Industrial Utility Efficiency

# Technology

Conventionally when we talk about oil lubricated screw air compressor maintenance, it is mostly about replacing consumables such as filters and lubricant on time. While these consumables have a defined usable life and have a direct effect on the efficiency and the life of the air compressor itself when not replaced on time, there are a few critical valves in the air compressor that require maintenance as well.

The plant upgrades, in combination with a progressive management strategy, allows the plant to consume less energy and reduce its reliance on outside contractors for biosolids removal, resulting in total operational savings of approximately \$60,000 per year. The plant is also positioned to efficiently manage the area’s wastewater for decades to come. ## Don’t Overlook Tubing Volume with Manifold-Mounted Pneumatic Valves To Conserve Energy The advent of manifold-mounted, plug-in pneumatic valves has been a boon for machine builders. It allows them to mount complete valve packages in a safe and secure location on a machine. Using a D-sub connector, serial interface module, or similar single-point wiring system, all of the electrical control outputs can feed into one location on the manifold, greatly simplifying the wiring. ## How to Implement Aseptic Technique in Microbiological Compressed Air Testing In modern and industrial work settings, people spend more than 90% of their time in enclosed spaces, such as warehouses, office buildings and factories. In most indoor environments, the air contains a variety of chemical and microbial particles, commonly defined as indoor pollutants, which can severely affect human health and product quality (1). Industries like food and beverage, medical devices and pharmaceutical manufacturers rely on their scheduled compliance testing to confirm the presence or absence of issues in workflow pipelines that are detrimental to the daily output and safety of the product. ## Automaker Saves$600,000 Yearly In Energy Costs & Improves Compressed Air System Reliability

The project, which also involved the addition of a booster air compressor and receiver tank – along with the installation of an important pressure control valve – gives the automaker the ability to run fewer centrifugal air compressors during peak production. In so doing, the plant saves nearly 6.1 million kWh and more than \$600,000 per year in energy costs. The project also qualified for a \$369,374 rebate from the local utility, resulting in a six-month project payback – all while improving system reliability.

## A Tale of Two Cities - Comparison of Fixed-speed and VSD Compressed Air Systems

The compressed air system at the mail sorting facility has been in service since the 90’s. Two older 50-horsepower (hp) air-cooled fixed-speed lubricated air compressors are housed in the equipment room of the facility. The air compressors duty cycle alternates between one another on a set schedule. A 240-gallon wet storage receiver is used to help with air compressor control, with the air flowing through the receiver to a non-cycling refrigerated air dryer and system filters before finally being passed to the plant.

## Chemical Packaging Plant Shaves 41% Off Annual Electric Bill with Compressed Air Energy-Saving Measures

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.

## Reducing the Global Warming Potential of Refrigerated Compressed Air Dryers

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?

## Profile: Case Controls and Centrifugal Air Compressor Management

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.

## Filling the Gap for Air Compressor Service Technicians

As demand for compressed air use continues to grow, the future looks bright for distributors who design, sell, install and service compressed air systems. But perhaps only one thing stands in the way of continued growth and profitability for the vast majority of distributors throughout the United States: the shortage of experienced air compressor service technicians.

## Reducing Brewing Costs with Onsite Nitrogen Generation

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.

## Air Compressors

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

## Air Treatment/N2

Modified Atmosphere Packaging (MAP) accounts for a significant amount of nitrogen usage in the food

## Blowers

The plant upgrades, in combination with a progressive management strategy, allows the plant to

## Compressor Controls

A large chemical plant in Celje, Slovenia, planned to retrofit a kiln used to produce titanium

## Instrumentation

In this article we clarify how the main KPIs can be monitored, and we will have a closer look at a

## Pneumatics

The industrial internet of things (IIoT) and industry 4.0 have digitally transformed the way

## Vacuum

It’s one thing to move materials during the production process, but when it’s a finished product on

## Cooling Systems

With efficient heat exchange an important requirement in the design of an HVAC system, the type of