Industrial Utility Efficiency    

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Outsourcing maintenance agreements for compressed air systems is commonplace in the food and beverage industry. The maintenance programs are often performed by air compressor distributors, who are experts in the specifics of the air compressors and compressed air systems they sell and service.

Auto

The project, which also involved the addition of a booster air compressor and receiver tank – along with the installation of an important pressure control valve – gives the automaker the ability to run fewer centrifugal air compressors during peak production. In so doing, the plant saves nearly 6.1 million kWh and more than $600,000 per year in energy costs. The project also qualified for a $369,374 rebate from the local utility, resulting in a six-month project payback – all while improving system reliability.

Bulk

Reverse pulse type dust collectors often represent a challenge to compressed air energy efficiency, and sometimes throw a wrench into the works by causing huge air pressure fluctuations, high transient flows and just plain large leaks. This article discusses this type of dust collector, often installed in food processing plants, and gives some real-life examples of problematic installations. Some suggested measures are mentioned to ensure your dust collectors keep running in a trouble-free manner.

Food

As a leading North American bakery company Weston Foods ensures its numerous facilities productively and cost-effectively produce high-quality baked goods. But it doesn’t stop there. It goes the extra mile to optimize and manage its utilities to conserve energy and protect the environment.

Medical

The air is delivered through a distribution piping system that ends with a medical air outlet within the room. Outlet requirements per room are governed by American Institute of America (AIA) Guidelines for Design and Construction of Hospitals and Healthcare Facilities. Equipment is plugged into the medical air outlet to treat the patient. Many studies have been done determining the load required for medical air compressors. The sizing can be calculated using several methods. 

Metals

The steel mill in this article is a rolling “minimill,” a facility that melts scrap recycled steel and produces rebar for the construction industry. It fits in SIC code 3310. There are many plants like this all over the world, providing an environmentally sound service and product for their local community. They recycle waste steel from local sources and support local infrastructure projects with rebar, using electricity generated locally.

Paper

Experienced auditors become wary when they see desiccant dryers installed in customers’ plants. These dryers are required when a plant needs instrument-quality compressed air, or when compressed air piping is exposed to freezing temperatures. However, while desiccant dryers can gain this level of quality, the energy cost of stepping up from a dewpoint of 35 oF to a level of -40 oF increases quite considerably. To attempt to reduce the energy costs of drying to these low levels, heated blower desiccant styles may be used. This article describes three common desiccant dryer types, as well as some experiences, good and bad, with heated blower types.

Pharmaceutical

Blood plasma is an indispensable resource in the production of life-saving medicines. It is also in high demand on global markets. To make more efficient use of this valuable commodity, Biotest AG developed a new large-scale production plant in Dreieich, Germany, for plasma fractionation capable of obtaining five instead of the previous three products from a single liter of blood plasma. As part of its strategy, Biotest AG worked with Festo to standardize automation components used at the plant, resulting in simplified installation and maintenance.

Plastics

The plant produces both molded and blow molded plastic parts on a 5 day per week, three shift schedule. Production and maintenance sometimes occurs on weekends, occasionally requiring the air compressors to run on a 24 x 7 basis so the practice was to leave the compressed air system always pressurized. The system consisted of three modulating lubricated screw compressors one sized at 150 hp and the others 125 hp (3 units), each controlled with their local compressor controllers.

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

When the New York City Transit Authority (NYCT) set out to comply with local regulations calling for reductions in energy usage, it leveraged new air compressors for use in transit bus maintenance and repair – and took things to another level by recovering air compressor waste heat to provide hot potable water for the bus depot. The air compressor and heat recovery system, installed in spring 2017, is on its way to helping NYCT achieve the best energy savings possible.

Wastewater

The plant upgrades, in combination with a progressive management strategy, allows the plant to consume less energy and reduce its reliance on outside contractors for biosolids removal, resulting in total operational savings of approximately $60,000 per year.  The plant is also positioned to efficiently manage the area’s wastewater for decades to come.
Helium is a precious noble gas that has become invaluable for leak detection, as well as cooling down magnets in medical equipment. This is why consumption of this essential industrial resource is increasing and its price is rising rapidly. To combat a looming shortage of this increasingly scarce resource, new methods of helium recovery are becoming more important than ever – as are specialized compressors for the same purpose.
Wastewater treatment processes have come a long way in the past century, but demand continues to grow for more reliable and efficient treatment technologies. As a result, industry professionals are searching for an all-encompassing solution to enhance their treatment plants and processes. One of the purest environmental aids on the market is oxygen.
When the New York City Transit Authority (NYCT) set out to comply with local regulations calling for reductions in energy usage, it leveraged new air compressors for use in transit bus maintenance and repair – and took things to another level by recovering air compressor waste heat to provide hot potable water for the bus depot. The air compressor and heat recovery system, installed in spring 2017, is on its way to helping NYCT achieve the best energy savings possible.
As many well know, system measurement is essential to ensuring a compressed air system is running efficiently and effectively, with good air quality and adequate pressure.  This is also well understood by a multi-national food company (name has been withheld to protect the innocent) who started a focused effort to measure and improve their compressed air systems in their many processing plants worldwide. 
Chicago Heights Steel, Chicago Heights, Ill., leveraged an advanced data monitoring system and adopted a demand-based compressor air management approach to save 2.5 million kWh and $215,037 per year in energy costs. With an incentive of $188, 714 from local utility ComEd, the project delivered a payback of 2.4 months.
Factory lasers use nitrogen right at the cutting point on the metal because the high temperatures used in the process can often cause oxidation. When oxidation occurs, the metal pieces being cut can be damaged, as can the tooling creating the cut. Structural damage or inaccurate cuts can make parts weak and render them useless. The use of nitrogen at the point of contact from laser to metal removes oxygen from the cutting area and helps cool the die as it cuts, thus preventing oxidation. This prevention improves the quality of the final products, produces less scrap metal and cuts back on the reworking of pieces.
When the 18th Century Italian physicist Giovanni Venturi discovered when air is forced through a conical nozzle its velocity increases as the pressure decreases, neither he nor anyone could conceive it would ultimately spawn one of the most used and most highly controversial products in the industry today- the Venturi vacuum generator (aka, ejector).
A flour based frozen foods manufacturer orders a compressed air efficiency audit. The audit establishes the cost of compressed air at $0.27/1000 cubic feet. The study finds the 116 pulse jet dust collectors represent the greatest opportunity for compressed air demand reduction and energy cost savings. A dust collector optimization study/service is suggested and the customer agrees to proceed. In this facility, pulse jet dust collectors are used to filter dust from raw materials entering the plant, for conveying and mixing of ingredients, and for the final packaged finished products leaving the plant.  
This article will focus on ISO8573-7 normative test methods and analysis for viable microbiological contaminants and how it can be fundamentally utilized in compressed air microbial monitoring plans. The quality of the compressed air must be monitored periodically to fulfill national and international standards. ISO 8573 is an available standard addressing compressed air quality. It consists of nine parts that address purity classes, specifications, and procedures. ISO 8573-7:2003, can be utilized across all industries’ compressed air microbial monitoring plans. It contains both informative and normative procedures but lacks any tested compressed air microbial specifications regarding colony enumeration limits for microbial plate counts.
A pharmaceutical plant, has had a compressed air assessment performed on two plant systems.  The studies uncovered poor compressed air production efficiency, high air dryer loss, and problems with high flow compressed air uses negatively affecting plant pressure. The plant implemented energy efficiency measures, on the two compressed air systems, saving 46 and 64 percent in energy costs respectively.