Industrial Utility Efficiency

# System Assessments

This article discusses some experiences in using cellular connected data loggers to perform a compressed air assessment during a time when travel was restricted. While not ideal, this exercise identified huge savings for this customer.

## Zinc Producer Reduces Compressed Air Use by 1,090 scfm

A zinc producer spends an estimated \$516,000 annually on electricity to operate the air compressors in a compressed air system at its north American plant. The current average electric rate, at this plant, is 5 cents per kWh, and the compressed air system operates 8,760 hours per year. This system assessment recommended a group of projects able to reduce these energy costs by fifty-one percent (51%) to an annualized \$270,000.  The simple payback of the project was 15 months – without taking into account potential incentive dollars from the local utility.

## Air Compressor Control at Remote Mining Complex

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.

## Great Plains and Air Capital Equipment Monitor Great Savings

Great Plains has carved a global reputation for producing world-class seeding equipment since it first opened its doors in 1976. Great Plains manufactures a range of products from grain drills and planters, to compact drills and tillage equipment. They have established an international business built on expertise, knowledge and a commitment to producing products meeting the rigorous demands of the agricultural sector.

## Compressed Air Assessment Finds Problems at a Meat Processor

A meat processor, located in Canada, hired a consultant to assess their compressed air system as part of a company-wide energy conservation effort. The assessment and analysis showed, despite having a modern compressed air system using a VSD air compressor and pressure/flow control, the system was running inefficiently and had significant levels of leakage and inappropriate use.

## International Wire Compressed Air System Upgrade Recovers Heat

While late summer may not be the time of year many of us think about heat recovery, the potential for energy savings in compressed air systems should be on our minds year-round. For those involved with the compressed air systems within International Wire Group’s facilities, energy savings is on their minds each day. This culture of continuous improvement has everyone on the lookout for savings wherever possible.

## Canadian Steel Processor Optimizes Compressed Air at Two Facilities

A steel distribution and processing company has upgraded and consolidated the compressed air systems in two of their distribution and processing facilities for big energy savings. The previous compressed air systems were running in modes of operation with very low efficiency. A complete replacement of the two systems with new air compressors and dryers has reduced the energy consumption significantly.

## Understanding Controls for Multiple Centrifugal Air Compressor Systems

Load-sharing is an important part of a multiple centrifugal-compressor master control system. It minimizes blow-off based on the available turn-down. In addition, remote start-stop saves more energy if load floats between different ranges. Finally, adding a screw compressor and implementing a hybrid control system might save the most energy and provide the best back-up. In any case, a well-instrumented system allows engineers and operators to assess, optimize and tune the system.

## Compressed Air Audit Discovers Problems at Electronics Firm

An electronics manufacturer with a very large compressed air system recently had a compressed air audit done in their plant to assess system efficiency. The audit discovered the system had been designed to be extremely efficient, yet some previously undetected problems were causing less than optimal operation. Despite being located in a tropical environment, this plant utilizes heat recovery to help reduce the overall energy consumption.

## Nitrogen, Vacuum and Compressed Air at a Snack Food Plant

This plant has three production lines producing snack food. Depending on the time of year and production demand the plant can operate anywhere from no production lines to all three production lines. A thorough supply and demand-side system assessment was done at this plant. This article will focus on some recommended demand-side reduction projects including nitrogen generation, air vibrators, leaks and vacuum venturis.

## Master Controls for Multiple Air Compressor Systems with VFD Compressors

When a system has the right combination of VFD and base-load air compressors, how do you coordinate their control? What tells the air compressors to run and load, to have just enough (or no) base-load air compressors and a VFD running, all the time air is needed? Appropriate master controls are needed. These controls are often called “sequencers” or “master control systems”.

## 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

There are a tremendous variety of unique and creative ways people in the food industry have

## Pressure

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

## Air Treatment/N2

Regular testing of pure gases helps to ensure the safety of consumers and of end products. Whether

## Leaks

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

## Pneumatics

In manufacturing and packaging facilities that rely on pneumatics, there’s a four-letter word worse

## Vacuum/Blowers

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