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.
In general, this article focuses on the definitions of terms often used to understand centrifugal air compressor performance. Comments are also made on how to measure power consumption. This article is not intended to be an engineering discussion of the various types and designs of centrifugal and other air compressors.
Compressed air is dried to prevent condensation and corrosion which can disrupt manufacturing processes and contaminate products. Water is the primary promotor of chemical reactions and physical erosion in compressed air systems. A myriad of desiccant dryer designs have been devised to provide “commercially dry” air, air having a dew point of -40°F or less, to prevent corrosion. Desiccant dryers use solid adsorbents in granule form to reduce the moisture content of compressed air.
High speed bearing technology is applicable for aeration blowers operating at much higher speeds than the typical 60Hz, 3600RPM for cast multistage units. High Speed Turbo (HST) units are usually single stage (though some utilize multiple cores) and rotate from 15,000 to 50,000RPM. At such high speeds, standard roller bearings cannot offer the industry standard L10 bearing life. Two types of bearing technologies have come to dominate the wastewater treatment market for these types of machines: airfoil and magnetically levitated. Often the two technologies are compared as equals, however, in many significant ways they are not.
Quite often the typical variability in compressed air flow demand does not proportionately translate into power reductions at the air compressors. This can be a result of numerous problems with the compressed air supply system. It is important to understand the supply-side’s ability to respond to the demand-side of the compressed air system. If the air compressors, on the supply-side, are not able to translate flow reductions into energy savings, implementation of demand reduction projects should be re-evaluated.
This article defines different aspects of regulator design and how they affect air wasted by droop. Some ways to reduce droop have be shown and some special case situations discussed. By taking care with regulator selection and installation, regulators can save large amounts of air instead of wasting it.
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.
It’s one thing to move materials during the production process, but when it’s a finished product on the packaging line, choosing the right material handling system is essential. Getting it wrong results in squandered production time when product loss occurs, and wasted raw materials.
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.
Rotary screw air compressor that makes its own lubricant from the surrounding air delivers oil-free compressed air to an environmental laboratory in Stuttgart, Germany - Many sensitive sectors of industry require oil-free compressed air. However, meeting this demand is often not as simple as it sounds. One way is to use oil-injected air compressors with downstream air treatment to meet the demand. A second option is oil-free air compressors, which operate without lubricants. Both versions have their own advantages as well as risks. Another alternative is to use rotary screw air compressors that use water as a lubricant.
When some people think about compressed air, they imagine the big, loud, dirty, unreliable machine in the back corner of their facility. Many businesses around the world rely on compressed air, and an unreliable air compressor can mean stopping an entire facility, costing thousands of dollars in lost productivity and repair labor. Additionally, that loud machine in the back corner is also a major energy consumer. So much so that many industry professionals refer to it as the “fourth utility.”
The 2016 AICD (Association of Independent Compressor Distributors) Conference & Exhibition was held May 15-17 in Chicago, Illinois. This first-class event recorded new highs for both member attendees and the roughly 76 exhibitors. AICD President Phil Kruger, the General Manager of Harris Equipment, said, “We strive to bring information, products and networking opportunities to our members, to make each member a stronger business. We also see ourselves as an association able to bring manufacturers and distributors together for mutual benefit."
Figuring out the energy savings for the switch from pneumatic to electric tools requires an estimate of energy use for each case. The effect of replacing a few tools in a large compressed air system may be too small to detect using power monitoring on the air compressors. However, it is still a good practice, and when part of a larger program to reduce air consumption, the combined efforts will amount to something measureable. Another positive aspect may be that reduced compressed air use frees up needed air compressor capacity.
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.
Compressed Air Best Practices® (CABP) Magazine and the Compressed Air and Gas Institute (CAGI) cooperate to provide readers with educational materials, updates on standards and information on other CAGI initiatives. CABP recently caught up with Rick Stasyshan, Technical Director for the Compressed Air and Gas Institute (CAGI) to provide readers with some insights into the benefits of CAGI’s Verified Performance Program for refrigerated compressed air dryers.
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.
In the food and beverage industry, the moment a product leaves the production line, the clock starts ticking down to when that product will no longer be viable for sale or consumption. To combat the clock, modified atmospheric packaging (MAP) techniques are used to help maintain product freshness and increase shelf life. Nitrogen is the most cost effective, efficient and widely used industry solution for a company’s packaging needs—whether it is for manufacturing cheese, coffee, dried snack foods, or fresh and ready-to-eat (RTE) foods. MAP also helps to decrease chances of contamination or spoiling, keeping products on the market for longer and ultimately increasing the reach of distribution.
Plastic injection molding is a common process in manufacturing, and it can be used to produce just about anything. To create a part, molten plastic is injected into a hollow mold, where it is formed and cooled before being ejected from the cavity. Plastic injection molders make a seemingly limitless range of products, from fishing tackle boxes and kayak paddles to tooth brushes and miniscule medical devices.