Industrial Utility Efficiency    

Technology

Introduced in the 1960s and operated successfully worldwide, the Heat of Compression (HOC) Desiccant Dryer has been a viable and successful compressed air drying technology for over 50 years.  In our ongoing series on missed-demand opportunities, we’ll discuss basic operating parameters of HOC dryers and shed light on common misperceptions associated with the technology.

Air Compressors

After getting its start manufacturing cost-effective products to the healthcare industry, 40 years later, 1888 Mills has become the fourth largest towel manufacturer in the world, and the largest towel manufacturer in the U.S. With facilities in the United States, Pakistan and Bangladesh, 1888 Mills’ towels are used in almost every corner of the world. 1888 Mills is recognized as a leader in innovation in the textile industry and produces 176,000 pounds of towels per week.

Air Treatment

Long gone are the days when cost and performance could be the only concern for companies manufacturing refrigerated compressed air dryers using refrigerant compressors. In 2019, accelerated governmental (Europe) regulations and a global concern for sustainability have brought new considerations to the table. What is the Global Warming Potential (GWP) of the refrigerants used in dryers and what is their environmental impact?

Blowers

High speed bearing technology is applicable for aeration blowers operating at much higher speeds than the typical 60Hz, 3600RPM for cast multistage units. High Speed Turbo (HST) units are usually single stage (though some utilize multiple cores) and rotate from 15,000 to 50,000RPM. At such high speeds, standard roller bearings cannot offer the industry standard L10 bearing life. Two types of bearing technologies have come to dominate the wastewater treatment market for these types of machines: airfoil and magnetically levitated. Often the two technologies are compared as equals, however, in many significant ways they are not.

Compressor Controls

Often, multiple centrifugal air compressors are set up to simply react to air demand, which requires the system to not only meet the new demand, but also make up for air depleted in the main header. This typically results in too much supply, which results in bypassing the air to atmosphere. The result is wasted energy use.

Instrumentation

In terms of compressed air systems, it’s not unusual to see a plant with 10 to 15 air compressors, each of which is rated to provide 3,000 to 4,000 scfm of air. The air is used for everything from moving product, to powering pneumatic tools, pumps, and fans, to cleaning. There are easily 1,500 pneumatic control valves at a single plant.

Pneumatics

For more than 20 years, Hungarian-based Doroti Pack Ltd. has specialized in the production and servicing of state-of-the-art packaging machines. Their focus is on developing, manufacturing, producing and selling premium-quality packaging equipment, including their line of DorPack thermoforming machines which are often used for food products such as fresh meat, fish, dairy products, bakery ware, confectionery and ready-cooked foods. Dorati Pack chose to incorporate Aventics pneumatic components in latest thermoforming machine for optimal productivity and machine longevity.

Vacuum

It’s one thing to move materials during the production process, but when it’s a finished product on the packaging line, choosing the right material handling system is essential. Getting it wrong results in squandered production time when product loss occurs, and wasted raw materials.

Cooling Systems

As a result of compressed air awareness training and a focus on energy management, two facilities in different parts of the world have reduced their compressed air demand substantially by removing vortex style cabinet coolers from some of their electrical panels and reworking the cooling systems.  These facilities were previously unaware of the high cost of compressed air and how much could be saved if other methods of cooling were used. This article describes some of their efforts in demand reduction.
A chemical packaging facility had done everything right when they last upgraded their compressed air system a few years ago. They installed a Variable Speed Drive (VSD) air compressor and implemented other energy efficiency measures, but plant expansions caused increased system demand, which exceeded the capacity of the system. The packaging lines were now seeing low pressure, causing shut downs in production. And projections showed plant demand would increase even further.
Brewing is normally broken down into four stages-malting, mashing, boiling and fermenting. The complex chemical processes begin with a few simple ingredients - hops, grain, yeast and water. Recently there have been technological advancements to safeguard that these steps are attained accurately, efficiently and with cost-savings. One particular improvement is the use of nitrogen during the brewing process. The addition of an onsite nitrogen generator allows brewers to reduce their nitrogen costs, eliminate downtime, and reduce safety risks related to bulk gas cylinder delivery and changeouts.
Experienced auditors become wary when they see desiccant dryers installed in customers’ plants. These dryers are required when a plant needs instrument-quality compressed air, or when compressed air piping is exposed to freezing temperatures. However, while desiccant dryers can gain this level of quality, the energy cost of stepping up from a dewpoint of 35 oF to a level of -40 oF increases quite considerably. To attempt to reduce the energy costs of drying to these low levels, heated blower desiccant styles may be used. This article describes three common desiccant dryer types, as well as some experiences, good and bad, with heated blower types.
Compressed Air Best Practices® interviewed Sang Woo Lee, CEO of Coaire Corporation. I had enough experience with compressors used in refrigeration to see there was a lot of area for growth, particularly with scroll technology given that its an oil-less air compressor in addition to its efficiencies, noise level and ability to offer customers longevity. I also liked that Coaire has a long history of innovative air compressor technology. In 1968, it became the first Korean company to develop and manufacture a reciprocating air compressor. Later, it became the first Korean manufacturer of rotary screw air compressors, which occurred after it established ties with SRM to develop unique airend technology.
In most industrial plants, data is everywhere. It resides in flow through pipes, pressure in tanks, vibration on rotating equipment, temperatures in heat exchangers, and electrical energy power consumption in motors. If we can acquire this data and make sense out of the patterns we can take actions to make our plants more efficient and reliable.
To address a mandate for cutting operations energy usage at facilities by 25 percent without major capital expenditures, a major manufacturing company set its sites on better control of its compressed air systems.  The project, implemented at 10 manufacturing plants over the course of three years, saves the company $977,093 annually in energy costs – and was completed with zero out-of-pocket costs.
Held September 16-19, 2018 in Chicago, the first-ever event drew 750 attendees who came together to learn and share ideas about the countless ways to achieve efficiencies with compressed air, blower, vacuum and cooling systems – and in the process – save energy and improve profitability.
Many food processing plants are already using oil-free compressed air at a low-pressure dewpoint. This has required the use of two-stage oil-free screw air compressors, centrifugal air compressors and other technologies, as well as regenerative dryers of one type or another. The most common oil-free air compressor in industry is the two-stage “dry screw” machine and the most common regenerative dryer type is the heatless type. These are combined in many food processing, pharmaceutical, and high-tech plants.    
Compressed Air Best Practices® Magazine interviewed Bob Groendyke, Vice President and General Manager, of Hertz Kompressoren USA. Hertz Kompressoren USA is headquartered in Charlotte, N.C. We’re a premium brand of the Dalgakiran Group Company, a leading international compressed air sales and service producer with a well-established worldwide network. Our parent company was founded in in Turkey more than 50 years ago and currently sells and services machines in 130 countries. Hertz Kompressoren has built a solid reputation by creating and manufacturing high-quality products offered at reasonable prices to satisfy our worldwide customer base.
Machines for filling milk or juice must often work around the clock. Given the critical importance of uptime, Elopak opted for Aventics food-compliant pneumatics when developing its E-PS120A - the first fully aseptic filling machine for gable top packaging. With an output of up to 12,000 cartons per hour, disruptions and downtime are not welcome with the aseptic filling machine.