Industrial Utility Efficiency
Given that compressed air leak management programs are meant to save energy, reduce CO2 emissions, and generate ROI, DENSO’s Maryville, Tennessee, manufacturing facility can definitively say it has scored a trifecta when it comes to results – and reaped benefits beyond hard numbers alone.
The purpose of this article is to investigate the cause and effect that can occur when you reduce demand with no supply changes and the alternative which will produce positive, long term results which you can take to the bank.
When was the last time you visited your compressor room? A week ago? Several weeks ago? If you are like many, you went in for the last scheduled maintenance interval and have rarely been back since. Air compressors, dryers and other air system components have become more reliable and self sustaining from a maintenance standpoint with each generation, requiring less and less human intervention.
This textile plant uses compressed air in their knitting, sewing, and dye house operations and needed a system designed for the significant fluctuations in demand. Compressed air demand profiles were placed into four segments; 1st shift peak demand and minimum demand, and 2nd shift peak demand and minimum demand.
There are a variety of means factories can use to remove or “blowoff” moisture from a package. Open tubes or drilled pipe are often viewed as simple low-cost methods. However, there are considerable drawbacks to these approaches, most notably – increased operating expense. While they may be convenient and inexpensive in the short term, these approaches often cost 5-7 times more to operate than preferred alternatives.
Compressed air users looking for energy reduction often identify their air compressors as a prime area for savings potential. But …what about end uses? There are a large number of obvious measures that can be implemented, such as leakage reduction, reducing open blowing and eliminating inappropriate uses..however, there are other more technical opportunities available that involve properly specifying or redesigning existing pneumatic circuitry in compressed air operated machines and processes.
Most systems are sized on the supply side at many times more volume and significantly higher pressure than is actually necessary to support the real demand plus a fudge factor generally created out of fear. I am sure that had the OEM defined what is not only minimally necessary in terms of mass flow at density (pressure and temperature), but also with the intent of the highest possible efficiency, we would approach things very differently.
Recently, The Kroger Company’s Indianapolis bakery identified the use of compressed air in a blow-off and conveyor gap transfer as a major source of energy loss and cost waste. According to the U.S. Department of Energy, “inappropriate use” of compressed air like blow-off produces high pressure atmosphere bleed leading to significant energy loss and unnecessary operational costs. Carrying a 10-15% efficiency return (according to the Department of Energy), compressed air applications can often be achieved more effectively, efficiently and less expensively with alternative solutions using a high flow rate and moderate pressure.
This Midwestern prepared food company now spends \$269,463 annually on energy to operate their compressed air system. This figure will increase as electric rates are raised from their current average of 6.2 cents per kWh. The set of projects recommended below will reduce these energy costs by \$112,902 or 41%. In addition, these projects will enhance productivity and quality and reduce equipment maintenance costs. Estimated costs for completing the projects total \$146,102, which represents a simple payback of 15.6 months.
One major problem that causes severe damage or system failure for any water treatment station is water hammer shock waves. “Water Hammer” or “Hydraulic Shock” is a pressure surge or shockwave resulting when a fluid (usually a liquid but sometimes also a gas) in motion is forced to stop or change direction suddenly (momentum change). The reversed momentum then continues to multiply the further it travels before being stopped.
"The Numbers Don’t Lie". It’s a popular saying everyone has heard before, applied to a variety of situations – political statistics, figures backing up an athlete’s performance and budget data.
Thirty percent is a big number. Applied to the above scenarios, it could entail a landslide victory or a hitter gaining entry into the Baseball Hall of Fame. But just imagine, if the manager of a wastewater treatment facility were to trim 30 percent from their operating costs, he or she might also consider that a landslide victory of their own.
