Industrial Utility Efficiency
The current cost to operate the compressed air system is \$139,100 annually, and the proposed measures will reduce it by \$50,700 annually. The proposed cost to complete the measures is $47,600 providing a simple payback of 11 months. The cost included in the Action Plan includes engineering, project assistance, services to maintain the gains, and a 10% contingency.
As in most industrial categories, compressed air is critical to the operations of a plastics plant whether it is blow molding, injection molding, or other processes. The opportunities to improve supply side (compressor room) efficiency are similar to all industrial compressed air systems, but are even more prevalent in some plastics facilities, especially blow molding.
Most P.E.T. bottle-blowing machines require anywhere from 550 psig (38 barg) to 580 psig (40 barg) and an air flow of 247 cfm FAD (420 m3/hr) to 3700 cfm FAD (6290 m3/hr). The air compressor technology used most prevalently for this application is the double-acting, oil-free, water-cooled, reciprocating air compressor. With the higher pressures and air flows that are required, the P.E.T. bottle blowing market is a strong niche market for the double-acting oil-free reciprocating (piston) compressors.
There are three main segments in Visteon's climate group are climate systems, powertrain cooling and engine induction. Climate systems include refrigeration compressors, fluid transport, heat exchangers, battery cooling modules, climate controls, auto defog/demist systems, and multi-zone HVAC systems. Powertrain cooling systems include heat exchangers (radiators, condensers, charge-air, exhaust-gas), airflow management, and diesel and hybrid thermal management. Engine induction includes air induction systems and intake manifolds.
Several days prior to our visit, during a cold winter evening, the lead air compressor in one mechanical room tripped off (apparently due to a fouled intake filter and low air flow through the machine). A crucial situation then developed: The "stand-by" unit did not start. Maintenance folks had to be called in to get a compressor running. That delay caused low plant air pressure, production curtailment and some defective product. They had yet to determine the conditions that caused the "no-start".
Encouraged by government regulators, the conversion to waterborne paints is now moving into the collision repair and refinishing industry. The conversion to waterborne paints is proving to have implications for the compressed air systems in the shops. This document provides a checklist of compressed air system topics to ensure a successful conversion to waterborne paints.
Nitrogen gas provides a number of diverse uses for a wide variety of manufacturers. As a sister function of compressed air, on-site nitrogen generation can provide additional opportunities for cost savings and other efficiencies for manufacturers who shift from delivered liquid nitrogen service.
Compressed Air Best Practices interviewed Doug Barndt (Manager, Demand Side Energy-Sustainability), Joseph Gress (Principal Engineer, Demand Side Energy) from Ball Corporation and Chris Gordon (Compressed Air System Specialist) from Blackhawk Equipment.
This article describes a compressed air retrofit project implemented at Kellogg’s Eggo factory located in San Jose, California. Kellogg’s continues to realize both annual energy savings and quality improvements because of the upgrade. In addition, Kellogg’s received a substantial utility incentive from Pacific Gas and Electric Company, which was based on the achieved energy savings.
Power Smart® efficiency measures for compressed air systems at Tolko’s paper mill and sawmill at The Pas are saving the company more than \$125,000 a year.
Pneumatic air cylinders play a major role in allowing a modern sawmill to produce at the high-speed production rates required. Stable air pressure is critical to allow the air cylinders to respond in a timely manner and avoid any production delays.
