Industrial Utility Efficiency

Air Compressors

When selecting an air compressor for your manufacturing operation, the common choice is the industry-standard rotary screw compressor. Known as the work horse of compressed air machinery, the rotary screw compressor comes in a multitude of sizes and power levels. However, centrifugal compressors have seen some exciting technological progress in recent years and offer a wide range of pressures, flow and turndown. Long known for their longevity and durability, they offer higher efficiency, even qualifying for energy rebate programs offered by local utilities and all, notably, produce Class 0 oil free air.

Distributor Profile: Northwest Pump & Equipment

Northwest Pump & Equipment was founded in 1959 - opening three branches on the same day in Portland, Seattle and Spokane. The business focus was to distribute petroleum equipment for the oil and gas market – primarily to service stations and oil jobbers. In-ground fuel tanks, hoists, lubrication equipment, lighting, farm pumps, air compressors and other gas pumping equipment were our primary product lines back when there were “Full-Service Gas Stations”. Over the years, this successful business model was expanded so the Company did business in California, Hawaii, Washington, Alaska, Arizona, Nevada, Idaho, and Montana.

Cornstarch Processor Saves $123,000 in Energy Costs

This is a corn mill processing cornstarch, sugar, and other byproducts. Ambient air is contaminated with extremely high levels of dust due to the manufacturing processes and material handling. Average electric rates at the plant are \$0.04 / kWh. The actual plant electric cost for compressed air production is \$553,630 per year.

Optimizing Centrifugal Compressors at a Glass Bottling Plant

This glass bottle production plant had a complete compressed air audit in 2001 and 2002 at which time many successful projects reduced and stabilized the demand at 3,148 scfm at 95 psig for the high pressure system air and 9,300-9,500 scfm at 58 psig for the low pressure system. Successful application of an oversized 7,200-scfm rated cycling refrigerated dryer completely dried up the high-pressure air, allowing the removal of several non-performing desiccant dryers and savings in direct kW and purge air.

Your Air Compressor May Be Smarter Than You Think

Not long ago most air compressors were controlled with mechanical pressures switches, relays and gauges. The setup of these units, especially when attempting to coordinate multiple compressors could be a frustrating and fruitless experience because often, no sooner than the controls were correctly adjusted, some sort of mechanical gremlin would throw something out of adjustment again.

Air System Pressure Influences Compressor Power - Part 3: The Influence of System Pressure on Compressed Air Demand

Energy conservation measures (ECM) associated with compressed air have received a significant amount of attention over the years, mostly due to a reasonably short financial return compared with other energy consuming equipment. Over time many of the corrective actions put forward to reduce compressed air energy consumption have been simplified with the goal of encouraging action. Although this is done with the best of intentions, sometimes simplifications and generalizations do not necessarily lead to positive results. One of the most common energy conservation measures for compressed air that leverages best practice calculations involves reducing system pressure. It is the objective of this series of articles to highlight some of the more common issues associated with estimating energy conservation resulting from changing system pressure.

A Compressed Air & Gas Institute Session - Heat Recovery from Industrial Compressed Air Systems

The rise in energy prices is an unwelcome reality in today’s manufacturing and business environment. And while the rate of price increases for natural gas, heating oil and electricity may vary from year to year, the upward trajectory is clear. Energy cost reduction strategies are vital to staying competitive. Compressed Air Best Practices® Magazine recently discussed heat recovery, from industrial compressed air systems, with the Compressed Air and Gas Institute (CAGI) and with CAGI member – Wayne Perry, Technical Director of Kaeser Compressor. Their inputs should provide you with some insight in energy-saving technology.

Air Compressor Heat Recovery

When compressed air is generated, heat is inevitably produced as a by-product. Anyone looking to enhance efficiency can use this heat and increase the efficiency of compressors to about 95 percent as a result. To achieve this, there are easy-fit heat exchangers which can be fitted to existing air compressor stations. This investment often pays for itself within less than a year.

 

Air System Pressure Influences Compressor Power - Part 2: The Influence of System Pressure on Centrifugal Compressors

It is common to see energy assessment specialists treat centrifugal compressors like positive displacement compressors when attempting to reduce compressed air system energy consumption. Unfortunately, centrifugal compressors are normally much larger, and miscalculations can easily represent hundreds of thousands of dollars in overestimated energy savings. These errors are not malicious; they result from oversimplified best practices perpetuated by individuals with limited centrifugal compressor knowledge. This type of knowledge is not readily available and most energy assessment specialists do not have access to engineering teams responsible for the technical development and design of centrifugal compressors.

Innovative Dual Pressure Control Improves Efficiency

Grand Manufacturing, a small community owned Canadian agricultural products manufacturer, has upgraded their compressed air system as a result of a production expansion, yet increased the compressed air energy efficiency 61% by consolidating their system and implementing an innovative dual pressure control strategy.