Industrial Utility Efficiency

Technology

An air compressor is synonymous with an electric heater – providing compressed air as a side effect. 85-90% of the electrical energy taken in by the air compressor is converted into heat, while the maximum efficiency of compressed air generation is less than 10%. In air compressor heat recovery systems, the focus is on capturing the heat energy contained in the oil, as up to 80% of the energy extracted from the power plant is found there.

A Case for Using Compressed Air Flow Meters

To accurately assess compressed air systems, it is best to gather as much information as possible, for as long as practical so a clear picture of the operation of the system can be formed. The basic equipment needed includes pressure and amp/power data loggers, but in the past decade some excellent advances in instrumentation design has made very affordable flow meters available. This article discusses using flow meters for an example compressed air assessment.

Moisture: the Assassin in Compressed Air Installations

Moisture can freeze in compressed air systems and cause rust and pitting in pipes and components. It can also flush out the lubricant resulting in accelerated tool wear and damage to valves and cylinders. Moist air is also a rewarding breeding ground for bacteria, which especially in the food and pharmaceutical industries can lead to product rejection and costly production downtime. It is therefore strange that many companies limit themselves to measuring only basic quantities such as pressure, flow and (absorbed) power.

Compressed Air Systems and Rocket Science

Would you believe the same technology used in the launching and controlling of a space rocket is also used in your compressed air system? Yes, in some cases, “rocket science” helps to solve problems in compressed air systems and ensures the performance of the installed units. In this article, we are going to explain the technology called the “Sonic Nozzle”, that combines a space rocket thruster and your compressed air system. Additionally, we are going to walk through a case study, step by step, to show how it works.

Achieving Sustainability Targets by Optimizing Compressed Air Use

By monitoring compressed air consumption using smart pneumatic sensors, companies can reliably reduce energy use and emissions. 

The digital transformation of pneumatic systems is one critical way that companies can improve operational sustainability. Advanced airflow-sensing technology provides compressed air monitoring and valuable insights that allow companies to control and significantly reduce the energy used to produce compressed air as well as related carbon emissions.

Metal Fabricator Measures Nitrogen Use, Receives a Surprise

Nitrogen is used in many facilities for a variety of purposes. The most common source of N2 is through the use of bulk liquid storage. A plant owner was recently surprised to learn that a large portion of his N2 was disappearing, without ever being used by his production process. This article discusses where it went and what we could do about it.

The 2022 AICD Show Report

The Association of Independent Compressor Distributors (AICD) held its annual show at the Westin Savannah Harbor Golf Resort & Spa in Savannah, GA in May of 2022. Participating distributor members and guest enjoyed a few days of networking events, trade show, speakers, the AICD Golf Tournament and more. 

Kaishan USA - All In with Global Manufacturing and Engineering Center

Today Kaishan USA, operates its global manufacturing and engineering center in Loxley, Alabama. The goal of the company, said compressed air industry veteran and Kaishan USA CEO Keith Schumacher, was to put the right pieces in place from the very beginning.

“To that end, we’ve invested $20 million in our facility and created a team allowing us to develop technologies and manufacture products not only for the Americas, but also for export globally,” Schumacher said.  

Lubricants for Centrifugal Air Compressors

Centrifugal air compressors efficiently convert energy utilizing a series of stages to compress and cool the air as it continuously flows through the unit. A centrifugal compressor imparts kinetic energy into the airstream by increasing the velocity of the air using a rotating element and then converts this kinetic energy into potential energy in the form of pressure. In between each stage of compression, the air is cooled, and excess moisture is removed to further increase the efficiency and air quality. 

Sensor Technologies Used in Dew Point Transmitters - Advantages/Disadvantages

Have you ever had a failing dryer in your compressed air system, ruining your production output, but it was not noticed until it was already too late? Dry compressed air is one of the most important quality parameters when it comes to process safety. When ambient air is compressed, the ratio of the humidity to the air volume will rise drastically. Therefore the higher concentration of humidity in the compressed air leads to a higher dew point temperature and the humidity is more likely to condensate at higher temperatures.

Why A Centrifugal Air Compressor May be the Better Choice

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.

Air Compressors

When selecting an air compressor for your manufacturing operation, the common choice is the

Air Treatment/N2

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Blowers

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Compressor Controls

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Instrumentation

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Pneumatics

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Vacuum

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Cooling Systems

This article will be of particular interest to industrial system operators unfamiliar with tankless