Industrial Utility Efficiency

Compressor Controls

A large chemical plant in Celje, Slovenia, planned to retrofit a kiln used to produce titanium dioxide. To make space for the new equipment related to the retrofit, the plant needed to relocate its high-pressure compressed air system feeding an adjacent pressing process used to dry the material before firing it in the kiln. However, a comprehensive compressed air audit using cloud-based software showed the plant did not need to relocate the system.

Automating Energy Efficiency in Compressed Air System Sub-Zones

The objective of a compressed air management system is to improve the Key Performance Indicator (KPI) of “Energy Intensity” as it relates to compressed air. This translates into improving the ratio between the volume of product shipped and the net electricity (kWh) consumed by the compressed air system. How many thousand bottles, per compressed air kWh consumed, were shipped this month?

A View From Europe. Challenge Convention: Compressor Management Systems Applied in the Automotive Industry

“First there are the old conventions. The majority of compressor houses still employ fixed speed compressors and a cascaded pressure switch control system. This arrangement will be familiar to many, but it is outdated and inefficient, and needs to be changed. There is a comfort factor with familiar technology, which is exacerbated by constant time pressure due to other day-today responsibilities and a lack of information and good advice on what can be achieved.”

 

VSD Compressor Control

“Compressed air systems with multiple compressors operating to supply demand requirements present unique challenges in compressed air system control schemes.”

Tier 1 Automotive Plant Saves $218,000 in Energy Costs

A Tier 1 automotive plant was spending \$364,259 annually on electricity to operate their compressed air system. This figure was expected to increase as electric rates were forecasted to rise from their current average of 7.16 cents per kWh. Our firm, Air Power USA, conducted a full supply and demand-side compressed air system assessment. The set of projects recommended by the assessment, would reduce these energy costs by \$218,670 or 60%.

Real-World $mart Sequencer® Controls

The \$mart Sequencer® is an air compressor control system designed to reduce a plant’s energy costs by continuously monitoring system demand and automatically selecting the most energy efficient combination of available air compressors.

Compressed Air Controls

Compressed air system controls match the compressed air supply with system demand and are one of the most important determinants of overall system energy efficiency. This article discusses both individual compressor control and overall system control of plants with multiple compressors. Proper control is essential to efficient system operation and high performance.

 

Starting a Long Distance Relationship with Your Compressed Air System

When was the last time you visited your compressor room? A week ago? Several weeks ago? If you are like many, you went in for the last scheduled maintenance interval and have rarely been back since. Air compressors, dryers and other air system components have become more reliable and self sustaining from a maintenance standpoint with each generation, requiring less and less human intervention.

Demand Versus Supply, Parts l and ll

The purpose of this article is to investigate the cause and effect that can occur when you reduce demand with no supply changes and the alternative which will produce positive, long term results which you can take to the bank.

Compressor Sequencer Problems and Solutions

The goals of this article are to show why sequencers often have problems, and to demonstrate how avoid problems by proper system integration and controls design.