Sitting on his desk the day Brian began his new job as Plant Engineer for Carbo Ceramics’ McIntyre, GA facility was a proposal to purchase a new 150 HP air compressor as a backup machine. The facility already had six of these machines and, yes, all six ran almost continuously.
In late October 2023, professionals from around the world gathered at the Best Practices 2023 EXPO & Conference at McCormick Place in Chicago, Illinois to source and learn about Sustainable, Safe and Reliable On-Site Utilities Powering Automation including compressed air, blowers, vacuum, pneumatics, motors and cooling water systems.
Swiss brush company Ebnat-Kappel uses non contact transfer technology from Bosch Rexroth to automate a problematic section of its packaging production process.
Roxane Laboratories, Inc., a subsidiary of Boehringer Ingelheim Corporation located in Columbus, Ohio, created a world-class air system that generated \$61,314 per year in electrical energy cost savings (1,156,868 kWh), improved productivity and quality, and allowed the successful completion of a significant plant expansion.
The secret to success is to understand the nature of what type of leak produces a detectible ultrasound and what does not, along with the techniques that can be used for effective leak identification.
Industrial plants are major consumers of water. Water is used in many processes. Sustainability projects focus on reducing the consumption of water and the energy-costs associated with cooling water so it may be effectively used.
This aluminum mill spends \$369,000 annually in energy costs to operate their compressed air system. This system assessment recommends actions reducing annual energy costs by \$120,000 and improving productivity and quality by delivering clean, dry compressed air.
Desiccant dryers are commonly used to bring the pressure dewpoint well below freezing (commonly -40°F) in order to prevent moisture from precipitating in the compressed air system and production equipment.
Compressed air dryers are important items to consider when evaluating the efficiency of a typical compressed air system. One of the keys to optimal system operation is ensuring the air is only dried to the level required by the actual needs of the facility.
Most facilities don’t prioritize the cost of operating compressed air systems—they just want to get the job done. A recent market study1 found that only 17 percent of compressed air users valued efficiency as a compressed air system management goal. Nine percent were concerned with containing energy costs. Seventy one percent simply wanted to deliver a consistent, reliable air supply.
This article reviews two major processes in paper mills: compressed air quality and air compressor cooling. The central air compressor room was expanded and relocated at the largest privately owned paper mill in Canada. The compressor space was required by a plant expansion, which would occupy the original compressor space for increased production.