Industrial Utility Efficiency    


An air receiver tank (sometimes called an air compressor tank or compressed air storage tank) is a type of pressure vessel that receives air from the air compressor and holds it under pressure for future use. The tanks come in a range of sizes and in both vertical and horizontal configurations. An air receiver tank provides temporary storage for compressed air. It also helps your compressed air system run more efficiently.
There are some fundamentals when it comes to compressed air system improvements. One strategy that is overlooked is just drawing the details of whatever aspect of a system you are looking at. It is fairly common to see a misdiagnosis of some particular technical issue that would have been obvious should someone have created the drawing to describe the problem.
Your air receiver tank works hard to keep your compressed air system running at optimal efficiency. For best results and safe operation, it’s important to make sure you have adequate storage capacity for your application. You also need to take proper care of your tank once it is installed. In this article we provide advice for air receiver tank sizing, safety and storage.
A food processor was having compressed air problems, so they invited a compressed air auditor into their plant for an assessment and to help them size future permanent air compressors. The plant was experiencing low air pressure and detecting water in the compressed air lines despite having a desiccant air dryer. The auditor thoroughly analyzed the compressed air system production equipment and did end-use assessment and leakage detection. This article discusses the findings leading to a potential cost savings of 52% of the current level.
This article reviews the benefits and design considerations of controlling system pressure from the air compressor room to the production headers and selected production processes and areas. Over the last several decades, the phrase “demand-side control” has become the generic term to describe establishing a “flat line” header pressure using proper storage and an appropriate pressure regulator, or “pressure flow controller.” Use of a demand-side controller to control pressure and flow can be implemented at the entry to the production area header(s) and at selected production areas or processes.
Compressed air represents one of the largest opportunities for immediate energy savings, which accounts for an average of 15% of an industrial facility’s electrical consumption. In fact, over a 10-year period, electricity can make up 76% of the total compressed air system costs. Monitoring compressed air usage, identifying compressed air waste and inefficiencies, and making investments in new compressed air equipment – including piping – are tangible ways businesses can cut their operating costs by lowering their electricity bill.
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.
The compressed air system at the mail sorting facility has been in service since the 90’s. Two older 50-horsepower (hp) air-cooled fixed-speed lubricated air compressors are housed in the equipment room of the facility. The air compressors duty cycle alternates between one another on a set schedule. A 240-gallon wet storage receiver is used to help with air compressor control, with the air flowing through the receiver to a non-cycling refrigerated air dryer and system filters before finally being passed to the plant.
Replacing unreliable air compressors is often a smart choice. Sometimes there is a better one. Take the case of a wallboard plant with two compressed air systems, including one for its board mill and another for its rock mill. Each had two 100 horsepower air compressors, all of which constantly overheated. When they did, plant personnel had to scramble to turn on a machine manually every time a unit shut down. Three units ran the plant so any shutdown had them walking on pins and needles.
As consumer awareness of the attributes of aluminum tubing have driven its popularity, so have a swell of additional well thought-out questions.  One question is asked with regularity, “What is done to protect the inside of the tubing”? Even though most all aluminum compressed air piping systems feature a painted or powder coated exterior, the interior of the tubing has no coating.
In an ideal world, we would all have plenty of space, time and money to create the perfect compressed air system. In practice, we have to balance our ideals versus what we can actually accomplish. Compressed air systems take considerable forethought and planning to achieve a perfect install; however, we can use some key takeaways from this article even if we are ever faced a less than ideal installation. Remember to keep the compressors cool, minimize piping pressure drop and to allow sufficient room around the equipment for service.