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 Lafarge Cement Distribution terminal located in Winnipeg, Canada has significantly reduced the site electrical demand and energy charges by changing the way they transport their cement.  Two new low-pressure rotary screw air compressors have replaced two large high-pressure air compressors that previously powered their dense phase transport system.  The resulting power reduction has saved the company 46 percent in transport operating costs.

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 Best Practices® Magazine interviewed Mr. Warwick Rampley, the National Sales Manager for Sydney (Australia) based, Basil V.R. Greatrex Pty Ltd. It’s not every day one is asked to deliver a system able to provide both a reliable compressed air dew point of -80°C (-112°F) and high purity nitrogen.  We work with some excellent technology suppliers and have engineered a rather interesting system.  Although our firm was founded in 1919, this application is one of the most demanding we’ve encountered. Basil V.R. Greatrex is a unique company as we focus only on compressed air measurement, compressed air quality and compressed air efficiency.

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.
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.
As a result of compressed air awareness training and a focus on energy management, two facilities in different parts of the world have reduced their compressed air demand substantially by removing vortex style cabinet coolers from some of their electrical panels and reworking the cooling systems.  These facilities were previously unaware of the high cost of compressed air and how much could be saved if other methods of cooling were used. This article describes some of their efforts in demand reduction.
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.
A trio of stationary compressors produce 630,000 m3/hr of air for the oxygen plant at Pueblo Viejo gold mine in the Dominican Republic. The oxygen is used by its autoclave processing facility to treat roughly 24,000 tons per day of refractory ore for the 60/40 joint venture between Barrick and Goldcorp Inc., operated by Barrick as Pueblo Viejo Dominicana Corporation.
Compressed Air Best Practices® Magazine spoke with Mark Shedd, Head of Oil-free Air, Aggreko Rental Solutions - There are two distinct compressed air systems in a refinery or petrochemical environment: plant air and instrument air systems. Instrument air systems are almost always 100% oil-free air compressors on both the permanent and temporary systems. The demand for compressed air purity, in instrument air systems, is so high that the permanent install back-up system is usually nitrogen.
A Canadian chemical plant installed a large heated blower-purge style compressed air dryer, years ago, to condition the instrument air system against freezing temperatures.  The dryer selected was oversized for the connected air compressors and had unused on-board energy savings features.  A compressed air assessment revealed the site air compressors and compressed air dryers were running inefficiently and causing in-plant pressure problems.  Repairs to a compressed air dryer and the replacement of aging air compressors and dryers has reduced compressed air energy costs by 31 percent.
Atlas Copco has a long history serving the Houston-based energy and chemical industries with custom-engineered packages. The objective of this article is to show just a few examples of the custom applications typically engineered and manufactured in the Atlas Copco Houston operation. Opened in 2012, Atlas Copco Houston produces standard compressed air dryers as well as completely engineered air dryers for all markets. The air flow capacity of the dryers, produced at this location, vary from 5 to 12,750 scfm. This capacity range covers heatless, heated purge and blower purge air dryers.