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

Parrheim Foods, a division of Parrish and Heimbecker, is an innovative starch, protein and fiber mill situated in Saskatoon, Saskatchewan, Canada.  The plant has improved system efficiency and reduced production problems by addressing some problems with the consumption of compressed air by their reverse pulse baghouse cleaning operations.  This effort has allowed them to turn off one of their 100 hp air compressors, saving significant electricity costs.

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

A newly constructed ethanol plant experienced control gap issues shortly after comissioning.  This article discusses the cause of the issue and how the problem was solved.

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 design of wastewater treatment plants is changing, and it has something to do with LEGO® bricks. More specifically, it has to do with how large and complex LEGO structures are built. If you follow the instructions carefully, you build module after module, eventually piecing them together to create a fully functional and cohesive unit.
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.
Compressed Air Performance Specialists (CAPS Inc.) is a compressed air consultancy located in Calgary, Alberta. In its most recent compressed air project, the company reduced a 200-hp, multi-compressor system down to a single, 100-hp variable speed drive (VSD) air compressor utilizing 75 hp of compressor energy (kWh), resulting in $70,000 in annual energy savings.
A major snack food manufacturer spends an estimated $148,220 annually on energy to operate the compressed air system at its food processing plant located in the Mid-Atlantic area.  As electric rates rise from their current average of 8 cents per kWh, their annual expenditure will only increase.
Cement production facilities have a significant number of dust collectors. Many have continuing problems with short bag life and low-pressure problems at the further points from the central air system. They often run on timers. When they try to run on demand control, they often get extreme short cycling, which causes even more bag problems. Most have gauges at the entry, on at least half of the dust collectors, and the compressed air feed lines are always the same size as the connector opening. This article reviews where these problems come from and provides some troubleshooting ideas.
Vale in Thompson, Manitoba, Canada has reconfigured a system of large turbo compressors in their mining, milling, smelting and refining operation and gained very large energy savings through a series of improvement projects. In addition, these projects qualified for some significant financial incentives from their local power utility.  Vale is a large multinational mining company with headquarters in Brazil.  Vale operations focus on the production of iron ore, coal, fertilizers, copper and nickel.  The Thompson Manitoba operations consist of mining, smelting, milling, and refining of Nickel in the 250 acre complex that employs 1,500 people.
In our discussions with Stephen Titus and James Bowers, National Sales Manager of Titus Air Systems, we talked about several examples of how The Titus Company provided custom-engineered solutions to various customers. The diversity and complexity of these jobs exemplify how The Titus Company has grown from a small distributorship operating out of a townhome to a thriving compressed air and gas solutions provider capable of tackling highly nuanced applications.
Compressed air audits for chemical and petrochemical plants have many characteristics in common with audits in other industries, but there are some differences in the way these businesses run that impact the goals of the typical audit and how that audit is conducted. In chemical and petrochemical facilities, the reason for auditing the demand side is different than that of other industries. Additionally, there are frequently applications with opportunities for improvement that are not always seen in other industries.  
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.
In rural China, approximately 30 million households receive cooking fuel from super-small anaerobic underground digesters? China is just starting to look at industrial biogas upgrading in a serious manner. The market is in its’ infancy but we believe in five years it will be the biggest biogas market in the world. Incineration is not popular as it requires a lot of energy. Here we have many manure-based issues. Soil and water contamination in densely populated areas can lead towards anaerobic digester projects. Today there are very few projects although we are doing one right now in northern China.