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.  

Saint-Gobain Makes Solving Sustainability Competitive and Fun

Challenging teams of employees to generate energy savings while having a good time in the process is the idea behind Saint-Gobain’s “Compress It,” which is the name given to the company’s competition and ongoing effort to reduce compressed air energy and costs. The initiative, which Saint-Gobain rolled out to manufacturing plants throughout North America in 2018, has been met with success. Compress It identified potential energy savings amounting to 26 Gigawatt-hours (GWh) of electricity and \$2.5 million.

Tier 1 Automotive Supplier Saves Energy Upgrading Centrifugal Air Compressor Controls

A Tier 1 automotive supplier was concerned its compressed air system was not operating as efficiently as it could be. The situation called for a site visit and metering and evaluation of the company’s air compressors to generate a representative data sample that accurately captured the compressed air needs during typical production and non-production periods.

Heat of Compression: A Major Energy Recovery Opportunity Often Ignored

Often when you mention heat of compression the first thought generally relates to HOC desiccant dryers, which are also an under-applied opportunity for heat recovery. However, there are many other heat of compression recoverable energy savings opportunities in all compressed air and gas systems. This article reviews many opportunities in energy heat recovery and provides answer to commonly asked question.

How to Avoid Control Gap with VFD Rotary Screw Air Compressors

Air compressors need to be matched to load effectively and efficiently. If the air compressors’ range of variation can’t be matched to the system variation, instability and/or inefficiency can result. This article discusses the problem when it isn’t matched, which is called “control gap” and what to do to avoid it.

Winpak Reduces Demand by 33% and Switches to Oil-Free Air Compressors

By making changes primarily focused on compressed air uses, Winpak, an international plastics products manufacturer based in Winnipeg, Manitoba, Canada, increased compressed air production capacity and reduced annual energy consumption by 33%. These benefits have been accomplished while the company was making the switch to lubricant-free compressed air to support product quality goals. This article discusses some of these changes and addresses measures that could be implemented in any compressed air system.

IUE-CWA Labor Union Members Embrace Energy Treasure Hunts

Manufacturers familiar with the U.S. Environmental Protection Agency (EPA) ENERGY STAR® Energy Treasure Hunts initiative know it’s a great way to save energy and natural resources – as long as it’s done right – which is why some are turning to perhaps their best asset to achieve success: their unionized workforce.

Protect Profits with Compressed Air Leakage Best Practices

This article discusses leak assessments and the barriers to effective leak management. Some best practices will be discussed as suggested tips to help you get the most of your leakage reduction efforts. We all hear it time and time again, leakage reduction is one of the first things we can do to reduce compressed air system electrical costs. Yet almost every industrial compressed air system assessment finds high levels of leakage, and too often plant maintenance staff are fully aware they have a problem but fail to act.

Avoiding Control Gap with Centrifugal Air Compressors

Have you ever wondered how to stay “in control” of an engineering organization with a fixed staff and a varying workload, where the engineers all have a mind of their own? “Herding cats” is what they call it.  Of course, that’s normal, right? Well, controlling multiple centrifugal air compressors is pretty close to that model, which can lead to a condition known as “control gap.”  This article discusses the reasons for control gap with centrifugal air compressors and solutions to help avoid it.

Compressor Controls

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

Piping Storage

Since completion of the system upgrade in the fall of 2020, PC Forge is on track to save an average

End Uses

The purpose of this article is to show there isn’t always a proportionally linear relationship

Pressure

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

Air Treatment/N2

Just as many ambient air issues with regard to the actual equipment operating environment are

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