Industrial Utility Efficiency    

Industries

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 Ford Motor Company Kentucky Truck Plant (KTP) not only manufactures upscale SUVs and pickup trucks painted in wide variety of stellar, high-quality colors and finishes –  it does so cost-effectively by conserving annual compressed air energy of approximately 9.2 GWh thanks to a major overhaul of the plant’s compressed air system.

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

Electricity and compressed air play an important role in the thermal and kinetic processes for everything from mixing and extruding the ingredients, deep-freezing to -13°F (-25°C), dipping into various chocolate coatings through to final packaging. Energy efficiency is therefore right at the top of Unilever’s list of priorities. As part of the Unilever Sustainable Living Plan, this global corporation has succeeded in saving more than $186 million in energy costs from efficiency improvements in production alone since 2008.

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

Manufacturers familiar with the U.S. Environmental Protection Agency (EPA) ENERGY STAR® Energy Treasure Hunts initiative know it’s a great way to save energy and natural resources – as long as it’s done right – which is why some are turning to perhaps their best asset to achieve success: their unionized workforce.

Paper

The facility has a compressed air system consisting of four, 200-horsepower (hp) two-stage water-cooled lubricant-free reciprocating air compressors. The air compressors are controlled individually with local pressure switch controls connected to a common pressure sensing point. These air compressors have been operating since the mid-1960s and are very difficult and expensive to maintain because parts are scarce and service companies with experience servicing this type of air compressor are difficult to find.

Pharmaceutical

This article is intended to show the relationships between risks and specifications, opportunities and responsibility in validation, and in particular, the use of modern and calibrated measurement technology in the sample chain.

Plastics

By making changes primarily focused on compressed air uses, Winpak, an international plastics products manufacturer based in Winnipeg, Manitoba, Canada, increased compressed air production capacity and reduced annual energy consumption by 33%. These benefits have been accomplished while the company was making the switch to lubricant-free compressed air to support product quality goals. This article discusses some of these changes and addresses measures that could be implemented in any compressed air system.

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.
A small pulse crop and seed processing facility located in Canada has upgraded their facility compressed air system to accommodate the expansion of their production capacity.  While completing this project the facility has learned some valuable lessons about sizing and maintaining lubricated screw air compressors and compressed air drying equipment.
Annual plant electric costs for compressed air production, as operating today, are $147,469 per year. If the electric costs of $750 associated with operating ancillary equipment such as dryers are included, the total electric costs for operating the air system are $148,219 per year. These estimates are based upon a blended electric rate of $0.087 /kWh. The air system operates 8,760 hours per year. The load profile or air demand of this system is relatively stable during all shifts. Overall system flow ranges from 800- 1,000 acfm during production. The system pressure runs from 95 to 80 psig in the headers during production.  
Parrheim Foods, a division of Parrish and Heimbecker, is an innovative starch, protein and fiber mill situated in Saskatoon, Saskatchewan, Canada.  The plant has improved system efficiency and reduced production problems by addressing some problems with the consumption of compressed air by their reverse pulse baghouse cleaning operations.  This effort has allowed them to turn off one of their 100 hp air compressors, saving significant electricity costs.
Petro Chemical Energy, Inc. (PCE) specializes in energy loss surveys for the refining and chemical industries. We’ve been providing Compressed Air Leak Surveys, Nitrogen Leak Surveys, Steam Leak Surveys and Steam Trap Surveys – for over twentyfive (25) years. We operate totally independent of all equipment manufacturers to ensure our clients receive a complete and unbiased report of the leaks in their facility. PCE has conducted compressed air leak surveys for hundreds of customers at thousands of sites. Undetected, compressed air and gas leaks rob efficiency in manufacturing and processing industries. As a result, businesses lose millions of dollars annually in energy costs and lost production time.
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.
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.
A pharmaceutical product manufacturer spends an estimated $137,443 annually on electricity to operate the oil-free air compressors in its compressed air system. The compressed air system operates well and is providing the level of purification required.  Our team visited the plant and identified a group of projects which could reduce compressed air demand and reduce energy costs by $42,248 – or 31% of current use.
A large pharmaceutical company needed huge flow rates of 30 psig air to aerate multiple fermentation processes which create food-grade materials.  Flow could vary from about 12,000 scfm to 35,000 scfm.  There were a variety of batch processes, mostly running independently.  An hour-by-hour schedule for anticipated air flow is developed every afternoon for the next day.  Based on that schedule, the boiler operators run the air compressors that can handle the load range for the whole day. In reality, the peak flow can be higher than anticipated.
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.
The Lafarge Cement Distribution terminal located in Winnipeg, Canada has significantly reduced the site electrical demand and energy charges by changing the way they transport their cement.  Two new low-pressure rotary screw air compressors have replaced two large high-pressure air compressors that previously powered their dense phase transport system.  The resulting power reduction has saved the company 46 percent in transport operating costs.