption within the hospital facility.