Industrial Utility Efficiency    

Vacuum/Blowers

Operating the vacuum system at higher levels (then necessary) affects the needed volumetric flow to compensate for leaks. This required compensation of volume (ACFM) must be added to the nominal production flow demand. The ambient air leak into the system will expand to the highest vacuum level, which is known as the “Expansion Ratio.”
Air cannons, also known as air blasters or just “blasters” belong to a family of products known as flow aid devices. For over 30 years, air cannons have been used widely in industries such as cement manufacturing, electric power generation, coal, metal, and non-metal mining, and pulp and paper manufacturing.
In February of 2008, a sugar plant near Savannah, Georgia suffered the ultimate tragedy. Fouteen employees were killed and 40 injured when finely ground motes of sugar dust ignited, setting off a violent blast. If the fatalities and a tarnished reputation weren’t enough, the Occupational Safety and Health Administration (OSHA) then fined the company more than 8 million dollars in workplace violations related to combustible dust.
Utilities have been cleaning their boilers for many years using either steam or high-pressure air.  In the past, when air was used, due to the size of the boilers and the reasonable quality of fuel used, a relatively small amount of cleaning was required.
Relatively few people realize that for a variety of industrial manufacturing applications, from air knife drying to simple blow-off nozzles, the use of high pressure compressed air that bleeds into the atmosphere represents a significant waste of energy.  
This steel processing facility has been operating for over one hundred years.  This facility is part of a large corporation with numerous plants around the world.  This audit focused on the compressed air system on one side of the Works which we will call the “North Plant”.