Industrial Utility Efficiency    

Industries

A small Australian company, Basil V.R. Greatrex (BVRG), is shaking up the compressed air industry in Australia. While other companies focus on the sale of more and bigger compressed air production equipment, BVRG is helping customers reduce their compressed air system size and lower system flow by attacking waste, inappropriate use, and at the same time improving air quality.

Auto

This northeastern U.S. automotive manufacturing facility spends $269,046 annually on energy to operate their compressed air system. This figure will increase as electric rates are raised from their current average of .019 cents per kWh. The set of projects, in this system assessment, reduce these energy costs by $110,166 or forty percent. Reliability of compressed air quality, however, is the main concern in this plant and the primary focus of this system assessment.

Bulk

The plant air system consists of eight, single-stage, lubricated, Sullair rotary screw compressors. All units are in good working order.  Units 2, 3, 4 and 7 are water-cooled and units 6, 8, 9, 10 and 11 are air-cooled. The main plant air system has two primary compressed air dryers, a Thompson Gordon model TG 2000 refrigerated dryer, and a Sullair model SAR 1350 heatless desiccant dryer.  Both units are working according to their design. The TG 2000 uses approximately 11.2 kW and is a non-cycling type unit, and the SAR 1350 uses approximately 200 cfm of purge air to regenerate the wet tower. 

Food

A major poultry processor and packager spends an estimated $96,374 annually on energy to operate the compressed air system at its plant located in a southern U.S. state.  The current average electric rate, at this plant, is 8 cents per kWh.

Medical

In the U.S. as an example, the NFPA has taken the view that if your compressor draws in good clean ambient air, the air stays clean through the compressor, is then dried and filtered, when you deliver it to the patient it will be entirely satisfactory. After all, when you went into the hospital that’s what you were breathing and when you leave you will breathe it again!

Metals

FABTECH 2016, North America’s largest collaboration of technology, equipment and knowledge in the metal forming, fabricating, welding and finishing industries, welcomed 1,500 exhibiting companies and a total of 31,110 attendees from over 120 countries last week to the Las Vegas Convention Center.

Paper

Rockline Industries is one of the largest global producers of consumer products, specializing in wet wipes and coffee filters. The company contacted the Arkansas Industrial Energy Clearinghouse after identifying that the compressed air system in their Springdale, Arkansas facility was a potential source of significant savings. Experts from the Clearinghouse then began working with Rockline Industries, representatives of the electric utility, and a local compressed air vendor to perform a complete evaluation of the system.

Pharmaceutical

Compressed air is used in a number of processes in the food industry. It is used as an ingredient in whipped products such as ice cream, to slice or cut soft products and to open packagesbefore filling of product. Currently, food manufacturers are under pressure to validate the safety of all ingredients or processes for regulatory compliance, but unfortunately, there is currently no standard method to evaluate the microbial content of compressed air.

Plastics

A plastic product manufacturer spends an estimated $245,000 annually on electricity to operate the air compressors in a compressed air system at its plant located in a midwestern U.S. state.  The main manufacturing process is plastic extruding. The current average electric rate, at this plant, is 7 cents per kWh. The compressed air system operates 8,760 hours per year and the load profile of this system is relatively stable during all shifts.

Power

Nuclear power plants produce electricity for people, business and industry.  Electricity is produced in a similar fashion as fossil fuel (i.e., coal, oil, etc.) power plants, using steam to drive a turbines which spin an electrical generator, producing the electricity. 

Printing

The Trinity Mirror Group print works on Oldham is one of the UK’s largest newspaper printers. The nine presses in the facility produce around 1million papers every day, including the Independent, the Daily Mirror and a range of local, regional and sports titles. Printing on this scale does not come cheap in energy terms, however. The plant’s annual electricity bill is in the order of £1.5millon. With energy prices on the rise, and a strong desire to improve environmental performance and reduce its carbon footprint, the plant’s management has recently embarked on a project to cut energy use substantially.

Transit

In aerospace manufacturing, tiny details matter most. For instance, if proper torque is not applied to the screws and bolts fastening an aircraft fuselage, catastrophic failures can result. Compressed air is used to power the tools needed to apply that torque, making the compressed air system a critical part of the facility, though it largely stays behind the scene.

Wastewater

A replacement strategy for air compressors and blowers integrated into a system-level approach towards energy efficiency can deliver significant energy savings and optimize equipment performance. At the Victor Valley Wastewater Reclamation Authority, a blower replacement project yielded annual energy savings of more than 928,000 kWh and $98,000 in energy costs, while improving the reliability of its secondary treatment process. In addition, the agency qualified for important incentives from its electric utility — significantly improving the project economics and resulting in a 2.94-year payback.
The 2017 International Production & Processing Expo (IPPE) had a great year with 31,649 poultry, meat and feed industry leaders from all over the world in attendance, setting a new record. There were also 1,273 exhibitors with more than 533,000 square feet of exhibit space, another new record. The Expo is the world's largest annual feed, meat and poultry industry event of its kind and is one of the 50 largest trade shows in the United States. IPPE is sponsored by the U.S. Poultry & Egg Association, American Feed Industry Association and North American Meat Institute.
A plastic product manufacturer spends an estimated $245,000 annually on electricity to operate the air compressors in a compressed air system at its plant located in a midwestern U.S. state.  The main manufacturing process is plastic extruding. The current average electric rate, at this plant, is 7 cents per kWh. The compressed air system operates 8,760 hours per year and the load profile of this system is relatively stable during all shifts.
Paying close attention to compressed air use is paramount for identifying potential energy-saving projects. The engineering team at Ball Corporation has been well aware of this fact for years. An active member in the Environmental Protection Agency’s ENERGY STAR® program, Ball Corporation scrutinizes manufacturing processes to maximize the energy efficiency of compressed air systems in each of its plants.
At a Midwest window manufacturing plant, the cooling process for the plastic frame pieces, after leaving the extruder, was critical to process productivity and quality. Too much cooling air (or not enough cooling air) would generate scrap and rejected product. The plants’ 17 extruders and 55 separate blow-offs in these lines had similar cooling stations at the cooling boxes. They consisted of about three hoses at each exit frame angled down to the extruded piece moving past it. The compressed air flow was controlled by a manual control valve set by an operator. The operator used his experience to control the flow delivered and thereby control the product quality.
A major poultry processor and packager spends an estimated $96,374 annually on energy to operate the compressed air system at its plant located in a southern U.S. state.  The current average electric rate, at this plant, is 8 cents per kWh.
FABTECH 2016, North America’s largest collaboration of technology, equipment and knowledge in the metal forming, fabricating, welding and finishing industries, welcomed 1,500 exhibiting companies and a total of 31,110 attendees from over 120 countries last week to the Las Vegas Convention Center.
Metaldyne Performance Group (called MPG in this article) Plant 1 in Columbus, Indiana (formerly known as Impact Forge) has made significant efficiency improvements to their compressed air system.  With the help of their service provider, IAC Air Compression, MPG has implemented some innovative control on their existing air compressors, added new air compressors with variable capacity control, and tied everything together with a modern central controller.  This installation has been recognized for its wise use of power by their power utility Duke Energy.
The useful and various properties of nitrogen (N2) in industrial applications rank it as one of the most specified gases in industry. For the manufacturer, nitrogen options exist in the choice of delivery system, compliance with clean air standards, safety and purity. In researching these choices, manufacturers can accurately select the optimum nitrogen supply required, often at a considerable savings. Selecting purity levels of 99.99% or higher in many industries and applications ads a variety of costs, both financial and efficiency, which may be needlessly incurred.
Made from various combinations of hops, grain, yeast and water, beer is a drink that has been produced for centuries. But while the ingredients are simple, the chemical processes behind the drink are anything but. Through various reactions, barley becomes fermentable sugars that are then digested by the active yeast to produce carbonation and alcohol. Although the basic principles behind brewing are little changed since their advent, the technological aspects are much improved. Today, large stainless steel tanks are used for fermentation and wort aeration, and complex, automated systems help with everything from temperature regulation to bottling.
Compressed air optimization measures adopted by PTMSB have reduced the consumption of compressed air by 31 percent resulting in savings of about 3,761,000 kWh per year in energy consumption. The monetary savings are MYR 1,090,627 per year ($255,000 USD). The CO2 reduction is estimated at 2,735 ton per year.