The System Assessment
Food
Since 2002, Energy Trust of Oregon has saved and generated 728 average megawatts of electricity and
Plastics
The Pepsi bottling plant in Winnipeg, Manitoba has upgraded both their main 100 psi compressed air
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
One of the most common problems in plants is low air pressure. One of the most common solutions is
Transit
Their job is to brake the cars by gripping the wheels. They are operated either pneumatically or
Metals
A zinc producer spends an estimated $516,000 annually on electricity to operate the air compressors
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
In an ideal world, we would all have plenty of space, time and money to create the perfect compressed air system. In practice, we have to balance our ideals versus what we can actually accomplish. Compressed air systems take considerable forethought and planning to achieve a perfect install; however, we can use some key takeaways from this article even if we are ever faced a less than ideal installation. Remember to keep the compressors cool, minimize piping pressure drop and to allow sufficient room around the equipment for service.
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One of the most common problems in plants is low air pressure. One of the most common solutions is to purchase new air compressors. Often this advice leads to a poor return on investment with the company’s hard-earned money. Often the issues are related to demand, distribution, or both. Solving the wrong problem can be expensive from a capital and operating cost perspective. Determining root cause analysis may cost more up front, but will save tens if not hundreds of thousands of dollars long term.
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This article is going to identify two air compressor control situations that will preclude translating air use reduction in the production area into lower input energy into the air compressor.
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The plant produces both molded and blow molded plastic parts on a 5 day per week, three shift schedule. Production and maintenance sometimes occurs on weekends, occasionally requiring the air compressors to run on a 24 x 7 basis so the practice was to leave the compressed air system always pressurized. The system consisted of three modulating lubricated screw compressors one sized at 150 hp and the others 125 hp (3 units), each controlled with their local compressor controllers.
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