Industrial Utility Efficiency    

The System Assessment

Food

Replacing air compressors, dryers and filters with more efficient models has saved electrical costs

Plastics

The beverage industry has been using polyethylene terephthalate (PET) 2-liter plastic bottles

Paper

Rockline Industries is one of the largest global producers of consumer products, specializing in

Printing

Several days prior to our visit, during a cold winter evening, the lead air compressor in one

Pharmaceutical

The United States accounts for roughly half of the global pharmaceutical market. This certainly

Auto

This northeastern U.S. automotive manufacturing facility spends $269,046 annually on energy to

Bulk

Making cement is an energy-intensive process. In a cement plant, the electrical energy load can

Transit

Boeing Canada Winnipeg (BCW) has been recognized with the best improvement project of 2013 within

Metals

Quite a number of worst-case compressed air scenarios have been encountered over the years but none

Medical

In the U.S. as an example, the NFPA has taken the view that if your compressor draws in good clean

Power

Nuclear power plants produce electricity for people, business and industry.  Electricity is

Oil & Gas

Biogas is an extremely valuable energy source. Originating from biomass, sewage, plants and

Wastewater

Recently the capacity of the Las Palmas, California, waste water treatment operations were expanded
Making cement is an energy-intensive process. In a cement plant, the electrical energy load can reach up to 25 MW, consuming 185 million kilowatt hours of electricity annually. In addition, the plant consumes a large amount of coal and natural gas. CalPortland is an enormous producer of cement, concrete, aggregates and asphalt. With 80 facilities spanning five states across the western U.S., one might logically assume that CalPortland consumes a lot of energy.
As a reader of this journal, you are well aware that large compressed air systems often have significant wasted air — often from leaks — that represent tens of thousands of dollars of waste per year. However, it is our experience that the so-called “low-cost” measures identified often go un-repaired, while other more costly capital projects get funded. Why? With an ROI of a half year or less, they seem like IQ tests to many compressed air auditors.
Many thousands of dollars of annual electrical savings are being achieved worldwide using special purge reduction controls on desiccant air dryers. These controls reduce the expensive purge air that must flow through the dryer to regenerate the desiccant beds. But, unexpected problems with these controls can cause hidden problems that can reduce or eliminate the savings.