Industrial Utility Efficiency    

Air Treatment

Made from various combinations of hops, grain, yeast and water, beer is a drink that has been produced for centuries. But while the ingredients are simple, the chemical processes behind the drink are anything but. Through various reactions, barley becomes fermentable sugars that are then digested by the active yeast to produce carbonation and alcohol. Although the basic principles behind brewing are little changed since their advent, the technological aspects are much improved. Today, large stainless steel tanks are used for fermentation and wort aeration, and complex, automated systems help with everything from temperature regulation to bottling.
Earlier this year, BEKO Technologies completed the third renovation of its eight-year-old facility, which provided perfect timing for the company’s 25th Anniversary Event held on September 22, 2016 in Atlanta, GA.  The celebration marked 25-years of operating in the American markets after the German parent company, BEKO Technologies GmbH, first set up shop in the Tulsa, OK area in mid-December of 1990.  This important milestone was celebrated with a guided tour at the newly renovated American headquarters that included new product introductions and live demonstrations.
The useful and various properties of nitrogen (N2) in industrial applications rank it as one of the most specified gases in industry. For the manufacturer, nitrogen options exist in the choice of delivery system, compliance with clean air standards, safety and purity. In researching these choices, manufacturers can accurately select the optimum nitrogen supply required, often at a considerable savings. Selecting purity levels of 99.99% or higher in many industries and applications ads a variety of costs, both financial and efficiency, which may be needlessly incurred.
Adsorption devices are commonly installed in compressed air systems to remove moisture.  Heatless compressed air dyers are the most common type furnished to meet the requirement for -40° F dew point “commercially dry” air, especially in systems of less than 1,000 standard cubic feet per minute (scfm).  Heatless air dryers are pressure swing adsorbers designed to retain the heat of adsorption within the desiccant beds during the drying process.
A Canadian chemical plant installed a large heated blower-purge style compressed air dryer, years ago, to condition the instrument air system against freezing temperatures.  The dryer selected was oversized for the connected air compressors and had unused on-board energy savings features.  A compressed air assessment revealed the site air compressors and compressed air dryers were running inefficiently and causing in-plant pressure problems.  Repairs to a compressed air dryer and the replacement of aging air compressors and dryers has reduced compressed air energy costs by 31 percent.
Compressed Air Best Practices® (CABP) Magazine and the Compressed Air and Gas Institute (CAGI) cooperate to provide readers with educational materials, updates on standards and information on other CAGI initiatives. CABP recently caught up with Rick Stasyshan, Technical Director for the Compressed Air and Gas Institute (CAGI) to provide readers with some insights into the benefits of CAGI’s Verified Performance Program for refrigerated compressed air dryers.
Atlas Copco has a long history serving the Houston-based energy and chemical industries with custom-engineered packages. The objective of this article is to show just a few examples of the custom applications typically engineered and manufactured in the Atlas Copco Houston operation. Opened in 2012, Atlas Copco Houston produces standard compressed air dryers as well as completely engineered air dryers for all markets. The air flow capacity of the dryers, produced at this location, vary from 5 to 12,750 scfm. This capacity range covers heatless, heated purge and blower purge air dryers.
In the food and beverage industry, the moment a product leaves the production line, the clock starts ticking down to when that product will no longer be viable for sale or consumption. To combat the clock, modified atmospheric packaging (MAP) techniques are used to help maintain product freshness and increase shelf life. Nitrogen is the most cost effective, efficient and widely used industry solution for a company’s packaging needs—whether it is for manufacturing cheese, coffee, dried snack foods, or fresh and ready-to-eat (RTE) foods. MAP also helps to decrease chances of contamination or spoiling, keeping products on the market for longer and ultimately increasing the reach of distribution.
Plastic injection molding is a common process in manufacturing, and it can be used to produce just about anything. To create a part, molten plastic is injected into a hollow mold, where it is formed and cooled before being ejected from the cavity. Plastic injection molders make a seemingly limitless range of products, from fishing tackle boxes and kayak paddles to tooth brushes and miniscule medical devices.
Any modern food manufacturing facility employs compressed air extensively in the plant. As common as it is, the potential hazards associated with this powerful utility are not obvious and apparent. Food hygiene legislation to protect the consumer places the duty of care on the food manufacturer. For this reason, many companies often devise their own internal air quality standards based upon what they think or have been told are “best practices.” This is no wonder, as the published collections of Good Manufacturing Practices (GMPs) that relate to compressed air are nebulous and difficult to wade through.
There is always something new to learn about compressed air systems – particularly in regards to compressed air dryer installations. As I discussed in Part 1 of this series, you can make compressed air dryer installations more reliable by understanding the consequences of any modifications you make to the system.  As a continuation of those ideas, Part II explores more ways to make a dryer installation more reliable. Discussions include: the difference between operating a desiccant dryer in a fixed cycle opposed to demand mode, what happens when you operate a heated desiccant dryer with the cooling air turned off, and how to deal with the unintended consequences of dedicating a desiccant dryer to a compressor.