Industrial Utility Efficiency    

End Uses

A chemical plant spends an estimated $587,000 annually on electrical energy to operate their compressed air system. In addition, the plant has an expenditure on rental air compressors of equal or greater size - but this will not be covered in this article. The plant was built in the 1940s and modernized in the 1970s. The plant generates its own power and serves many processes. The average cost per kWh is $0.0359.
Over the last several decades, Air Power USA has reviewed many various types of plastic injection molding operations throughout the U.S.
A recent comparative vacuum technology study performed by Dr. Kingman Yee, as part of a Chrysler Summer Intern Professors Program, found that air consumption could be reduced by 98% when equipping a robot’s end-of-arm tooling with COAXÆ technology and a Vacustat™ check valve.
This stamping plant is a 2.5 million-square-foot facility with over two thousand employees.  At the time of the assessment, the plant was processing approximately 1,600 tons of steel per day into automotive vehicle components and parts such as body parts.
Faced with rising energy costs, a large electroplating company sought to improve the efficiency and reliability of its compressed air system. After getting a quote from their vendor on a new 300-hp compressor to replace an existing unit, the company sought a comparison quote due to the significant investment the new compressor represented. Based on a recommendation from one of their customers, they turned to Scales Industrial Technologies.
Boeing Canada has replaced their onsite membrane style Nitrogen generator with a new more modern system with increased capacity and higher efficiency.  As a result, the company is now using minimal amounts of expensive liquid Nitrogen, and has reduced the energy cost per unit of gas produced by 83%.
Relatively few people realize that for a variety of industrial manufacturing applications, from air knife drying to simple blow-off nozzles, the use of high pressure compressed air that bleeds into the atmosphere represents a significant waste of energy.  
This steel processing facility has been operating for over one hundred years.  This facility is part of a large corporation with numerous plants around the world.  This audit focused on the compressed air system on one side of the Works which we will call the “North Plant”.
New Flyer Industries is a Winnipeg based heavy duty bus manufacturer, supplying vehicles to the US and Canadian markets.  The company specializes in vehicles with†alternative-fuel drives such as electric trolleys, gasoline-electric and diesel-electric hybrid vehicles; as well as standard diesel buses.