Industrial Utility Efficiency

Bulk

MSHA Regulations for Safe Compressed Air Operation

By Paul Edwards, President, Compressed Air Consultants

This article reviews key Mine Safety and Health Administration (MSHA) requirements affecting compressors, air receivers, pressure systems, piping, hoses and compressed air use. It also examines common field hazards, inspection and maintenance considerations, equipment safety requirements and worker training provisions. Practical examples illustrate how mine operators and compressed air professionals can identify potential hazards and improve safety while working within the applicable MSHA framework.

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20 Years of Case Studies: Plants Sharing Best Practices

Edited by Troy Dreier, Senior Editor, Compressed Air Best Practices® 

For 20 years, Compressed Air Best Practices® Magazine has published articles focused on helping manufacturers reduce power demand, lower water consumption, and improve the performance of compressed air, cooling, blower and industrial vacuum systems. In this article, we highlight a sampling of those stories across the following industries: Plastics and Packaging Food and Beverage Automotive and Transportation Cement, Building Materials, and Mining Metals, Pulp, and Paper Pharmaceuticals, Healthcare, and Research Wastewater Treatment
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Compressed Air at a West Texas Silica Mine

By Troy Dreier, Senior Editor, Compressed Air Best Practices® Magazine 

Compressed air system reliability relies on engineering expertise, environmental management and proactive maintenance. This article highlights how Brandon & Clark improved performance in two demanding applications: reducing failures in a dust-heavy silica mining operation through frequent preventive maintenance, and executing a complex disassembly and reassembly of a 300 hp air compressor in a confined university facility while preserving the OEM warranty. These cases show how tailored solutions and long-term service strategies enhance system reliability.
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High-Altitude Mining and Steel Production in Peru

By Troy Dreier, Senior Editor, Compressed Air Best Practices® Magazine

Before CAGI data sheets were created, air compressor distributors and their customers could only go by the manufacturers’ claims. He found there wasn’t any uniformity to the numbers manufacturers put out, so making comparisons was challenging. Some compressed air manufacturers measured capacity from the bare airend, while others measured from the air compressor’s outlet.
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Air Cannon Innovations in Preheater Towers

By Brad Pronschinske, Director of Air Cannons Business Group, Martin Engineering

An essential part of the cement production process is the consistent flow of bulk materials, as poor material flow can put a stranglehold on a plant’s profitability. Accumulations in storage systems and process vessels can choke material movement, causing bottlenecks that create expensive obstacles to equipment performance and process efficiency. Poor material flow also raises maintenance expenses, diverting manpower from core activities. If they become severe enough, flow problems can bring production to a complete stop.
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Compressed Air System Design for Dust Collectors

By Hank van Ormer, Technical Director, AP Energy

The dust is collected on the bag or fingers, and when the cake of dust is of appropriate thickness and structure, a pulse or pulses of compressed air hits or shocks the bag and knocks the cake off. This pulse may sometimes be accompanied by physical shaking and even reverse air flows, depending on design.
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Eagle Mine Redesigns Compressed Air System for Uptime Gains

By Mike Grennier, Compressed Air Best Practices® Magazine

When the design capabilities of an installed compressed air system didn’t align with real-world production needs at its ore processing mill in northern Michigan, Eagle Mine decided to move beyond theoretical compressed air concepts and deal in reality. After thorough analyses of its compressed air challenges and implementing a variety of solutions, the team at the mill bolstered the operation’s ability to efficiently mill approximately 2,200 metric tons of ore per day.
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HAUG Oxygen Compressors for Efficient Gold Extraction

By Paul Frank, Technical Proposal Manager, Sauer Compressors USA

Logistics and supply problems are widespread on the African continent. Lack of infrastructure as well as capacity and efficiency deficiencies can affect supply chains and make them more expensive. Gold mines, which are often located in secluded areas, therefore seek to provide their entire infrastructure themselves. Even the oxygen required for efficient gold extraction by cyanide leaching is therefore not delivered but generated on site.
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CalPortland® Continues to Walk the Walk in Sustainability

By Mike Grennier, Compressed Air Best Practices® Magazine

A major producer of cement and building materials, CalPortland’s energy management efforts have reduced the company’s overall energy intensity by 17.5% since 2003, avoiding $149 million in unnecessary energy costs – and over 3.3 million metric tons of Greenhouse Gas (GHG) emissions. In 2020, the company achieved what no other U.S. Industrial company has: It earned the ENERGY STAR® Partner of the Year Award for the 16th consecutive year.
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Dust Collector Pilot Program Points to 16 GWh of Energy Savings at Imerys Minerals Processing Facilities

By Mike Grennier, Compressed Air Best Practices® Magazine

For Imerys S.A. there’s little question about the importance of managing dust collection systems it uses to control and reduce harmful particulates in its worldwide minerals processing facilities. And now there’s zero doubt about the tremendous energy savings it stands to save by reducing the amount of compressed air needed for these same dust collectors.
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Sustainability is “Part of Who We Are” at Eastman

By Mike Grennier, Compressed Air Best Practices® Magazine

By making sustainability a requirement and a core element of its growth strategy, Eastman has improved the energy efficiency of manufacturing operations by 13% since its baseline year of 2008 (the year Eastman became an ENERGY STAR® Partner). By 2018, Eastman had decreased its greenhouse gas intensity by 20%, two years ahead of its goal. Additionally, Eastman received the 2019 ENERGY STAR® Partner of the Year Award for Sustained Excellence, marking the company’s eighth consecutive ENERGY STAR award: two years as Partner of the Year and six years of Sustained Excellence recognition.
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How to Keep Reverse Pulse Dust Collectors Operating Efficiently and Reliably

By Ron Marshall, Marshall Compressed Air Consulting

Reverse pulse type dust collectors often represent a challenge to compressed air energy efficiency, and sometimes throw a wrench into the works by causing huge air pressure fluctuations, high transient flows and just plain large leaks. This article discusses this type of dust collector, often installed in food processing plants, and gives some real-life examples of problematic installations. Some suggested measures are mentioned to ensure your dust collectors keep running in a trouble-free manner.
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A Pulse Jet Dust Collector Optimization Study

By Russell Morine, Compressed Air Systems Evaluation Specialist, The Baker Group

A flour based frozen foods manufacturer orders a compressed air efficiency audit. The audit establishes the cost of compressed air at $0.27/1000 cubic feet. The study finds the 116 pulse jet dust collectors represent the greatest opportunity for compressed air demand reduction and energy cost savings. A dust collector optimization study/service is suggested and the customer agrees to proceed. In this facility, pulse jet dust collectors are used to filter dust from raw materials entering the plant, for conveying and mixing of ingredients, and for the final packaged finished products leaving the plant.
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Correctly Solving Low Air Pressure Problems

By Paul Edwards, President, Compressed Air Consultants, Inc.

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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Air Compressor Control at Remote Mining Complex

By Ron Marshall, Marshall Compressed Air Consulting

A large mining complex in a remote northern region of the world invited a compressed air auditor in to assess the efficiency of a problematic system. Site personnel and their air compressor supplier were concerned a system in one of the buildings was not running optimally, and wanted to know what size of compressor to install in the facility. The auditor found significant savings in this target system, but even larger potential savings were found in other ancillary systems in the complex, as part of an extra investigation conducted while at the site. Overall, the potential energy savings total more than half of a million dollars, if all recommendations are implemented.
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Low-Pressure Air Compressors Deliver Savings for Lafarge Cement Distribution

By Ron Marshall, Marshall Compressed Air Consulting

The Lafarge Cement Distribution terminal located in Winnipeg, Canada has significantly reduced the site electrical demand and energy charges by changing the way they transport their cement. Two new low-pressure rotary screw air compressors have replaced two large high-pressure air compressors that previously powered their dense phase transport system. The resulting power reduction has saved the company 46 percent in transport operating costs.
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Atlas Copco Rental Provides Quick Solution for Dominican Gold Mine

A trio of stationary compressors produce 630,000 m3/hr of air for the oxygen plant at Pueblo Viejo gold mine in the Dominican Republic. The oxygen is used by its autoclave processing facility to treat roughly 24,000 tons per day of refractory ore for the 60/40 joint venture between Barrick and Goldcorp Inc., operated by Barrick as Pueblo Viejo Dominicana Corporation.
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Detailed Design — An Ounce of Design is Worth a Pound of Project

By Paul Edwards, Compressed Air Consultants, Inc.

Insufficient focus at the design phase will kill a project. In one aerospace project, insufficient detail was paid to the physical size of the air compressor. The compressor didn’t fit in the allocated space—requiring the extension of the building, and costing tens of thousands of unbudgeted dollars. That had a significant, negative impact on the project return.
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CalPortland Energy Management Earns Another ENERGY STAR Award

By Compressed Air Best Practices® Magazine

Making cement is an energy-intensive process. In a cement plant, the electrical energy load can reach up to 25 MW, consuming 185 million kilowatt hours of electricity annually. In addition, the plant consumes a large amount of coal and natural gas. CalPortland is an enormous producer of cement, concrete, aggregates and asphalt. With 80 facilities spanning five states across the western U.S., one might logically assume that CalPortland consumes a lot of energy.
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Managing Dust Collectors in Cement Production

By Hank van Ormer, Air Power USA

Cement production facilities have a significant number of dust collectors. Many have continuing problems with short bag life and low-pressure problems at the further points from the central air system. They often run on timers. When they try to run on demand control, they often get extreme short cycling, which causes even more bag problems. Most have gauges at the entry, on at least half of the dust collectors, and the compressed air feed lines are always the same size as the connector opening. This article reviews where these problems come from and provides some troubleshooting ideas.
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Vale Thompson Turbo Compressor Upgrades

By Ron Marshall for Compressed Air Challenge®

Vale in Thompson, Manitoba, Canada has reconfigured a system of large turbo compressors in their mining, milling, smelting and refining operation and gained very large energy savings through a series of improvement projects. In addition, these projects qualified for some significant financial incentives from their local power utility. Vale is a large multinational mining company with headquarters in Brazil. Vale operations focus on the production of iron ore, coal, fertilizers, copper and nickel. The Thompson Manitoba operations consist of mining, smelting, milling, and refining of Nickel in the 250 acre complex that employs 1,500 people.
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Pneumatic Conveying Energy Assessment Saves $321,000

By Don van Ormer, Air Power USA

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.
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A View From India: Pneumatic Conveying of Bulk Materials

By G.D.Nigudkar, TATA Consulting Engineers

In thermal power stations, nuclear plants, and chemical and industrial plants, different types of bulk materials are used. The materials exist in different forms including lump, powder, granules, chips, and pallets. These bulk materials, in their different forms, require efficient and reliable material handling systems.
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Dealing with High-Volume Intermittent Demands

by Ron Marshall and Bill Scales for the Compressed Air Challenge®

In many industrial plants there are one or more applications with intermittent demands of relatively high volume. One example is the use of dense phase transport systems to convey the cement. Dense phase systems can cause severe dynamic pressure fluctuations affecting quality of the end product in a plant.
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Material Conveying with Pneumatic and Vacuum Systems

By Hank Van Ormer, Air Power USA

In many manufacturing operations, a very significant compressed air use is pneumatic conveying of many types of materials such as cement, fly ash, starch, sugar, salt, sand, plastic pellets, oats, feeds, etc. Often these are systems that use high-pressure air (100 psig class) reduced to lower pressures (15 psig, 45 psig). This creates an air savings opportunity.
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