Industrial Utility Efficiency

# System Assessments

Analysis of the pressure data logging showed that, while the variable speed drive compressor maintained a constant discharge pressure near 120 psi, the pressure at various critical points fell to as low as 85 psi during peak production operations. General pressure in the plants, especially Plant 2, fluctuated between 102 and 112 psi, showing that the pressure/flow control valve was not regulating properly, and that Plant 2 lacked enough general storage volume to support transient flows.

## DOE Better Plants Partners Get Serious About Compressed Air Systems

Compressed air is used in all the company’s plants and is often the single largest energy end use within them. As a result, compressed air energy-saving measures are often replicable across the company and offer significant positive impacts. One area of focus is with compressed air leaks since they are “the best low hanging fruit to focus on and they always keep popping up and waste energy”.

## What is CFM in Compressed Air? How Much Do I Have? How Much Do I Need?

Do the questions in the title seem like simple questions? There are many things that confuse the issue including air compressor condition, controls as applied, interconnecting pipe size and configuration and effective storage. All of these have been covered in many technical compressed air papers and articles. The topic many don’t use or understand is how to calculate the actual value of these initial questions at the operating sites and conditions.

## Moisture: the Assassin in Compressed Air Installations

Moisture can freeze in compressed air systems and cause rust and pitting in pipes and components. It can also flush out the lubricant resulting in accelerated tool wear and damage to valves and cylinders. Moist air is also a rewarding breeding ground for bacteria, which especially in the food and pharmaceutical industries can lead to product rejection and costly production downtime. It is therefore strange that many companies limit themselves to measuring only basic quantities such as pressure, flow and (absorbed) power.

## Compressed Air System Design for Dust Collectors

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.

## Achieving Sustainability Targets by Optimizing Compressed Air Use

By monitoring compressed air consumption using smart pneumatic sensors, companies can reliably reduce energy use and emissions.

The digital transformation of pneumatic systems is one critical way that companies can improve operational sustainability. Advanced airflow-sensing technology provides compressed air monitoring and valuable insights that allow companies to control and significantly reduce the energy used to produce compressed air as well as related carbon emissions.

## Compressed Air Systems and Rocket Science

Would you believe the same technology used in the launching and controlling of a space rocket is also used in your compressed air system? Yes, in some cases, “rocket science” helps to solve problems in compressed air systems and ensures the performance of the installed units. In this article, we are going to explain the technology called the “Sonic Nozzle”, that combines a space rocket thruster and your compressed air system. Additionally, we are going to walk through a case study, step by step, to show how it works.

## Metal Fabricator Measures Nitrogen Use, Receives a Surprise

Nitrogen is used in many facilities for a variety of purposes. The most common source of N2 is through the use of bulk liquid storage. A plant owner was recently surprised to learn that a large portion of his N2 was disappearing, without ever being used by his production process. This article discusses where it went and what we could do about it.

## Commercial Bakery Compressed Air Audit Optimizes the Constituents of Demand

The current cost to operate the compressed air system is \$139,100 annually, and the proposed measures will reduce it by \$50,700 annually. The proposed cost to complete the measures is \$47,600 providing a simple payback of 11 months. The cost included in the Action Plan includes engineering, project assistance, services to maintain the gains, and a 10% contingency.

## Three Ways To Make Packaging Lines More Sustainable

Sustainability is a high priority for today’s consumer packaged goods (CPG) companies. Driven by environmental responsibility, government regulations and customer preferences, CPGs are actively seeking ways to decarbonize their packaging lines and use eco-friendly packaging materials. Many have started monitoring the energy consumption of their equipment in real time and upgraded critical areas of their packaging processes using two key technologies: pneumatics and ultrasonic welding.

## Air Compressor Inlet Issues with Airborne Contaminants

Just as many ambient air issues with regard to the actual equipment operating environment are created by personnel and can be corrected by personnel, inlet air contamination is always created by humans and there is almost always a correction that will either eliminate the issue or mitigate the effect.

## Compressor Controls

As part of its ongoing corporate initiative to find ways to reduce its energy bills, and the costly

## Piping Storage

Moisture can freeze in compressed air systems and cause rust and pitting in pipes and components.

## End Uses

The dust is collected on the bag or fingers, and when the cake of dust is of appropriate thickness

## Pressure

Most industrial systems like compressed air have essentially random demand if you look at the long-

## Air Treatment/N2

Nitrogen is used in many facilities for a variety of purposes. The most common source of N2 is

## Leaks

One of the best ways to reduce compressed air costs is to look for ways to reduce leakage flow, an

## Pneumatics

Sustainability is a high priority for today’s consumer packaged goods (CPG) companies. Driven by

## Vacuum/Blowers

Operating the vacuum system at higher levels (then necessary) affects the needed volumetric flow to