Industrial Utility Efficiency    

Technology

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.

Air Compressors

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.

Air Treatment

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.

Blowers

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.

Compressor Controls

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.  

Instrumentation

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.

Pneumatics

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.

Vacuum

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.

Cooling Systems

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.
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.
Sometime in mid-2015, I received a call from a project engineer at a major plastics firm. He had a troubling issue with one of his PET bottle plants. The bottom line was this: They could not run all five high production blow-molding machines at one time—even though they were able to do so 18 months previously.
Any modern food manufacturing facility employs compressed air extensively in the plant. As common as it is, the potential hazards associated with this powerful utility are not obvious and apparent. Food hygiene legislation to protect the consumer places the duty of care on the food manufacturer. For this reason, many companies often devise their own internal air quality standards based upon what they think or have been told are “best practices.” This is no wonder, as the published collections of Good Manufacturing Practices (GMPs) that relate to compressed air are nebulous and difficult to wade through.
Air-operated double diaphragm (AODD) pumps are common to many manufacturing facilities. As estimated by veteran compressed air auditor Hank van Ormer of Air Power USA, approximately 85 to 90 percent of plants in the United States have AODD pumps. They are used for all kinds of liquid transfer applications, like those found in chemical manufacturing, wastewater removal, and pumping viscous food products.
There is always something new to learn about compressed air systems – particularly in regards to compressed air dryer installations. As I discussed in Part 1 of this series, you can make compressed air dryer installations more reliable by understanding the consequences of any modifications you make to the system.  As a continuation of those ideas, Part II explores more ways to make a dryer installation more reliable. Discussions include: the difference between operating a desiccant dryer in a fixed cycle opposed to demand mode, what happens when you operate a heated desiccant dryer with the cooling air turned off, and how to deal with the unintended consequences of dedicating a desiccant dryer to a compressor. 
Compressed Air Best Practices® Magazine and the Compressed Air and Gas Institute have been cooperating on educating readers on the design, features, and benefits of centrifugal compressor systems. As part of this series, Compressed Air Best Practices® (CABP) Magazine recently caught up with Rick Stasyshan, Compressed Air and Gas Institute’s (CAGI) Technical Consultant, and Ian MacLeod of CAGI member company, Ingersoll Rand. During our discussion, we reviewed some of the things readers should consider when installing a centrifugal compressor system.
One of the statements made in the Compressed Air Challenge’s Fundamentals of Compressed Air Systems seminar is that improvements can always be made to every compressed air system, including new ones. The statement definitely applies to a Canadian pork processing facility built a few years ago. This article is based on a compressed air audit performed two years into the life of a brand new plant. The audit found numerous problems and made recommendations that helped reduce plant compressed air operating costs by 60 percent.